HES magazine May 2012 by Michael Dominguez

MAY 2012 Issue 7

Pumps and Valves Richter Peripheral Pumps Master Wax Production Page 23 & 24

Latest News

5-8

Explosion Protection

13-17

Buyers Guide

29 & 30

MAY 2012

LATEST INDUSTRY NEWS

INTERNATIONAL NEWS

5-8

EXPLOSION PROTECTION

13-17

PUMPS AND VALVES

18-19

EDITORS CHOICE – SELECTING POSITION SENSORS

23-24

BUYERS GUIDE

29-30

HAZARDOUS ENGINEERING SOLUTIONS

Latest News

The Iranian Regime Had Announced That It Would Ban Oil Exports To Europe Before The Eu Sanctions Could Come Into Force. US led sanctions are starting to have an effect in Iran and the pain will inevitably impact the hardest on ordinary people but according to Dr Peter Slowe – vice-president of the Labour Finance and Industry Group – we have to ask ourselves what would be the cost of not imposing sanctions.

BEKA publish Application Guide describing installation of Ex nA instrumentation

“No sanctions and a continuation of Iran’s uranium enrichment programme will lead to a direct threat of nuclear attack on Israel by an unstable and dangerous regime which believes in martyrdom so wouldn’t care about the inevitable mutual destruction.” “Under these circumstances, Israel would be forced to launch a large-scale pre-emptive attack on Iran’s nuclear facilities. In this case, all we can really do is pray,” said Dr Slowe - who is MD of Projects Abroad the world’s largest volunteering organisation who support philanthropic projects worldwide. The US – supported by the EU – believe that cutting the flow of oil revenue to the Iranian regime will force them back to the negotiating table after the last talks failed in 2010 when the UN Security Council demanded a halt to uranium enrichment in Iran. President Obama and the Israelis have not dismissed the possibility of attacking Iran if the issue is not resolved. In return, Iran is threatening to attack US bases in the Gulf and close the Strait of Hormuz. “The West was far to slow putting oil sanctions in place. We’ll all benefit when the theocratic dictatorship in Iran is overthrown, and oil sanctions – combined with the current policy of carefully targeted bombings and assassinations – will pile on the pressure,” said Dr Slowe – who was a financial advisor to the Blair government. “It’s a tragedy that ordinary Iranians will suffer too but, in the end, sanctions will help to bring about the conditions for a Persian Spring which will be even more beautiful than the Arab Spring. India and China, who buy lots of Iranian oil, ought to join in the sanctions but they probably won’t until they actually see that the violent and unstable alternative hits them where it hurts – right in the treasury.”

NEW! CILS-8200 Fully Submersible, Computer Printable Rating Plate Labels Resistant to seawater, petrol, diesel, oils, chemicals, solvents, etc, Industrial Labelling Specialists CILS have launched the ultimate computer printable

In this new 26 page Application Guide AG310 the well known guru Chris Towle explains the philosophy of Zone 2 apparatus and how extra low voltage Ex nA certified instrumentation may be safely installed in these low risk areas. Current ATEX and IECEx standards are discussed together with installation practice, constructional requirements, documentation and routine inspection.

fully-submersible rating plate label, providing long-term product I.D. for

Of particular interest is the use of Ex nA

some of the toughest industrial environments.

certified apparatus with instruments using

Printable in minutes straight from a Laser,

other protection techniques.

Chris

Inkjet or Thermal Transfer printer, variable data

shows how an Ex nA loop powered

(serial numbers, barcodes etc) can be added

indicator in Zone 2 may be used to

‘in-house, on-demand’, saving time and

monitor the output from a Zone 1 Ex d

cutting costs.

transmitter, simplifying installation and reducing cost.

The specially formulated CILS-8200 hi-tech adhesive ensures permanent bonding to

Although using BEKA 4/20mA loop

all smooth, textured, powder-coated, cast

powered indicators to illustrate

metal and other difficult surfaces when fully

recommended installation practice, the

submersed.

examples apply to most low voltage Ex nA apparatus.

For more information on the CILS rating plate label range, visit: http://www.cils-international.com/content/cils-industrial-computer-printable-rating-plate-labels

Copies of this Application Guide may be

CILS International

downloaded from the BEKA associates

Tel: +44 (0)1903 219000

website http://www.beka.co.uk/ag310.

Fax: +44 (0)1903 219111

pdf or requested by phoning the BEKA

Web: www.cils-international.com

sales office 01462 438301.

Email: info@cils-international.com

HAZARDOUS ENGINEERING SOLUTIONS

Latest News

No Nuclear Investment Threatens the UK’s Energy Security

Climate Center To Offer Welding Gases From Its Nationwide Network Of Branches

Today (29/03/12) RWE Npower

The Braze-A-Gas package includes oxygen and acetylene cylinders, flame torches and accessories to enable engineers to braze a full range of pipe work and system components.

and E.ON have announced a halt to any investment in new nuclear generating capacity in the UK with fears that the UK could become a lame duck over

In a significant addition to its range, Climate Center has announced that it is to supply welding gases to the refrigeration and air conditioning trade via its nationwide network of branches.

“It means contractors can now source everything they need for a project from a single supplier, rather than having to go to a specialist supplier for welding and brazing gases. It will save people time and money and make life more convenient,” says Robert Franklin, who heads up Climate Center’s cooling business.

reliant on costly imports.

Use of brazing has increased significantly in the refrigeration and air conditioning sector recently due to the trend away from use of traditional flare connections and their replacement with fully-brazed, sealed systems, in order to minimise refrigerant leakage.

It is generally agreed that despite

Oxy-acetylene is the preferred medium for brazing as it delivers the hottest flame (3500deg C) of all commonly used fuel gases. This is important in ensuring full penetration of filler metal into the brazed joint to create a strong, refrigerant-tight seal.

concerns about safety post-Fukushima, nuclear needs to play an important role in the UK’s energy future to guarantee security in an ever more uncertain (and

While other types of brazing fuel are only suitable for use with smaller pipe work and components, oxy-acetylene can be used with larger diameter pipe, bigger components such as vibration eliminators and a range of materials, including copper and steel. Oxygen cylinders are colour-coded with a distinctive white shoulder, and acetylene cylinders are painted the traditional maroon with a reflective stripe, to increase visibility in low light conditions.

expensive) energy landscape. Today’s

Accessories available in Climate Center’s Gas-Arc range include gauges, safety goggles and flame torches.

news that the two European behemoths

Oxy-acetylene welding supplies will be added to Pipe Center’s offering in the near future.

of RWE Npower and E.ON will not provide any investment in nuclear plants going forward due to costs of shutting reactors down in Germany and an

New Draeger Flame Detector Offers False Alarm Immunity In Rail Or Road Applications

uncertain economic climate may be

Designed for standalone operation, the new Draeger Flame 3000 is an explosion-proof Flame Detector.

music to the ears of renewable energy

Ideal for use in fuel transport terminals, it is not affected by sunlight and, in traffic tunnels, is impervious

campaigners but could shift the pressure onto gas supplies to plug the looming supply gap. While the government may have pre-empted this with a vision to invest in gas supplies around the Shetland Isles, this is will most likely not be sufficient to meet the UK’s future needs.

Two nuclear consortia remain with plans on the table – NuGen (GDF Suez and Iberdrola), which is planning to build a plant in West Cumbria, and Centrica and EDF with joint plans to build a plant at Hinkley Point. If these consortia also shelve their plans, the UK will be even more reliant on gas imports, as gas fired generation will be required to shoulder even more responsibility to supply baseload power.

HAZARDOUS ENGINEERING SOLUTIONS

to headlights, flashing lights and hot engines. This advanced image processing detector is also suitable for use in rail loading areas as the sensitivity remains unaffected by moving reflections and, in addition, an automatic shutdown system can be used to extinguish all fuel type fires. Based on the proven technology of the Draeger Flame 5000, this advanced image processing detector offers a reliable solution to flame detection and false alarm immunity. Believed to offer the greatest coverage area of any flame detector on the market, the Draeger Flame 3000 has a rectangular, pyramid shaped field of view. Representing a radial projection of the sensing element, this extends to 110° horizontal and 80° vertical, with an increased range of 60 metres to an n-Helptane 0.1m2 pan fire. Housed within a single unit and approved to ATEX, IECEx and FM, the detector combines digital signal processing with software algorithms to process and interpret the characteristics of a flame. These image processing algorithms are so discriminating that the detector is immune to false alarms. Requiring only one detection sensitivity setting, the Flame 3000 is unaffected by the background radiation found in many industrial environments. Superior false alarm immunity is also possible against common sources of unwanted alarms such as hot processes, hot work, hot CO2 emissions and flare reflections. Easy to install with a stainless steel mounting bracket that can be rotated to ensure optimum positioning in relation to the potential fire source, it is also flexible in use. In addition to standalone operation, the Flame 3000 can be integrated with a control system or fire panel, via 0 to 20mA or relay outputs, to provide both fault and fire signalling. Personnel in close proximity to the detector can quickly confirm the system status via a tri-colour LED. Green indicates normal operation, yellow highlights a fault and red warns of the presence of flame. Functionality testing can be a complicated and difficult process. An advanced optical verification test using the Draeger FS-5000 ensures that the unit remains ready to perform as and when it is needed. Able to activate the Flame 3000 from a distance of up to 8m, this Flame Simulator eliminates the need for scaffolding or ladders when carrying out functional testing and, as a result, further reduces maintenance costs. Developed for use in extreme offshore environmental conditions, the FS-5000 electronics are secured in an enclosure specifically designed for Zone 1 hazardous areas. Draeger Fire and Gas Detection Systems offers products, services and system solutions for all encompassing toxic, flammable and oxygen detection, flame detection and design, build, commission and maintenance of fire and gas detection systems for protection of personnel and assets. Further information is available from Customer Service, Draeger UK Limited, Ullswater Close, Blyth Riverside Business Park, Blyth, Northumberland, NE24 4RG. Tel: 01670 561413. Fax: 01670 544475.

Latest News

Toledo Fabrics Introduces High Visibility Orange Knitted Flame Retardant Protal Fabrics Waxman Fibres has worked in partnership with knitted fabric manufacturer Toledo Knitting to produce a world-first in flame retardant high visibility orange fabrics for protective clothing. Incorporating Protal, Waxman Fibres’ next generation inherent flame retardant fabric solutions, the new Toledo range passes the high visibility EN471 and EN11612 heat and flame standards, without compromising on comfort, breathability or cost effectiveness. Peter Seward, Waxman Fibres’ technical director said: “High visibility orange is almost impossible to achieve with any fabric other than polyester, which although very cheap to produce, is neither flame retardant, nor comfortable to wear. “There is a significant demand for high visibility orange fabric, particularly within the transportation sector and we are delighted that through working in partnership with Toledo we have been able to combine our ground-breaking Protal blend with their expertise to produce this exciting product.” The new flame retardant high visibility fabric can also be dyed in accordance with the GO/RT 3279 standard for railway workers and subcontractors. Waxman’s Protal offers extremely high levels of multi-hazard protection, it is also comfortable for the wearer and thanks to its

unique breathability properties, is ideal for people working in hot climates, as very lightweight fabrics are available. Protal is available in a variety of weights and colours, including high-visibility. The inherent flame retardant properties do not deteriorate as they are ‘built in’ to the fibres. As well as eliminating the need for costly re-treatment and unpleasant odours, this gives Protal the edge in practical comfort. It is suitable for woven, knitted or non-woven protective workwear and is designed for use as next to skin, liner, inter-liner and outer fabric. Waxman Fibres Ltd is a subsidiary of the Waxman Group of Companies, based in Elland, West Yorkshire. The company operates in international markets. End users include major utilities, civil engineering, construction and petrochemical sectors.

Waxman Fibres Ltd, Grove Mills, Elland, West Yorkshire, HX5 9DZ Website:www.protal.co.uk

Mutech Limited Announces 20% Increase In Workforce Mutech Limited, one of the UK’s leading electronics design and manufacturing companies in the field of intrinsic safety, has expanded its staff by 20% over the last six months. The company now employs 18 people. The recruitment drive will support a burgeoning order book. Henry Wolfe joins the Mutech design team as Senior Design Engineer, specialising in hardware and PCB layouts. As part of Mutech’s objective to provide more software intelligence to customers’ product ranges, Stephen Landamore has been selected for the role of Senior Software Engineer. Two assembly operatives have been appointed. Christine Pearce has ten years’ experience in electronics assembly. Husein Ariwala has five years’ experience in PCB assembly. Colin Cameron, Mutech’s Managing Director, firmly believes that investing in people is key to the company’s success. “Our recruitment drive over the last six months has been essential to meet the needs of our growing order book and customer expectations.” Mutech Limited designs, builds and tests ATEX and MSHA approved

HAZARDOUS ENGINEERING SOLUTIONS

products for customers in the fields of mining and other hazardous areas. A member of the Association of British Mining Equipment Companies (ABMEC), Mutech has 25 years’ experience in electronics design and manufacture of intrinsic safety equipment for leading companies worldwide. For more information please contact: Sarah Varney, email: sarah.varney@mutech.co.uk Mutech Ltd, Unit 9, Wharfside Business Park, Irlam Wharf Road, Irlam, Manchester M44 5PN, Tel: 0161 872 0400, www.mutech.co.uk

HAZARDOUS ENGINEERING SOLUTIONS

Latest News & Products

Beko Technologies solves KP Foods’ drying problems. KP Foods, a part of the United Biscuits group have had issues in recent years with refrigeration dryers failing because of the acidic conditions on site due to ingredients such as acetic acid affecting the internal copper tubing of refrigeration dryers. A number of different brands of dryer have been tried and tested on site with limited success. Some dryers actually failed in less than 6 months. BEKO TECHNOLOGIES looked at the PH value of the condensate and the acidic ambient conditions. From this a tailor-made DRYPOINT RA 600 solution was offered, where all the internal copper piping and condensate discharge points of the dryer were coated with a special anti-corrosion treatment. The first RA dryer sold to KP Foods has been installed on site now for nearly 4 years without a single failure. This was a major factor in the choice for the new dryers for the Hoops compressor room location. Pressure drop was also a major factor as well as pipe work distribution. With this in mind BEKO were invited to tender for the whole turnkey project which included removing all the old equipment, supply and installation of new dryers, filters and pipework. BEKO HAZARDOUS ENGINEERING SOLUTIONS

successfully won the order for the complete turnkey project and in conjunction with Direct Air and Pipework of Coventry the whole installation was carried out in less than 48 hours. The installation included a complete new 6” manifold, 4” drops into the 2 x DRYPOINT RA 600 dryers and 2 x Flanged filters. Timing was essential as the compressed air went off at 2pm on a Saturday and had to be installed and running by 8pm on a Sunday. The installation was successfully carried out on time. KP Foods are now reaping the rewards in energy reduction of very low pressure drop and a constant dewpoint throughout their factory with the added reliability of the BEKO DRYPOINT RA range.

BEKO Technologies Limited

E-mail: info.uk@beko.de

Tel: 01527 575778.

Website: www.beko-technologies.co.uk

International News

Explosion At German Chemical Plant Kills One A recent blast at a chemical plant in Germany’s western city of Marl killed at least one person and left two others injured An explosion at a chemical plant in Germany killed at least one person and left two others injured Saturday. A tank exploded at the Evonik Degussa plant in the western city of Marl and started a blaze, which about 100 fire fighters managed to bring under control. The injured man was flown to hospital, while a third person suffered only light injuries and was discharged earlier today. Marl, a city of 87,000 in the Ruhr industrial heartland, is an important chemical industry hub. Its chemical park is among Europe’s biggest, with 30 firms employing about 10,000 workers producing more than 4,000 products.

“A column of smoke rose 100 meters high”

The blast – whose cause was not immediately known – was triggered in a tank containing substances used in the production of plastic parts in the auto industry, as well as in electronics and cosmetics. A column of smoke rose 100 meters high in the wake of the explosion, but initial checks by environmental authorities don’t indicate there’s any danger to health.

Borders & Southern Makes ‘Significant’ Gas Discovery Off Falkland Islands Explorer Borders & Southern has discovered “significant” gas condensate reserves south of the Falkland Islands, opening up a new and controversial oil and gas basin. Shares in the Aim-listed company fell 32pc, to 89.5p, however, having almost doubled in value last week, amid rumours the company had struck crude oil. Gas condensate - a lighter, petrol-like substance - could be more challenging to extract commercially, analysts said, and data on the scale of the discovery are, at this stage, vague. Borders & Southern said it would now conduct tests on samples of fluids

a discovery with the company’s first exploration well and to have

recovered from the reservoir. “It is too early to give an accurate resource

opened up a new hydrocarbon basin.

estimate,” it said, but the rock was “likely to contain significant volumes”.

“There is clearly a lot of work ahead of us to understand the size and

Its chief executive, Howard Obee, said: “We’re delighted to have made

value of the discovery, but it is a great start and the potential of the basin is exciting.”

“There is clearly a lot of work ahead of us to understand the size and value of the discovery, but it is a great start and the potential of the basin is exciting.”

Oil was found to the north of the Falklands two years ago by Rockhopper, which is now seeking to develop its assets. However, this is the first discovery of resources to the south of the disputed islands.

HAZARDOUS ENGINEERING SOLUTIONS

Explosion Protection Floodlights

New Explosion Protected Floodlights Withstand Arctic Conditions COOPER Crouse-Hinds has launched a new robust range of explosion protected Ex-floodlights for high pressure sodium discharge lamps installed in extreme environments with ambient temperatures from -55 deg C to +55 deg C. The new FLT 10 series of Ex-floodlights from COOPER Crouse-Hinds is based on the company’s proven PX 04 series of Ex-floodlights, but has a redesigned flameproof enclosure that extends the permissible ambient temperature range down to -55 deg C. The FLT 10 is suitable for Zone 1 and 21 hazardous gas environments, as well as Zones 2 and 22 hazardous dust environments in accordance with European ATEX Directive 94/9/EC. The floodlights are protected to IP66 and are suitable for illuminating large areas or objects within a wide range of harsh industrial environments including chemical and petrochemical processing plants, onshore and offshore oil & gas platforms, pipelines, refineries and loading plants located in Arctic regions. The FLT 10’s efficiency (62% in operation) and design features are further improved by the use of a new polished aluminium wide-angle or narrow-angle reflector, which optimises illumination. The housing of the light fitting is made from copper-free aluminium and the protective cover from a mechanical, thermally-resistant borosilicate glass. All external captive screws are made from stainless steel.

The FLT 10’s electrical components are thermically separated in their own compartments and have a separate Ex-e, maintenance-friendly connection. The floodlight is further protected with a pulse igniter with automatic cut-off and an electronic ballast with thermal fuse. The FLT 10 is also supplied with an adjustable mounting frame, which enables optimum illumination and light guidance. For more information on COOPER Crouse-Hinds’ FLT 10 series of Ex-floodlights, please contact the European Marketing Department on +49 6271806500 or email sales.cch.de@ cooperindustries.com or visit www.coopercrouse-hinds.eu.

Denso Void Filler Aids Corrosion Prevention at Aberdeen Harbour Aberdeen Harbour Board has recently completed the redevelopment of shipping berths at Torry Quay to meet the requirements of larger supply ships for the North Sea oilfields. The main contractor was McLaughlin & Harvey from Belfast.. An integral part of the quay construction is formed by ten metre horizontal tie-bars which are cast into a structural concrete slab located four metres below the finished surface. The bars protrude through the main quay wall formed by sheet piles and act as a fundamental component of the structure, thus requiring protection from the harshest marine conditions. In order to deter corrosion and help elongate the structures life span it was a design requirement to conceal the exposed ends within steel cylinder caps and provide an anti-corrosion void filler compatible with the cathodic protection system. McLaughlin & Harvey sourced Winn & Coales (Denso) Ltd’s Denso Void Filler from local stockists, SIG Construction Products of Perth, and acquired approval by the consultant designers Arch Henderson for use. Winn & Coales Denso Void Filler is based on a microcrystalline petrolatum containing corrosion inhibitors and moisture repellents. It forms a

permanently flexible medium for the encapsulation and protection of bearings, tendons, stay cables, etc. It has been used on a variety of major civil engineering projects, including both Severn Bridges. Winn & Coales (Denso) Ltd Chapel Road, London SE27 0TR Tel: 020 8670 7511. Fax: 020 8761 2456 e-mail: mail@denso.net web: www.denso.net

HAZARDOUS ENGINEERING SOLUTIONS

Explosion Protection

Get Alarmed Before There Is Fire Or Explosion Detect Heat (and Fire) and report/alarm from 60 – 385°C in Engine-rooms, Windmills, Power

Learn more by visiting www.lico.at or www.fenwal-direct.eu

Plants, Ovens, Generators, Trains, Dryers, Gas turbines, Heating rooms, Factories, Inventories and many more. Reliable 2- or 4-wire N/O or N/C switches, FM approved, connect to your existing alarm system or take the comprehensive LICO HDL & Stand-Alone or intermitting Alarmpanel HDL to secure lifes and your values by “in advance monitoring”. LICO Electronics GmbH Klederinger Str. 31 A-2320 Kledering Austria Tel + 43 1 706 43 00 Fax + 43 1 706 41 31 email: office@lico.at

LICO Hungaria Kft Raba u. 4 H-2030 Erd, Hungary Tel + 36 23 520 113 Fax + 36 23 520 115 email: office@lico.hu

LICO Mecatronic S.R.L. Str.Bucinului Nr.2B / 19 RO-540526 Targu-Mures Romania Tel. +40 365 807 497 Fax: +40 365 434 999 Email: office@lico.ro

Water Mist Generator For Shock Wave Attenuation Water mist generator designed for protecting people from unauthorized explosions in underground structures, oil platforms and methane explosion in coal mines. The new generator activates at the command received from a blast detection wireless system. The activated generator produces a tailored water mist with droplet sizes in the range of 25-400 micron that are discharged along selected sections of a tunnel. The time of activation from the moment of blast is 11 ms, the mist discharge speed is 60-80 m/s, the volume of discharged water mist is 90-100 liters per activated station, and the shock overpressures are decreased by a factor between 1.9 and 2.3.

Left: water mist generator for horizontal dispersal. Above: for vertical dispersal. 1 - absorber control block 2 - high pressure camera 3 - water container 4 - nozzles

Center for Infrastructure Protection and Physical Security (CIPPS), University of Florida, 365 Weil Hall, PO Box 116580, Gainesville, FL 32611-6580, USA (tedk@ufl.edu)

HAZARDOUS ENGINEERING SOLUTIONS

Explosion Protection

Alpha And Verlinde Combat Explosive Environments Devon partners France to leave competition for dust Devon based Alpha Lifting services reports great success within the UK for Verlinde’s ATEX (explosion proof products) cranes and equipment. This latest news comes in the wake of an upsurge in demand for explosion proof products in a wide range of sectors, from the traditional industrial and petrochemical markets, to new manufacturing, engineering and health and safety environments needing to comply with the latest EU industry standards. ATEX compliance consists of two European directives concerning what equipment is required for use in an explosive atmosphere, and since 2003 all European organisations must protect employees from such atmospheres. Verlinde has been designing products for safe use in such environments for some time now and increasing demand from the UK market needed a supplier and expert ‘on the ground’, which led the French giant to turn to Alpha Lifting Services. Commenting on Alpha’s selection, business development manager for Verlinde, Simon Rothechild, said: “Alpha Lifting Services has over 20 years experience in advising customers on explosion proof products, so it was a simple decision to appoint them as the agent for Verlinde incorporating explosion proof equipment. This is a growing market in the UK and we wish them well with.” Verlinde’s most popular products in this field are the Eurolift, Eurochain and Eurobloc products, which remain identical in performance to the standard cranes of this type but are fully EX (ATEX certified) explosion proof. They are perfect for offshore platforms, but as EX certification is not a standard feature, a UK based agent was required who would understand the needs of those working in these sectors and be able to recommend the appropriate cranes and hoists. While ATEX products are often perceived as products for the petrochemical industry, the fact is many materials in dust form (if they oxidise) can generate a potentially explosive mix. While coal is the well-known example, other, seemingly more mundane substances can be equally dangerous. These include flour, sugar and even powdered milk – which puts ATEX cranes high on the menu for the food industry too. “The market for explosion proof products is growing and in some ways doing much better than the market for standard lifting equipment,” said Thomas Descamps, managing director of Verlinde. “Verlinde explosion proof products are set apart by the use of spark proof materials (such as

bronze) and by having units sealed to protect them from flammable gasses or dusts that may be present in hazardous environments and we welcome having the expertise of a company like Alpha on board with us in this critical area.” Alpha Managing Director, Raymond Marks, commented: “We have been supplying Verlinde products for some time now, but we are seeing increasing demand for our expertise in the field of ATEX products,” he explained. “It is nice to have our expertise formally recognised by Verlinde and with all the projects that are going on at the moment, 2012 looks set to be a big year for both companies.”

Renowned as France’s leading builder and exporter of hoists and lifting equipment, Verlinde has a growing number of distributors across the UK and worldwide ready to talk to you about your requirements. For your nearest distributor or for any further information: e-mail contact@verlinde.com or visit www.verlinde.com

HAZARDOUS ENGINEERING SOLUTIONS

Pumps & Valves

Richter Peripheral Pumps Master Wax Production Whilst the properties of Montan wax, also known as lignite wax or OP wax, make it a superb raw material for the manufacture of car and shoe polishes and as a lubricant for moulding paper and plastics, these same properties present unique challenges for engineers who wish to convey the wax within a process. Clariant Produkte (Deutschland) produces and processes, among other things, synthetic and natural waxes at their Gersthofen site in Bavaria. Whilst the Synthetic waxes are used in printing inks, paint systems and textiles for coating citrus fruits, the natural montan waxes are mainly for the care product sector as they improve scuff resistance, increase water repellence, and impart high gloss. They are obtained by solvent extraction of certain types of lignite or brown coal, commercially viable deposits of which exist in only a few locations, including Amsdorf, also in Germany. Franz Kovanetz, Production Engineer at Clariant, explained his process requirements, “Montan wax is recovered from bitumencontaining lignite and processed in several stages to obtain the end product. We have operating conditions here under which some pump designs would fail very quickly!” “Firstly, we need pumps which can convey a foaming, corrosive medium at a pressure of over 4 bar. Centrifugal pumps frequently fail in this task; if the media starts to foam, conventional centrifugal pumps cavitate, causing damaging vibrations. In addition, as we are dealing with molten wax, the pumps must be heatable to run at temperatures of up to 130°C with heating provided by steam at 145°C. They must also be able to handle varying volumes, from between 300 and 2,000 litres per hour.” “Finally, in the process stage of oxidation, pumps have to convey on the one hand, the oxidant itself, and on the other hand, the oxidation product still contaminated with oxidant. In this step of the process, legislation demands the use of hermetically tight pumps. In the past, all conventional magnetic drive pumps caused problems in this application. That meant shorter service lives due to sedimentation and damage due to cavitation.” These challenging requirements had created severe problems for the plant engineers as he continued, “For a long time there was not one single pump manufacturer who could offer a corrosion-resistant centrifugal pump with this broad range of flow rates - 2000 l/h was not the problem, but rather the low flow rate of 300 l/h. Some manufacturers even declined to offer, given the required pressure of over 4 bar. The centrifugal pumps with mechanical seals available 20 years ago had a service life of between one day and two weeks – a dream for every pump manufacturer, but a nightmare for ourselves!” Franz Kovanetz and his team finally achieved a service life of around two years using a specially installed mechanical seal to comply with the challenge of statutory demands regarding freedom from leaks. HAZARDOUS ENGINEERING SOLUTIONS

Above: The MPB peripheral pumps run at temperatures of up to 130°C; heating is provided by steam at 145°C.

At that time, they also tried out the standard process pumps of the MNK series from Richter Pumps, but even these very robust pumps did not have a satisfactory service life for this application owing to the extreme cavitation. The breakthrough was only achieved by using Richter’s MPB peripheral pumps which are specially tailored to the delivery of low flow rates at high delivery heads - a range not economically covered by standard centrifugal pumps. The pumps are hermetically sealed and have a magnetic power coupling which equates to no seals and virtually maintenance-free operation. Varying volumes can be coped with efficiently by means of frequency control. Peripheral pumps, also known as regenerative or regenerative turbine pumps, are designed for relatively low capacities which require pumping to high heads. Their impeller has short vanes at the periphery which pass through an annular channel. The fluid enters between two impeller vanes and is set into a circular motion - this adds energy to the fluid particles which travel in a spiral-like path from the inlet to the outlet. Each set of vanes continuously adds energy to the fluid particles. Peripheral pumps are more efficient at these low flow, high head conditions than centrifugal pumps, they also require much less NPSHA (Net Positive Suction Head Available) than an equivalent centrifugal pump. Of particular importance, they can also handle liquids with up to 20% entrained gases. The design of a peripheral pump is specially geared to conveying fairly small volumes to very large heads - operating conditions which framemounted pumps do not cover economically. The Richter MPB pump is self-priming up to approximately 6m (water @ 20°C), conveys volumes between 0.1 and 5 m³/h and achieves delivery heads of up to 100 m. It covers a temperature range from -60 to 150°C and operates from a vacuum (at standstill) up to 16 bar, depending on the accessories. It is hermetically tight and has a magnetic drive rating of 6 kW at 2900 rpm or 7.2 kW at 3500 rpm on request. Thanks to the choice of materials (PFA/ PTFE, SSiC), the MPB peripheral pump virtually has universal corrosion resistance and can handle media with a gas content of up to 30% by volume. The reduced life cycle costs of the peripheral pumps give Clariant two major advantages as Franz Kovanetz explained, “Firstly, we have

Pumps & Valves resistance and it easily withstands even very small temperature shock.” commented Franz Kovanetz. Today, Richter peripheral pumps are the standard at Clariant for conveying highly oxidising substances and other corrosive media. These pumps are proving successful and have the longest service lives thanks to special technical details: An MPB pump installed for test purposes in 2004 is also still running without any problems in 2011. Richter Pumps are available in the UK exclusively through Billinghambased Tomlinson Hall Ltd who were appointed sole UK distributor this year. The appointment coincided with Tomlinson Hall’s success at this year’s Pump Industry Awards where the company was named Britain’s Pump Distributor of the Year for the second consecutive year. Renowned for their innovative magnetic drive and mechanically sealed plastic-lined pumps for difficult corrosive and hazardous fluids, Richter pumps have now become the standard within the European chemical, petrochemical and pharmaceutical industries and other sectors where corrosive, hazardous, contaminated, pure and ultrapure media are used.

Performance curve of the MPB peripheral pump from Richter: a straight line with maximum delivery head at zero conveyance and zero head at maximum conveyance. This curve shows the special feature of a peripheral pump: a centrifugal pump with displacement characteristic.

a considerably longer service life and the maintenance costs are substantially lower. Given the expected service life of four years, we are assuming a cost advantage of several thousand euros for each pump.” “Secondly, and equally important, is that the plant has to cope with fewer disruptions. Every interruption in a continuous process always means affecting product quality. Even if one continuous plant is run constantly, the product quality remains at a high level without fluctuations. Moreover, all pumps are integrated into the process control system – for example, there is also an automatic routine for cleaning the pump.”

Colin Simpson, Sales Director at Tomlinson Hall, added, “Richter has set the bar for PFA-lined magnetic drive and mechanically sealed pumps for decades, and we are delighted to have been chosen to help re-establish the brand here. The appointment is also further testament to our own commitment to providing the very best global pump products to industry.” “Richter’s innovative approach to its products, coupled with its reliability, environmental protection and low maintenance requirements has ensured the brand remains an excellent investment for buyers. Their products vastly outperform the competition on a number of operational levels throughout the world, including those produced here in the UK. This year will also see the global launch of their new range of PFA-lined and mechanically sealed pumps so it’s exciting times for both organisations.” The cutaway diagram of an MPB pump permits a view of the narrow impeller.

The long service life with low maintenance costs is mainly due to the design of the impeller seal - the patented sealing lips integrated in the impeller provide the sealing, which is crucial for high efficiency, between the impeller and the housing wall of the silicon carbide ring channel. The sliding surfaces of the ring channel are polished to a high-gloss finish – which allows the sliding of the impeller sealing lips producing minimum friction and minimum wear. Another crucial advantage is the simple and quick assembly: the resilient sealing lips dispense with the need for adjustment of the impeller ring channel to an accuracy of 0.1 mm. Such close but hydraulically important gaps frequently result in premature wear in conventional peripheral pumps – especially with fluctuating temperatures – and require a large amount of time for their precise assembly and maintenance. However, the sealing lips of the Richter MPB impeller compensate for the dimensional changes caused by thermal action. This is particularly important for Clariant: both the oxidant and the oxidation product still containing acid have temperatures of well over 100°C. “The Richter peripheral pump offers very good temperature

Tomlinson Hall is a family owned business based on Teesside specialising in the distribution of pumps, power transmission equipment and engineering supplies. In March the company was named as Britain’s Pump Distributor of the Year for the third consecutive year in this year’s prestigious Pump Industry Awards. For further information on Richter pumps, please contact Colin Simpson on (01642) 379500 or visit www.richterpumps.co.uk

HAZARDOUS ENGINEERING SOLUTIONS

Atex Milling

Understanding ATEX Milling By Colin Ellis (Managing Director, Hanningfield)

ntroduction to ATEX Past legislation to control explosive atmospheres

has only been concerned with electrical equipment. The current ATEX directives now include hazards from mechanical sources, such as mills. A seized bearing or mechanical failure causing excessive heat generation is as likely a cause of explosion as an electrical fault and is now considered of equal importance in the design and use of size reduction equipment for powder processing.

ATEX Standards There are currently two European directives in existence, 94/9/EC which is principally for manufacturers and another for operators of the equipment 99/92/EC. 94/9 EC is implemented in the UK by the Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres Regulations 1996 (EPS Regulations). 99/92/EC is implemented in the UK by the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). Both EU directives have been in place for several years, 94/9/EC since 1st July 2003 and the provisions of 99/92/EC extended to 1st July 2006. Complying with ATEX To comply with these standards a number of precautions must be taken to eliminate any risk potential. The first step is to carry out a risk analysis (Ignition Hazard Assessment) on the product to be milled and the environment in which the size reduction process will take place. This assessment will determine type of hazardous zoning inside and outside the mill and should be carried out by the user of the equipment. Using the information provided, the mill supplier can then design the equipment to meet the appropriate ATEX Directive measures. The mill supplier is also responsible to advise the user of any precautions necessary to operate the mill safely. ATEX Categorisation In addition to the consideration of mechanical machine features, further categorisation is divided between gas and dust risks. The levels of risk fall into various zones; 0, 1 or 2 for gas, 20, 21 and 22 for dust. There are also individual equipment categories; 1, 2 and 3 (see table).

To comply with each level of risk various accessories may be fitted to the machine such as temperature sensors, nitrogen purging systems, earth-bonding and anti-static castors. ATEX rated electrical equipment and accessories are also used including motors, safety switches and control panels. Equipment Location It is important to ensure that when positioning equipment that either contains an explosive atmosphere, or is situated in an ATEX zoned environment that the location is matched with the equipment in use. If the equipment is situated in an ATEX zoned area then the external features of the mill must comply with the ATEX provisions according to the zone. Special care should be taken relating to the effect on the surrounding area and also affects resulting from the surrounding area. Manufacturerâ&#x20AC;&#x2122;s Responsibilities The mill manufacturer has a responsibility to the customer to provide correctly designed equipment and the user or purchaser has a legal right to expect an acceptable level of safety from the equipment supplier. It is therefore or paramount importance to ensure the user has adequate information on the limitations of use and operating parameters. Adequate instructions of the limitations of use and operation must be supplied along with training where required to ensure equipment is use safely and as intended. The ATEX Compliant Hanningfield Mill With many years experience of designing and supplying explosion category milling equipment, the Hanningfield UNI-MILL provides the ideal solution to meet ATEX legislation directives. Special features such as continuous earth design, temperature monitoring and nitrogen purging ensure appropriate compliance measures are in place for every machine supplied to meet the level of hazard specified. Although ATEX legislation appears to be quite complex, with proper consultation between user and supplier a safe system that meets the requirements of ATEX can be fully complied with.

Zone (gas)

Zone (Dust)

Zone Definition

Equipment Category

Protection Method

Explosive atmosphere is present continuously, for long periods or frequently.

Equipment must be safe under normal operation, expected and rare malfunction.

Explosive atmosphere is likely to occur occasionally under normal operation.

Equipment must be safe under normal operation, expected malfunction.

Explosive atmosphere may occur under abnormal operation and only persists for a short period.

Equipment must be safe under normal operation.

HAZARDOUS ENGINEERING SOLUTIONS

NEW PRODUCT

INDUSTRIAL ACCELEROMETER

PCB Piezotronics Introduces New High Temperature Icp® Industrial Accelerometer PCB Piezotronics, a world leader in vibration, acoustic, pressure, force and torque sensors, has introduced a new high temperature ICP® (IEPE) industrial accelerometer that is capable of operation up to 163°C. The new HT602D01 is ideal for paper machines and similar applications where high humidity and dusty environments would cause problems for alternative charge mode sensors. The sensing element of the HT602D01 provides nominal sensitivity of 100mV/g over a frequency range of 0.5 to 8000Hz (±3dB). Unlike many sensors on the market, PCB Piezotronics’ HT602D01 uses a shear sensing element to minimise the base bending and thermal transient effects that occur in conventional compression mode accelerometers. This renders the HT602D01 accelerometer far less sensitive to unwanted electrical output and leads to more accurate measurement of the actual vibration event. Featuring a 2-pin MIL connector, the sensor can be used as a dropin replacement for many existing accelerometers but offers the higher temperature range compared with conventional industrial devices. It is priced very competitively against charge mode equivalents and possesses a number of other features that assist in making vibration HAZARDOUS ENGINEERING SOLUTIONS

measurements easier. These include a 360° swivel mount that allows for easy cable orientation and minimises the restrictions of cable bend radius; hermetically sealed stainless steel sensor housing with optional PTFE jacketed cables to eliminate the restrictions of lower cost polyurethane cables in the presence of acid fumes; and case isolated to prevent ground loops. All standard PCB sensors and products are supplied with a two-year warranty and the company also offers to all customers, at no charge, 24-hour emergency telephone support. This service makes product and application support available to customers and end-users, day or night, seven days per week. PCB Piezotronics Ltd, Tel: +44 (0) 1462 429710 | Fax: +44 (0) 1462 429798. Email: ukinfo@pcb.com | Web site: http://www.pcbsensors.co.uk

Editors Choice

Selecting Position Sensors In High Vibration Environments – The Do’s And Don’ts Machines that are subject to harsh or prolonged vibration present challenges for many components – none more so than position and speed sensors. In this article, Mark Howard of Zettlex, lists 10 simple rules for design engineers when selecting position and speed sensors that must cope with shock or vibration. There are many examples of harsh shock and vibration environments: off-road vehicles, airborne avionics and mining equipment. There are also some less obvious examples such as pumps and refrigeration plant, where the vibration is less extreme but persists over many years. Of course, characteristics will vary from application to application but generally all environments with vibration or shock can present significant problems for electrical control systems, particularly position and speed sensors.

wear and so they have a finite lifetime. If we consider a potentiometer with a lifetime of 1 million cycles, for example, this is likely to be fine for a benign application which cycles perhaps 100 times per day because this equates to 10,000 days (or 27 years). However, place the same potentiometer in an application which is vibrating at 20Hz (as shown in Figure 1) such as an engine or a pump, and the same potentiometer is likely to fail in less than a day. This is because the

The following 10 simple rules should help design engineers select position or speed sensors that won’t fail once installed in the field:

potentiometer’s contacts will see each vibration as a cycle on a microscopic scale. If the potentiometer is normally positioned at a particular point, the wear effect is accelerated and the potentiometer

1. Use non-contact sensors

is likely to fail even more quickly.

Potentiometers are by far the most common form of position sensor but are generally not suitable for environments with either extreme or

2. Damp the sensor electrical output

prolonged vibration. This is because a potentiometer’s sliding contacts By definition, the position or speed being measured is likely to be changing at the vibrating frequency (or some function of the frequency). A sensor with undamped electronics will output the measured position and so its output will appear to bounce along at the vibration frequency. However, if the sensor is damped, the sensor’s output becomes the average of its measured position. In some sensors the length of time over which the output is averaged can be varied – from a fraction of a second or many seconds – to suit the application.

If a switch or solenoid is to be activated at some point in the measurement cycle (e.g. a pump switch when a tank is full) then

Figure 1 – Potentiometers are generally not suitable for harsh vibration applications

it may be that the switching point is made repeatedly over a short period due to the cyclic nature of the vibration. This will cause the switch or solenoid to open or close rapidly, in turn causing rapid start-stop of the host system. This can be solved by either damping

HAZARDOUS ENGINEERING SOLUTIONS

Editors Choice the sensor or by introducing some hysteresis, which will only allow it to switch after a set time.

3. Measure position or speed directly not indirectly

If position or speed is to be measured in a vibrating system, it is likely that different components within the system will be vibrating at various frequencies and amplitudes. Accordingly, it is more important in vibrating environments to measure the position of the actual elements whose position or speed is to be measured directly. This is opposed to measuring position indirectly – say at the end of a gear train or multi-link mechanism. Without direct measurement, measurement accuracy will be degraded.

epoxies used for electronic encapsulation and these are an excellent method of securing position sensors into the host equipment. This has

4. Avoid glass scales for optical sensors

added advantages of providing a barrier against contaminants and improving heat dissipation at elevated temperatures.

Optical position sensors often use a glass scale through which they shine and measure their light path. In benign environments most

8. Stress relieve connecting wires

optical sensors will perform satisfactorily – provided that there is no foreign matter to interfere with the optical path. However, any glass

Wires and cables tend to be forgotten in stress and vibration analyses but

scale is susceptible to fracture in environments with heavy shock or

a moving cable is a sure way to generate problems from conductors or

vibration. Of course this results in catastrophic failure of the optical

electrical joints cracking due to fatigue. Potting is the preferred method of

sensor, with little or no warning.

eradicating such problems but alternatives include cable wraps, potting or tightly fitting conduit.

5. Minimise the weight of the sensors 9. Lock any fasteners An often overlooked phenomenon is that damage imparted to sensors is usually not directly due to the vibration itself but rather

This may seem an obvious step but nevertheless it is one that is often

as a result of the momentum of the sensor’s own components.

forgotten. Fasteners that secure position sensors should be bonded into

Minimising weight will minimise momentum and hence minimises

position with thread lock or, preferably, an anti-rotation fastener such as

the potential for damage. Lightweight sensors are generally less

a tab washer to prevent hex-headed screws from turning and becoming

susceptible in harsh vibration environments.

loose.

6. Use heavy duty connectors - or preferably no connectors

10. Use caution with magnetic sensors

The single largest cause of electrical failure in hash vibration

If a magnetic sensor is to be used then extreme care should be exercised

environments is cables and connectors. Harsh vibration

in its selection. Firstly, modern rare earth magnets (notably NdFeB types)

environments are no place for the flimsy connectors normally

are extremely brittle and subject to catastrophic failure if subject to shock.

used on consumer electronics. Instead, connectors should be

Magnetic reed switches are prone to fatigue over prolonged periods

heavy duty – such as military standard 38999 (shell types) – or at

where the vibration causes the magnetic switching vane to vibrate and

least include jackscrews to bind the connector’s male and female

hence fatigue quickly. Magnetostrictive sensors rely on delicate and

elements. If possible, connectors should be eradicated and electrical

precise location of (easily damaged) amorphous crystal ribbons in wave

interconnections made by direct wiring or flying leads.

guides. The fixture of the ribbon in the wave guide is susceptible under conditions of either shock or vibration.

7. Potting and encapsulant

For more information on new generation inductive position

An excellent way to mitigate problems due to vibration is to pot sensors and cables into position. There are a wide variety of 2-part HAZARDOUS ENGINEERING SOLUTIONS

sensors, please contact Zettlex UK Ltd on 01223 874 444 or visit the website at: www.zettlex.com or email info@zettlex.com

Certification

Fire And Gas Detection Specialist Achieves Cisco Certification Oxford based fire and gas detection systems specialist Industrial Design has achieved Cisco certification, allowing it to service large networked sites from March 2012 as part of its agreement with Cisco UK. On large sites where fire and gas detection systems need to be connected together, CISCO networking is used on a wide scale. Industrial Design’s new certification will allow the company to access the resources and support necessary to work on such complex projects. Technical support, including smart design and assistance with network configurations in situ, is also now available from Industrial Design as a result of the certification. On sites spanning more than three or four kilometres, where control panels need to be connected together and proprietary systems are not capable or suited to the infrastructure, Industrial Design will be accessing further resources such as Ethernet on copper or fibre optic cable on Cisco equipment. “Acquiring CISCO Select Partner certification guarantees the quality and reliability of the network design and components we use in our detection systems,” explained Mike Fikuart, managing director of Industrial Design. “We specialise in fire and gas detection, suppression, emergency shutdown systems and access control – in a word, “safety”. When a person or a site’s wellbeing is at stake, we

will do anything to ensure nothing goes amiss and that we have 99.999% availability,” he said. “We have been a registered member with CISCO for a long time, but we felt the need to take things a step forward and receive a higher level of support from our network partner. Obtaining the CISCO Select Partner certification testifies to our staff’s expertise and commitment to a job well done,” concluded Fikuart. Cisco Systems is an American multinational corporation headquartered in San Jose, California that designs, manufactures, and sells networking equipment worldwide. Telephone: +44 (0) 870 128 3835 Fax: +44 (0) 870 131 4307 e-mail: mike.fikuart@industrialdesign.ltd.uk www: www.industrialdesign.ltd.uk

Atex Couplings

BEDFORD OPTO TECHNOLOGY LTD We design,develop and manufacture,in Scotland,ATEX and IECEx certified Opto Couplers.We offer tubular transistor output 10kV through hole; surface mount transistor 10kV; surface mount high speed opto logic output;through hole high speed opto logic types. We also have a true surface mount lead free soldering compatible 10kV transistor replacement for the OPI1000LE types,this has yet to be submitted for ATEX/IECEx approval. We have been in existence for 37 yrs and specialise in solving Opto Electronic problems.Whilst much of our product range is custom made we offer a standard range of LED Bargraphs,LED circuit board indicators,IR transmissive and reflective switches. Early in 2012 we will be announcing the availability of a second generation high speed series of Opto couplers offering pin compatibility with our current OPI2000 types.These will use new internal components to strengthen the dual sourcability of the range. ATEX and IECEx certification will be applied for later this year. If you have an Opto problem you would like us to look at whether it HAZARDOUS ENGINEERING SOLUTIONS

be ATEX/IECEx or not please contact us.We provide a prompt low cost service from prototypes through to full production tooling. Bedford Opto Technology Ltd 1 Biggar Business Park, Market Road Biggar, ML12 6FX Telephone 0044 1899 221221 Email enquiries@bot.co.uk Web www.bot.co.uk

BUYERS GUIDE 2012

CONSULTANCY & INSPECTION

ATEX EXPLOSION HAZARDS

CONTROL PANELS

ENCLOSURES

CABLE GLANDS

DRUM HANDLING

CONTROL PANELS

HAZARDOUS AREA STATIC CONTROL

EXPLOSION PROTECTION

HAZARDOUS ENGINEERING SOLUTIONS

BUYERS GUIDE 2012

ATEX INPECTION SOFTWARE

CONSULTANCY

TRAINING

TEST CERTIFICATION

Advertise Here To advertise in our classified section please contact EMS magazine on: 01634 731646 or email: info@hazeng.com HAZARDOUS ENGINEERING SOLUTIONS