Ensuring Safety and Efficiency with the Right HMI
18 MEASUREMENT & INSTRUMENTATION: Better Cleaning and Protection for Reliable Sterile Processes with Electronic In-line Pressure Measurement.
The VisuNet GXP and VisuNet FLX series HMIs from Pepperl+Fuchs set new standards for safety and efficiency in hazardous industrial environments, meeting rigorous explosion protection requirements while offering sleek designs and flexible adaptability. Featuring modular designs and advanced technologies, these HMIs ensure operational excellence and compliance with industry standards, making them a smart investment for industries prioritizing safety and productivity.
In the complex and often hazardous landscape of industrial operations, ensuring maximum safety while maintaining operational efficiency is not only a goal, but a necessity. Human-machine interfaces (HMIs) are the critical link between the human operator and the sophisticated machinery used in today's industry. The VisuNet GXP and VisuNet FLX HMIs from Pepperl+Fuchs represent a significant step forward in the field of explosionprotected HMIs. Developed with precision and foresight, these series are an example of how cutting-edge technology can meet strict safety standards to protect human lives and infrastructure investments.
Explosion protection is more than compliance and safety
The inherent risks of operating in environments with explosive atmospheres - whether
due to flammable gases, vapors or combustible dusts - require HMIs that do more than just meet safety standards. The VisuNet GXP and FLX series not only meet ATEX, IECEx and NEC requirements, as well as other global standards, but also offer a sleek design. Thanks to the innovative design, these HMIs ensure that there is no ignition source, providing safety for operators and safety managers alike. The integration of intrinsically safe circuits and sand-encapsulated enclosures illustrates the holistic safety approach of these series.
Slim design and flexible adaptability up to Zone 1/21 and Div. 2
Unlike the bulky and heavy designs often associated with explosion-proof devices, the VisuNet GXP and VisuNet FLX series feature a lightweight and compact form factor without compromising on safety or functionality. This
design innovation not only simplifies installation and mobility, but also opens up new possibilities for system integration and customization. The adaptability of the two HMI series is also underlined by the fact that they allow for a variety of customized modifications, from mobile trolley solutions to a wide range of mounting options, ensuring that all operational requirements are met precisely.
Precision in hygiene and safety in the pharmaceutical industry
The strict regulatory environment in the pharmaceutical industry makes the development and operation of HMIs even more complex. The VisuNet GXP and VisuNet FLX series take up this challenge with features that meet the special requirements of the pharmaceutical industry: GMP-compliant design, easy cleaning and minimized risk of contamina-
tion. These HMIs feature an edgeless design and an antibacterial keypad, housed in an IP66-rated stainless steel enclosure (or alternatively aluminum) to withstand aggressive cleaning agents. The integration of VisuNet Control Center add-on software also increases operational efficiency by enabling remote management and maintenance of all HMIs, reducing the need to physically enter cleanrooms, which is often preceded by a time-consuming decontamination process. VisuNet Control Center makes it possible to install updates on all devices simultaneously from a central location. This guarantees quick and easy management of HMIs and ensures that cybersecurity standards are always up to date.
In industries where the environment itself presents considerable challenges, the VisuNet GXP and VisuNet FLX series are characterized by their ruggedness. The new extended temperature variant of the VisuNet FLX HMI series has a marine-grade aluminum housing and can withstand even extreme temperature fluctuations from -20 to +50 °C. Together with suitable sunshields, they are therefore perfect
for outdoor applications, for example in ship and truck loading and filling applications. The option of attaching additional sunshields to protect against sun, rain and environmental influences further underlines the adaptability of these HMIs to any application scenario.
The concept of modularity is at the heart of the VisuNet HMI series and not only enables
Modularity means flexibility: The VisuNet HMI systems consist of 3 modules: Display Unit, Computing Unit and Power Supply Unit. Picture: Pepperl+Fuchs
flexible customization, but also simplifies maintenance. The division into three main components - the Display Unit (DPU), the Computing Unit (PC Unit or Thin Client Unit) and the Power Supply Unit (PSU) - enables parts to be replaced and upgraded quickly, even in hazardous areas. This design approach minimizes downtime and logistical issues associated with repairs and demonstrates an understanding of the operational realities of the industry working in hazardous areas.
Manage all thin client HMIs from a central location with VIsuNet Control Center. Picture: Pepperl+Fuchs
The VisuNet GXP and VisuNet FLX series from Pepperl+Fuchs are more than just HMIs; they are proof of the ability to combine safety, efficiency and flexibility in the most demanding industrial environments. By integrating advanced technologies, meeting the strictest safety standards and offering exceptional customization options, these series set new standards for what can be expected from HMIs in hazardous areas. For industries looking to improve their operational capabilities while ensuring the safety of their employees and equipment, the VisuNet series is a smart and future-proof investment.
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Absolute sterility, optimised processes and lower operating costs – the food industry is challenged to align its production procedures amid these conflicting interests. The measurement technology employed to check individual process parameters plays a decisive role here. WIKA has now opened up a new chapter in pressure instrumentation: an in-line process transmitter with a “dry” measuring cell takes monitoring of this variable in sterile applications to a higher level.
Production under aseptic conditions is the most vital prerequisite of flawless product quality. The ability to clean pipelines and tanks without residue is a central task in the sequence of individual steps. That sounds easier than it is in practice. All processes are instrumented throughout with heterogeneous components, peppered with shut-off valves, pumps and measuring devices of assorted origins. Not surprisingly, this enormous di versity entails considerable effort for cleaning. Several cycles are necessary involving dif ferent substances such as citric acid and lye, with sterile saturated steam to finish off. This final step in the clean ing process is also a critical moment. If steam at a temperature of up to 150°C comes together with water particles from previous cleaning cycles, explosive reactions are inevitable. These hydraulic shocks –also known as “water hammer” – take the form of pressure surges that make plant opera tors’ hair stand on end. The force unleashed by water hammer can dam age the pressure measuring instruments installed in the process to the point of failure. The only option in this situ ation is to stop the process and re place the affected devices.
Faster detection of damages
However, since not all damage results in failure, it may not be detected immediately, in which case the impact of water hammer could well be even more severe – for example, if the product is contaminated. This is because some of the measuring points in food production are equipped with diaphragm seal systems with integral pressure or process transmitters. If their diaphragms on the process side are damaged, the transmission fluid will leak from the diaphragm seal and contaminate the product. Contamination can also occur with ceramic sensors. If damaged, these immediately go into error mode, yet detached ceramic particles get into the medium nevertheless. Here, too, product purity is no longer ensured. In most instances, the affected batch must subsequently be destroyed. The economic con-
DMSU21SA diaphragm seal system with built-in diaphragm monitoring. Source: WIKA
sequences are devastating: since such plants generally run 24/7, a large amount of product will already have been turned over before counteraction is taken. In the past, loss on this scale could only be avoided by using a diaphragm seal system with built-in diaphragm monitoring (a patented WIKA solution). This works with a double diaphragm: if the diaphragm on the process side is damaged, the system simultaneously outputs an alarm signal. The second diaphragm then seals off the process until the problem has been fixed. WIKA’s new development for monitoring pressure in sterile processes is aimed at further reducing the potential hazards outlined above while at the same time optimising the cleaning process. As the name suggests, the DMSU22SA in-line process transmitter with the HART®7 communication protocol and a flanged connection becomes an integral part of the pipeline. Its design enables better flow behaviour than conventionally mounted instruments.
An advanced hygienic design concept makes the measuring element many times more resistant to water hammer and other extreme process conditions. The DMSU22SA also records the pressure without transmission fluid, so that in the event of damage contamination is avoided. This is the chief difference compared to traditional in-line measuring arrangements with in-line diaphragm seals or flush mounted process transmitters. At the heart of the new device is a hermeti-
cally sealed sensor element made of 316L stainless steel. Similar to a Bourdon tube, it is elliptical and is accordingly deformed under pressure. A Wheatstone bridge attached to the sensor body allows pressure-induced changes in the electrical resistance to be accurately detected and sent to the transmitter. The DMSU22SA also has a PT sensor for active temperature compensation between 10°C and +80°C. Error compensation is up to ten times better than with conventional devices, so that more precise process control is possible.
Although the pipeline and the pipe sensor have different diameters, a drag coefficient measurement has confirmed that the new measuring instrument exhibits significantly better flow behaviour than other solutions, including those with hygienic connections. In other words, the dead space-free design means less energy is needed to maintain the process pressure or for CIP / SIP processes and reduces the consumption of water and cleaning agents.
The pipe sensor has an extra-robust wall for enhanced process reliability. Depending on the version, it is up to ten times thicker than a standard diaphragm seal (0.05 mm). Yet persistently unfavourable process conditions
DMSU22SA in-line process transmitter with HART®7 communication protocol and a flanged connection for improved product safety.
Source: WIKA
can cause leaks in spite of this, with the result that product gets into the space between the sensor and the support tube. This space is evacuated and has built-in vacuum monitoring, with a sensor that reacts at a pressure of just 50 mbar. The plant operator receives
Solutions for retrofitting and new installations
Pressure monitoring implemented using an in-line process transmitter is primarily recommended for new plants. Retrofitting an existing plant with the new system gives rise to disproportionately high costs for the operator. To minimise the risk of product contamination, manufacturers can opt for a retrofit comprised of WIKA’s DMSU21SA diaphragm seal system with built-in diaphragm monitoring. WIKA’s in-line process transmitter with a “dry” measuring cell and built-in sensor monitoring makes processes in food production more reliable. This new development with the model designation DMSU22SA prevents product contamination and enables more precise process control thanks to active temperature compensation. Its flow behaviour reduces the consumption of operating fluids. The device is primarily designed for use in new plants with digitised processes.
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Non-browninglensesfordifferentCMOSsensorsizes Withrecentadvancesintechnology-CMOSsensorsare beingdevelopedcapableof withstandinghigherlevelsof radiationthanwaspreviously possiblemakingthemaviable optionforamuchlargerrange ofnuclearapplication.Inordertotakeadvantageofthehigher resolutioncolourimagesprovidedbyaCMOSsensor,morenuclear cameramanufacturesarelookingtousethemasanalternativeto traditionaltubes.Asaresult- Resolve Optics hasnotedagrowing demandforcustomnon-browninglensesoptimisedforthelarge varietyofdifferentformatsthatCMOSsensorsareproducedin. To fulfilthegrowingdemandfromdifferentmanufacturersofradiation tolerant,colourCMOScamerasResolvedevelopeda10xnonbrowningzoomlensdesigntoprovidebetterHDcolourimagesfor nuclearapplications.TodateResolveproducedversionsofthis non-browninglensoptimizedfor¼-inch,1/3-inchand2/3-inch CMOSsensorformats. TheHDzoomlensdesignusesnon-browning glasses,speciallyselectedtoproduceclearsharpimagesfreeof thestrongyellowtintthathastraditionallybeenalimitingissue whenusingnonbrowninglensesoncoloursensors.Theglassused intheselensescanwithstandlong-termexposuretoradiationup toanaccumulativedoseofonehundredmillionradandtemperaturesupto85°Cwithouttransmissionloss.
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Foreasieraccesstodiagnosticdataofsensors
Bürkert isprovidingcustomerswith morediagnosticdatafromitsType 8222conductivitysensorsandType 8202pHsensorsbyembeddingthe IO-LinkandBürkertbüSindustrial protocolsintoitsELEMENTNeutrino rangeofproducts.Thedigitisationof theseproductsallowsmaintenance andoperationstobestreamlined throughremotemonitoringcapabilities,supportingprocessuptimeinwaterqualityorchemicalapplications. Operatorsarenolongerlimitedtoafewoutputs,buthave accesstoawealthofdiagnosticdataonmanyotherfactorsthat affecttheperformanceandconditionofthesensors. Andallofthis canbeaccessedremotely.Theabilitytostreamlinemaintenance throughremotemonitoringisakeybenefit.Diagnosticscanbe carriedouttodeterminetheconditionofequipmentandthenature ofpotentialrepairsbeforevisitingthesite.Thisallowstheright sparestobepreparedbeforeleavingtheworkshop,avoiding multipletrips.ThisgivesOEMstheopportunitytoofferproducts thatactivelyreducemaintenancerequirementsandcosts. Forend users,accuratereal-timesensorandprocessdataenablesamore proactiveapproachtoequipmentmaintenancewhich,combined withreducedmaintenance,significantlyimprovesuptimeand productivity-allwhilereducingoperatingcosts.
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Shallow-depth1/8''casingwithIP65frontprotection Moore Industries announcesthe 330R21/8DINprocessand temperaturepanelmeterto replacethediscontinued330R processmonitor.The330R2 coversawiderangeofprocess andtemperatureapplications withitsuniversalinputanddualprocessrelays.Itfeaturesa UV-resistant,sunlight-readable4-digitdisplay.Withanoperating temperaturerangeof-40to65°C,the330R2isidealforharsh outdoorenvironments.The330R2ishousedina1/8DINcaseand acceptsawiderangeofanalogueinputsincludingprocessvoltage (0-5V,1-5V,0-10V,±10V)andcurrent(0-20mA,4-20mA,±20mA) inputs,100OhmRTDsandthefourmostcommonthermocouples. Highlightsofthe330R2includetheabilitytoprovide24VDCto powerthetransmitter's4-20mAsignalwiththehigh-levelinput poweredunits,simplifyingwiringandreducingoverallinstallation costs.Inaddition,anisolated4-20mAoutputoptionisavailablefor retransmissionofprocessandtemperatureinputs.The330R2isa versatileanddurablepanelmeterinashallow1/8DINhousing withaNEMA4X&IP65frontpanelwithadjustabledisplay intensityforoutdoorapplications. With2SPDTFormCrelays,the 330R2providesalarmandcontrolflexibilityforcriticaltemperature andprocessloops,includingpumpcontrolapplications.Themeter canbequicklyandeasilyprogrammedfromaPCorinthefield.
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Minimisingdowntimeswithpredictivemaintenance
TheKKostal InveorMPPandMPMfrequencyinvertersolutionsarenow equippedwiththe"VibrationMonitoring"functionasstandard.Duringoperation,thesystemcanbemonitoredfor irregularitiescausedbyvibration.The dataiscollectedandcanbefurther processedviaMQTT.Fortheuser,thisis thegatewaytopredictivemaintenance, whichenablesthemtopreventunexpectedfailuresandminimisedowntime costs. TheInveorgivestheuserthegreatestpossibledegreeof freedomwhenconfiguringthedrivesystem,asthedrivecontroller issuitableforalltypesofmotor.Thismeanstheycanplanforthe futureandarelessdependentonrareearths.Savingscanalsobe madeonacquisitioncosts,astheInveorcanoptimallycontrolany brandofmotor,meaningthatusersarenotforcedtobuyamore expensivesystemconsistingofmotorandinverterfromthesame supplier. TheInveorfrequencyinverterisdesignedtobemounted directlyontothemotor.Plug&Playcreatesamodularunitconsistingofmotor,gearboxandinverter.Costsavingsareachievedby eliminatingtheneedforacontrolcabinetandlongmotorcables withappropriateshielding. Thesensorlesscontrolprocessisable tooptimallyrecognisetherotorpositionandreliablycontrolthe motor,evenatlowspeedsrightuptostandstill.
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Flexibleusewithstaticandretractablefittings
WiththeUniclean700series,KKnick introducesamodularcontrolsystem thatcanbeinstalledveryquicklyand cost-effectivelyasaflexibleentrylevelsolutionforautomatedsensor cleaning.Withitsinnovativeconcept andfocusedfunctionality,theUniclean 700complementsexistingportfolioof KnickcontrollersusedintheestablishedcCaresystemforfullyautomatedcleaningandcalibration.Themodulardesignoftheindividual componentsgivesthecustomerahighdegreeofflexibility. However,thecompactdesignmakesinstallationveryeasy.With theUniclean700controlsystems,Knickofferstheuseraflexible andexpandablesolutionthatissuitableforusewithbothstatic andretractablevalves. Thecost-effectivesolutionisusedinwaste watertreatmentplantsandinthemetalprocessingindustry.Thisis whereheavysoilingandhighsensorwearareencountered.The newseriesalsoexcelsinthefoodindustry.Insugarfactories,for example,sensorsoftenbecomeencrusted. Withthenewseries, Knickoffersanentry-levelsystemforautomaticcleaningofpH sensors,whichisvaluableinmanyindustries.Italsoworkswith thirdpartytransmittersorfittings. Themodulardesignallowsfor easyconversionswhenneeded.Thismeansthatcleaningcontrol systemscanbequicklyadaptedtoprocesschanges.
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Forcontinuousorbatchprocessesinbatteryproduction
ThenewCS+loss-in-weightfeeder systemfrom S Schenck Process perfectlymeetsthe different requirementsinbatteryproduction. It canbecustomizedtomeet individualcustomerrequirements. Themodulardesignmakesitpossible tocoveralargefeedingrangewith justonefeedertype:CS+issuitable forsmallquantitiesfrom30litresperhouraswellasforhigh feedingcapacitiesofupto3,000litresperhour.Toprevent metal-to-metalcontact,componentscanbeoptionallycoated. Smoothsurfacesandlimitedrelativespeedsoftheagitatorand screwminimizemetalabrasion.ThepatenteddesignoftheCS+ combinesthiswithaquick-actingflapthatpreventsmaterialfrom tricklingoutduringthebatchprocess. TheCS+loss-in-weight feedersystemalsoofferstheuserpermanentlyhighaccuracyfor consistentlyhighproductquality.Intelligentpressuremanagement preventstheingressofambientairandmoisture.Thisprevents pressurefluctuationsfromhavinganegativeimpactonthedosing accuracy.Atthesametime,thesystemimpresseswithitssimple andpracticaldesign,whichalsoallowsseveraldosingunitstobe installedinthesmallestofspaces.Lastbutnotleast,CS+fits seamlesslyintosystemconceptsthatrelyonaconsistentcontainmentconcepttolimitdustemissions.
Real-timeinsightsfortheidentificationofpollutants Vaisala announcedthelaunchof theAirQualityTransmitter560 (AQT560)acompactairquality sensorwithawidedetection range—PM1,PM2.5,andPM10— andauniquecalibrationsystem andalgorithmsthatenableunmatcheddetectionaccuracyand efficiency.TheAQT560standsout asthemostdependablecompact air quality sensor for measuring particle matter (PM). Its precision in detecting aerosol number concentration of particles within the size range of 0.3 to 10 microns is unparalleled. As a result, the sensor excels in accurately providing PM1 concentrations for sources primarily influenced by combustion (such as traffic, residential wood burning, and wildfires), PM2.5 concentrations dominated by long-range transport, and PM10 concentrations driven by abrasive processes (such as road dust, sandstorms, construction, and mining). Leveraging Vaisala's intelligent humidity control system and algorithms, the sensor detects the most important pollutant gases in ambient air, such as NO, NO2, CO, and O3. The sensor is designed for highest dependability with cutting-edge optical components and a rotary vane pump to provide optimal flow management and control, delivering trustworthy intelligence. It can be used standalone or with existing networks.
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3D-PRINTEDMAG-DRIVEPUMPSHROUD High-techshroudavoidsdisadvantagesinoperation Oneofthetechnicalhighlights from K KSB fortheACHEMA 2024willbethenew3D-printedcontainmentshroudfor mag-drivepumpsofthe Magnochemtypeseries. NamedMagnoProtect,the componentoffersthesamesafetyasadouble-walledcontainment shroud-withoutthelatter'sdisadvantagesofheatingupand havinghigheddycurrentlosses. Whileprovidingcomparable safety,theoverallefficienciesofthenewmag-drivedesignsclearly exceedthoseofcannedmotorpumps.Designedwithastructureof channels,thenewcontainmentshroudoffersasecond,redundant, staticsafetybarrierpreventingleakageofthefluidhandled. A pressuretransmittermonitorsthevacuumgenerated,whichis presentduringnormaloperationinthechannelsofthecontainmentshroud.Thecontainmentshrouddesignischaracterisedby highmechanicalstrengthandgoodwearproperties.Ithasbeen optimisedtominimiseheatlossesandeddycurrents. Convertinga standardisedchemicalpumpwithmechanicalsealtoamagnetic driveiseasierandmorecost-efficientthanretrofittingitwitha cannedmotor.ThegeometryanddimensionsofthenewcontainmentshroudareintegratedinthemodularsystemofMagnochem, allowingmetallicorceramiccontainmentshroudstobereplaced easily. Thisenablesoperatorstoupgradeolderpumpsets.