october 2008 • safety & securitymedia.tim-europe.com/archives/pcne/2008/10/pcne.pdf ·...

October 2008

• Safety & Security

Chopper pumps improvescreening transfer

Page 24

• Safety & Security4-19

Explosion-proofactuator controlsystemPage 31

• Energy & Water• Energy & WaterPage 20-25

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SLI: enter 24515 at www.tim-info.com/pcne

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October 2008 3

Industry News

EEnnddrreessss++HHaauusseerr iinnaauugguurraatteess pprreemmiisseess iinn MMaanncchheesstteerr

The Swiss process automation company En-

dress+Hauser is celebrating its 40th anniversary

in the UK. This momentous occasion in the

company’s history was marked by the inaugu-

ration of brand new state-of-the-art offices.

The premises have been built on the existing site

in Manchester and incorporate a sales, service

and manufacturing facility. The real bonus,

however, has been the improved training facil-

ities and the inclusion of a Visitor Centre boast-

ing seating for more than 120 people! The

proceedings were attended by Manchester’s

Lord Mayor Mavis Smitheman and Endress+Hauser

company founder Georg H Endress and his

family.

BBAASSFF mmaakkeess ooffffeerr ttoo aaccqquuiirree CCiibbaaBASF plans to acquire Ciba Holding AG, Basel,

Switzerland, a leading specialty chemical com-

pany, and will make a public takeover offer to

Ciba’s shareholders. BASF will pay CHF 50.00

in cash for each nominal share in Ciba. BASF and

Ciba have reached a transaction agreement in

which the Board of Directors of Ciba supports

BASF’s offer and recommends its acceptance to

Ciba’s shareholders. The offer corresponds to a

premium of 32 percent above the closing price

for Ciba’s shares on September 12, 2008 and a

premium of 60 percent above the volume-

weighted average share price for Ciba shares in

the 30 days prior to announcement of the pub-

lic takeover offer. Based on all outstanding Ci-

ba shares and including all net financial liabil-

ities and pension obligations, the enterprise val-

ue would be CHF 6.1 billion (approximately

€3.8 billion).

DDeemmaanndd ffoorr iinndduussttrriiaall vvaallvveess iinn CChhiinnaa ccoonnttiinnuueess ttoo rriisseeGains will be driven by rapid growth in process

manufacturing, public utilities construction

and general construction activity overall as

China continues its process of industrializa-

tion and urbanization. China is a net importer

of industrial valve products, with a trade deficit

of 950 million yuan and gross imports represent-

ing 30 percent of demand in 2006, reflecting

high domestic demand and the relatively low

standards of valve manufacturing technology in

China. Demand for standard valves will contin-

ue to account for the larger share of total sales,

exceeding 50 billion yuan in 2011, reflecting their

widespread application in Chinese industrial

processes. The process manufacturing industries

(particularly chemical production and petro-

leum refining) and public utilities (especially elec-

tric power generation) will continue to be the

leading markets for industrial valves. These

and other trends are presented in ‘Industrial Valves

in China’, a study from The Freedonia Group,

Inc., a Cleveland-based industry research firm.

CCooooppeerraattiioonn aaggrreeeemmeenntt bbeettwweeeenn FFlloottttwweegg aanndd HHuubbeerr

The signature of the cooperation agreement

during the IFAT 2008 trade show was the start

of a cooperation between the two medium-sized

companies active in the field of water treat-

ment. Hans Huber AG, headquartered in Berch-

ing, Germany, is a leading supplier of ma-

chines and plants for wastewater, grit, and

sludge treatment for municipal and industri-

al applications. Flottweg AG, headquartered in

Vilsbiburg, Germany, is a leading manufac-

turer of industrial centrifuges for solid/liquid

separation used all over the world in the

chemical, pharmaceutical, petrochemical,

mining, food, and beverage industries. The

partnership of the two technology companies

has lead to a win-win situation: Huber can again

offer its customers complete equipment for

sewage plants. Flottweg provides Huber with

the premium-decanters used for the thicken-

ing and dewatering of a variety of sludges in

wastewater and water treatment.

EEmmeerrssoonn PPrroocceessss MMaannaaggeemmeenntt aannnnoouunncceess nneeww eexxeeccuuttiivvee aappppooiinnttmmeennttss John M. Berra, president of Emerson Process Man-

agement announced a number of leadership

changes to take place over the next few

months. Effective Oct. 1, 2008, Steven A. Son-

nenberg will become executive vice president

of Emerson and business leader of Emerson

Process Management, serving as president.

Berra, who has been business leader since

2000, is taking a new role as chairman of

Emerson Process Management to focus on

strategic planning, technology, key customer

relationships and organizational planning.

"Steve is an integral member of the Emerson

management team and has long played a

strong role in growing Emerson Process Man-

agement's leading position around the world,"

Berra said. "I'm excited for the future of this busi-

ness under his leadership."

PCNE_02_03.qxp 9/29/08 3:01 PM

4 October 2008

EDITORS Constanze Schmitz

Jürgen Wirtz

[email protected]

EDITORIAL ASSISTANT Viki Huys

[email protected]

PUBLISHING GROUP Karen Verriest

EXECUTIVE [email protected]

PUBLISHER Oliver Schrader

[email protected]

PUBLISHING DIRECTOR Marketta Lähde

[email protected]

CIRCULATION DIRECTOR Marcel Santy

[email protected]

WEBMASTER Filip Burm

[email protected]

MANAGING DIRECTOR Orhan Erenberk

[email protected]

EUROPE

AUSTRIA• Yakup Gaygusuz,

Tel: +49-(0)2324-68 68 812E-mail: [email protected]

BENELUX • William de Jager

Tel.: +32-(0)3-285 33 91Fax: +32-(0)3-285 33 35E-mail: [email protected]

FRANCE• Sylvie Seurin

Tel: +33-(0)1-41 31 74 60Fax: +33-(0)1-41 31 74 51E-mail: [email protected]

• Jean-Claude BerthonnetTel: +33-(0)1-41 31 74 64E-mail: [email protected]

• A2 Développement, Céline GarciaTel: +33-(0)4-78 42 01 01E-mail: [email protected]

GERMANY• Yakup Gaygusuz

Tel: +49-(0)2324-68 68 812E-mail: [email protected]

ITALY• Marco Vitali

Tel.: +39-02-7030 63 37E-mail: [email protected]

ISRAEL• Heddy Eldar

Tel: +972-(0)3 632 21 13E-mail: [email protected]

POLAND• Agencja Media4M

Tel: +48 (0)12 394 58 48Fax: +48 (0)12 383 23 94Email: [email protected]

SCANDINAVIA, FINLAND• David Lansdowne

Lansdowne Media Services Ltd.Tel: +44-(0)1442-87 77 77E-mail: [email protected]

SWITZERLAND• IFF media ag

Bruno FischTel: +41-(0)52-633 08 84E-mail: [email protected]

TURKEY• Ahmet Serkan Çiftçi

Thomas Endüstriyel Medya Yay. ve Paz. Ltd. Sti.Tel: +90 (0) 216 550 86 80Fax: +90 (0) 216 550 86 85Email: [email protected]

UNITED KINGDOM• David Harvett

Lansdowne Media Services Ltd.Tel: +44-(0)121-705 21 20E-mail: [email protected]

USA & CANADA

• Herbert WeikesThomas Publishing Co.Intl.International Magazine GroupTel: +1-212-629 1546E-mail: [email protected]

ASIA/PACIFIC

CHINA, HONG KONG SAR, MACAO SAR• Arrow Deng

Thomas China (Beijing)Tel.: +86-(0)10-5869 5011E-mail: [email protected]

JAPAN• Ichiro Suzuki

Incom Co. Ltd.Tel: +81-(0)3-3260-7871E-mail: [email protected]

OTHER COUNTRIES

• Karoline BruseTel.: +49-2324-686880E-mail: [email protected]

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Thomas Industrial Media bvbaHendrik Consciencestraat 1b, 2800 Mechelen, Belgium

Tel. +32-(0)15-45 86 00, Fax +32-(0)15-45 86 10www.pcne-online.com

Welcome to the October issue of Processing & Control News Europe, providing you with an

update on the newest products and showing you innovative solutions and applications from all

corners of the processing world.

In our product focus on safety and security we show you how to deal with the ATEX directive,

how to implement functional safety and how a PLC keeps bottling machinery flexible.

In our industry special on energy and water you can discover a SCADA system that evolves to

manage energy usage and chopper pumps dealing with high flows in a water pumping station.

Furthermore you can read about automation in a 200 year old pottery, encoders that ensure accu-

rate fish cutting and how effective packaging can be guaranteed even with frequent format

changes.

For further information to all products and solutions covered please use our SLI Instant Reader

Service. It's fast and easy.

On our website www.pcne-online.com you will find the electronic version of Processing & Control

News Europe. It contains all articles and product news from this issue and offers our easy SLI

reader service.

Our next issue will be published in November, it will feature a product focus on motion

technology and in our special we will look into topics concerning the oil and gas industry.

Comments, ideas, questions? We welcome your feedback!

Enjoy your reading!

Sincerely yours

Constanze Schmitz

Editor PCN Europe+

[email protected]

Dear Reader,

© 2008 Thomas Industrial Media bvbaProduction by Crossmark bvba, Bonheiden, Belgium,

Printing by CORELIO printing, Erpe-Mere, Belgium

POSTMASTER: Send address changes to: Processing & Control News Europe,

Marcel Santy, [email protected]

PCNE_04_05.qxp 9/29/08 3:06 PM Page 2

October 2008 5

Content3 Industry news

6-7 Encoders ensure accurate fish cutting

8-9 Speed control for a cement kiln

10 Effective packaging despite format changes

14-16 Dealing with the ATEX directive

17 Passport to functional safety

18 Safety PLC for bottling machines

20-21 Polyester resins for wind turbine blades

22-23 SCADA system manages energy usage

24 Chopper pumps for screening transfer process

25 Putting a water system back into operation

26-27 Automation keeps a pottery cutting edge

28 Stainless conveyor for radioactive waste

33 Upcoming events

34 Companies in this issue

Cover background picture is courtesy of Citect

Volume 5 - Issue 10

PCNE_04_05.qxp 9/30/08 1:53 PM Page 3

Somebody, who has made a business out of theintermediate steps, is the Baader company, basedin Lübeck, North Germany. Here machines forthe food industry are designed and manufac-tured; these carve meat of all types into portionssuitable for sale – the main focus however is onmachines that process fish – from small gradingmachines up to large production equipment,which can completely skin and fillet the fish.The products from Lübeck are in use all over theworld and can be found, wherever fish is caughtor farmed.

The machines are fully automated and theprocess sequences are carried out seamlessly.In short, the freshly caught fish arrive at one endand the processed fillets drop off the conveyorbelt at the other. A closed loop under vacuumensures that everything remains inside the ma-chine during the gutting process and all wastethen lands in closed containers, which can betransported away for use in the feed and fertil-izer industries.

High precision is of utmost importance, so as toensure that on the one hand as little good fleshas possible is trimmed off and on the other thatno bones remain behind to upset the customer.An automated control was designed for the pro-cessing, to minimize errors when cutting theflesh – Wachendorff encoders represent an inte-gral part of this.

The first stage of the production process is tomeasure the fish; here a measuring wheel, attachedto the encoder via a spring lever, travels over

6 October 2008

Tons of fish fillets pass daily over

shop counters, yet hardly anyone

spares a thought to how the contents

of the nets out there at sea end up

being the ready-to-eat pieces with

no skin or bones.

Encoders Ensure AccurateFish Cutting and Trimming

PCNE_06_07.qxp 9/30/08 2:02 PM Page 2

FLEXIM GmbH · Berlin, Germany · Tel.: +49 (30) 93 66 76 - 60 · Fax.: +49 (30) 93 66 76 - 80

low installation costsdrift free performancefor nearly all pipe materialsfor pipes from DN 6 up to DN 6500

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Non-Invasive Flow Measurement with

FLUXUS® ADM

the fish, thus detecting its profile. The encoder reg-isters the distance travelled by the wheel and makesthis data available to the cutting controller.

Other processing alternatives can be discounted,as each fish is different, its surface being curvedirregularly, wet and reflecting. This means that non-contact methods cannot be employed. Furthermore,all the internal machine components becomesoiled very quickly, so these need to be tough andvery easy to clean.

This is why Rüdiger Eggert, who is in charge of theelectrical engineering department at Baader, us-es Wachendorff encoders here. They are perfect-ly suited to such extreme conditions thanks to theirrugged construction and high IP67 level of pro-tection (IP65 directly on the shaft). The coated ver-sions of the 58 series, which are used here, are food-grade and resistant to salt water, making them theideal choice. Once the profile of the fish has been established,it is transported via conveyor belts to the knives,

which in a split-second remove the head, finsand innards and then the bones. Depending on thetype of fish, this is then skinned as required. So thatthe knives can work accurately at all points, en-coders are also used when moving the fish forwardduring the processing - these ascertain the exactposition and supply this data at the start andend of each cut.

The big advantage of these encoders lies in thefact that the encoder bearing can also assume thefunction of the counterbearing – this meansthat one mounting bracket can be eliminated, sav-ing on costs. The stainless-steel shaft withstands

high loads, vibration and external forces. Theoperating temperature range of between –40and +80 degrees Celsius ensures reliable meas-urement in every environment – even with fishcooled on ice. Thanks to their optimal combina-tion of mechanics, optics and electronics, theWachendorff products are amongst the safest, mostreliable devices available today. Naturally theWachendorff product range also includes acces-sory products, such as the measuring wheel andspring lever.

WACHENDORFFSLI: enter 25173 at www.tim-info.com/pcne

October 2008 7

SLI: enter 22233 at www.tim-info.com/pcne SLI: enter 21940 at www.tim-info.com/pcne

JUMO heatTHERM-ATFirst surface-mounting thermostat featuring the push-in® connection system

http://A104.jumo.infoe-mail: [email protected]

Phone: +49 661 6003-060.0

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PCNE_06_07.qxp 9/30/08 2:02 PM Page 3

Castle Cement is the UK arm of HeidelbergCement, a world-wide build-ing materials group. Heidelberg Cement was founded in Germany in1873 and now employs 76,000 people in 50 countries. The modern ce-ment kiln, at Castle Cement’s Padeswood works in north Wales, is beingspeed controlled by two, 300 kW ABB industrial drives. The drives work inmaster-follower arrangement. Here, both drives have an individual gear boxwhich in turn drives a common girth gear that is attached to the kiln shell.The benefits of this arrangement mean that the speed of the driveschange as the kiln feed increases or decreases. “This speed control is es-sential for the quality of the product,” stresses Castle Cement’s plant elec-trical engineer, Dave Jones.

Another benefit for Castle Cement is that the AC drives, with Direct TorqueControl (DTC), offer torque control and speed control accuracy, ensuring un-interrupted and stable running, irrespective of the kiln speed or the kiln load.Power supply failures and other special occasions result in the need to restartthe kiln. Restarts, requiring a very high starting torque, are easily achievedwith DTC. The drives control characteristics, enables accurate control of thekiln, thus optimising the fuel consumption and the production flow.

8 October 2008

Castle Cement employs industrial AC drives with Direct

Torque Control to ensure uninterrupted and stable

running or their state-of-art kiln,

irrespective of the speed or the load. The drives enable

accurate control of the kiln, thus optimising the fuel

consumption and the production flow.

Speed Control for a Modern Cement Kiln

PCNE_08_09.qxp 9/30/08 3:27 PM Page 2

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Not only has the new €86 million kiln 4 installation increased production atthe works from 500,000 to over 800,000 tonnes of cement per year, but it op-erates to the very highest levels of environmental control, performance andenergy saving.

Central to the greatly improved energy saving of the 65 metre long kilnis an industrial drive used on the ID fan, which at 2MW is the largest driveinstalled at Padeswood. The ID fan, located near the preheater tower, drawsgases through the kiln, precalciner and cyclones before emitting them throughthe exhaust stack.

There are three fans involved in the kiln process and each one iscontrolled by an industrial drive. Apart from the 2MW ID fan, there isan exhaust fan, rated at 750kW that takes gases to the atmosphere viathe dust collecting bag filters and a cooler fan rated at 560kW whichtakes the cooler exhaust gases to atmosphere. A further four fans, rat-ed 110 kW, 160 kW, 200 kW and 250 kW push the air into the gratecooler to reduce the temperature of the hot clinker to a set point.

All these airflows have to be adjusted and controlled as atmosphericconditions, process conditions and ventilation needs greatly effect theflow requirements. The control method employed has a major effecton the running costs. For example, a damper with a fixed speed mo-tor is the least energy efficient solution and the ABB industrial driveshave proved to be the most energy efficient.

“We have about 3.5MW of variable speed drives on fan applicationsand we would expect a 25 to 30% saving over conventional technol-ogy. Low voltage AC drives are primarily used for load matching result-ing in significant energy saving as well as for reduced maintenance ben-efits,” says Dave Jones. “Maintenance is considerably reduced becausemany of the drives have replaced DC drives and slip ring motorswhich required replacement carbon brushes costing over £7,500 peryear in total.”

By installing the industrial drives on the kiln, the ID fan and the oth-er fans, Castle Cement hopes to improve its profitability through increasedsystem availability, energy savings and reduced maintenance. Addition-al benefits of the variable speed drives include total process control-lability and the elimination of motor noise and fan vibration. Castle Ce-ment uses ABB low voltage AC drives for over 150 other applicationsincluding mills, pumps and conveyor belts. In addition, the plant us-es some 450 electric motors.

Meanwhile the sites’ overall improved performance is attributed to theuse of alternative fuels, in which Castle Cement has been a pioneer.Alternative fuels to be used at Padeswood include Cemfuel, which isprocessed from the residue of recycled waste solvents and Profuel, whichcomprises paper and plastic wastes. In the future, vehicle tyres will al-so be used as an alternative fuel.

The opening of the new kiln has resulted in the closure of three exist-ing kilns at Padeswood and two wet kilns at the company’s Ribbles-dale works in Lancashire. This will reduce the company’s carbon diox-ide emissions by 17.5% per tonne of cement produced against 2004performance. Acid rain gases at Padeswood will be reduced by a stag-gering 75%. Since the new kiln came into operation, dioxin levels havebeen reduced to be amongst the best in the world while sulphurdioxide emissions are down by over 90% and carbon dioxide by 20%.

Mike Eberlin, managing director of Castle Cement said: “Kiln 4 will leadto major improvements in the local environment. It will also help re-duce Wales’ dependence on landfill sites while using waste both forcleaner production and lower energy consumption.”

ABBSLI: enter 24441 at www.tim-info.com/pcne

October 2008 9



PCNE_08_09.qxp 9/30/08 3:27 PM Page 3

Galderma has been using the P 91 intermittentmotion cartoner for over a year now. In theFrench factory at Alby-sur-Chéran, the Swissmanufacturer of dermatological products de-clared itself very pleased with its work withRomaco. “The cartoner is running very reliably,has a compact design and is easy to operate,”reported Stéphane Serre, Project Manager ofGalderma. “Format changes occur frequentlyand are quick and easy to do, which very muchsuits our conditions of production.”

The cartoner is used for secondary packagingprocesses on Galderma’s vial line. In addition tothe main product in the Cetaphil care range, twelveother products are packed into folding cartonson the same line, which is why smooth handlingof format changes takes top priority. The carton-er is designed so that format changes can be car-ried out directly by the shift personnel. Thisspeeds up the order of events and allows aconstant production flow, which crucially in-creases the effectiveness of the plant.

With an annual turnover of about €735 million,Galderma, the Swiss pharmaceutical company,is a market leader in dermatological products.This international company, based in Lausanne,was founded in 1981 as a joint venture be-tween Nestlé and L’Oréal.

The manufacturer has offered an extensive prod-uct range of medicines and care products for treat-ing diseases of skin, hair and nails for over 25years.

Galderma has three production locations aroundthe world in France, Canada and Brazil. In Alby-sur-Chéran in the Rhône-Alpes region, the phar-maceutical company employs 120 people in itsresearch and development centre, and a further160 in production. Liquid and semi-liquid sub-stances for seven product lines with numerousdifferent applications are produced in the facto-ry and processed into end products. All primaryand secondary packaging processes are there-fore handled internally.

For Galderma, the intermittent cartoner wasspecially oriented towards the secondary pack-aging requirements of the vial range and inte-grated into the existing line. The plant runs atmedium speed here, with an output of 60 fold-ed cartons per minute (the maximum packagingspeed of the P 91 series is 140 cartons perminute). The plant operation is controlled cen-trally. A touch-screen provides fast access evento current production and allows individual op-erations to be tailored flexibly.

Ergonomic aspects also played a large part in de-ciding on this technology. The balcony design ofthe machine allows good access to all machinecomponents and makes it easier to load the fold-ing cartons. The servo drives and the use of a Ven-turi vacuum unit for picking up and opening thefolding cartons and adding the package inserthave led to a significant reduction in noise ex-posure for employees. The whole product trans-fer runs over toothed pulleys, which is whythere is absolutely no need to use chains or me-chanical gearwheels. This significantly reducesnoise emissions.

“Collaboration with Romaco was extremely pro-fessional,” said Olivier Lidurain, Responsible forProduction Optimization of Galderma, in praiseof the service provided by the packaging special-ists. “Individual support by the Romaco techni-cians responsible was viewed very positively byour employees, primarily because any questionsthat came up could be clarified in French.” Tar-geted training on the machine for employees pro-vided smooth workflows during production andincreased the productivity of the whole plant.

ROMACOSLI: enter 25174 at www.tim-info.com/pcne

10 October 2008

The pharmaceutical company

Galderma uses an intermittent

cartoner for secondary packaging

processes. Benefits are the ability

to change formats rapidly and

a reduction in noise through the use

of actuators and toothed pulleys.

Effective Packaging DespiteFrequent Format Changes

PCNE_10_11.qxp 9/29/08 4:05 PM Page 2

Process Analytics Shows Its Colors.


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One of the new minefields for a product man-ager is the mandatory European Community(EC) Harmonized Safety Compliance Directivesand Standards, with the most current beingATEX directive 94/9/EC. ATEX stands for “Atmos-phere Explosive” (in French) and it is the law inthe EU. Only EU certification agencies are allowedto certify products in accordance with the ATEXdirective. Despite the fact that ATEX compliancetesting has been mandatory in Europe since Ju-ly 1, 2003, many manufacturers are still not in-tegrating the time, labor and cost implicationsof ATEX compliance into their R&D projectplanning and resource allocation.

It has become almost impossible to completeproduct design and secure its timed launchinginto the marketplace without considering all ofthe compliance issues necessary for the glob-al marketplace. Clearly, a product should first andforemost be designed to conform to all thecompliance requirements for all the targeted mar-ketplaces, national and international. This maysound obvious, but many large and multi-nation-al firms have lost huge contracts, big orders andeven had to scrap designed products becausethey could not meet ATEX compliance require-ments.

In some cases, the instrumentation was perfect-ly adequate for the task and met nearly everyother safety directive; but, because it had not yetbeen ATEX-certified, it was unacceptable. Ingeneral, an instrument that can meet most in-ternational safety directives can probably meetATEX requirements, but it first must pass the ATEXcertification process. The devil is in the de-tails, though. Sometimes changes have to be madeto meet ATEX requirements.

Compliance issues and legislation are becom-ing increasingly complex and detail-orient-ed, hence more of a burden to manufac-turers. We cannot describe all the mi-nor differences between ATEX andother requirements in this article, butwe will review some of the funda-mental differences betweenNorth American and Europeanrequirements.

Hazardous Area Classi-ficationsIndustrial operationsoften involve us-ing, processingor storing haz-

ardous (flammable) materials. Among the manyprotection techniques commonly used to anni-hilate, purge or drastically minimize the risks ofexplosion are Intrinsic Safety and Flame/Explo-sion-Proof apparatus, which are highly com-mon in the process instrumentation industry. Suchmethods must be embedded in the initial en-gineering design and subsequent testing ofelectronic devices, and maintained through in-stallation and commissioning.

There are a great number of potential ignitionsources such as unauthorized smoking and useof naked flames, hot surfaces from the processitself, frictional sparking from rusty metals andstatic electricity, including problems from cloth-ing. Most of these sources, at least to some ex-tent, can be controlled and minimized, andthis comes under the heading of sound engineer-ing designs, good plant management and effec-tive control systems. There is however, an ad-ditional problem.

The electrical apparatus necessary to operate theplant’s pumps, lights, instrumentation, and oth-er equipment is itself a potential source of ig-nition. Thus, the very apparatus which should beserving to provide better control over the plantand process may be making the site more,rather than less, dangerous.

The identification of Hazardous “Classified” Lo-cations in a plant is usually carried out by ex-perts or highly qualified personnel, such asprocess, industrial or chemical engineers. Thepossibility of a hazardous atmosphere beingpresent and its condition and duration must beestablished. If an area is known to not containhazardous materials or potentially explosiveatmospheres, then it is classified as a non-haz-

ardous area or a safe location.

In the United States, the classification ofhazardous locations is based on the

National Electrical Code (NEC), whilein Canada the Canadian Electric

Code (CEC) applies. In Europe,Asia and Australia, the tenden-

cy is to follow the recom-mendations of the Interna-

tional ElectrotechnicalCommission (IEC).

In Europe, compli-ance with ATEX Di-

rective 94/9/ECis mandatory

Negotiating the maze of national and

international rules and regulations

can baffle a product manager.

This article reviews some of the

fundamental differences between

North American and European

requirements.

Dealing with the ATEX D

Safety & Security14 October 2008 PRODUCT FOCUS

PCNE_14_15_16_17.qxp 9/29/08 4:25 PM Page 2

when installing and commissioning electron-ic or mechanical devices in hazardous locations.Once an area is classified as potentially explo-sive, a risk analysis will normally dictate thatonly suitably certified electrical and qualifiedmechanical equipment can be installed.

These regulations force manufacturers to gaincertification of electrical and/or mechanical prod-ucts that can be used in a potentially explosiveatmosphere. In many cases, legal requirementswill not allow non-certified products to beplaced in the field, whether mandated by thecompany, the end-user or by specific legislativerequirements and even possibly by insurancepolicy underwriters.

In Europe, hazardous areas are classified into threezones which are directly related to the pre-dicted occurrence of when and the duration thatan explosive atmosphere may be present in thearea. These zones are:

ZONE 0: Where an explosive atmosphere iscontinuously present, or present for long peri-ods of time. ZONE 1: Where an explosive atmosphere islikely to occur in normal operation. ZONE 2: Where an explosive atmosphere is notlikely to occur in normal operation and if it doesoccur, it will exist only for a short time.

Furthermore, European standards require thatapparatus be subdivided into two groups: I andII. Group I is for apparatus to be used in mineswhere the danger is represented bymethane gas and coal dust. Group II isfor apparatus to be used in surface in-dustries where the danger is repre-sented by gas and vapor that hasbeen subdivided into threegroups: A, B and C. The tableshows the similarities or dif-ferences between the NorthAmerican and Europeanpractices, regarding theclassification of haz-ardous locations. Itis important tonote that in thetable below,

Zone 2 (IEC/Europe) and Division 2 (NorthAmerica) are similar to a great extent but arenot identical, while Division 1 includes thecorresponding Zones 0 and 1. An instrumentdesigned for Zone 1 cannot necessarily be di-rectly used in Division 1, and no quantifica-tions of the expressions “long period of time”for Zone 0, “can be present” for Zone 1 andDivision 1, and “not normally present” for Zone2, are given.

In common practice, for Zone 0, a level of prob-ability of a dangerous mixture present morethan 1% of the time is generally accepted. Lo-cations classified as Zone 1 have a level ofprobability of a dangerous mixture between0.01% and 1% (maximum 100 hours peryear), while Zone 2 locations can be consid-ered dangerous when said mixture is presentfor no more than one hour per year.

The main difference between the North Amer-ican and the European classification of hazardouslocations is that there is currently no direct equiv-alent to the European Zone 0 in the North Amer-ican system; however, existing standards maybe revised to allow an equivalent representa-tion. Zone 0 is therefore the most dangerous.An instrument designed for Zone 0 must be in-capable of generating or accumulating suffi-cient energy to ignite the fuel mixture.

SSaaffeettyy MMeetthhooddssTo minimize the risk of explosion, elimination

of one or more of the components of the ig-nition triangle (Figure 2) is necessary. There

are three basic methods of protection:

Explosion Containment: The onlymethod that allows the explosion to

occur but confines it to a well de-fined area, thus avoiding the

propagation to the surroundingatmosphere. Explosion/Flame-

Proof enclosures are basedon this method.

Segregation: Amethod that at-tempts to physi-cally separate or

isolate the electrical parts or hot surfaces fromthe explosive mixture. This method includes sev-eral techniques such as pressurization and en-capsulation.

Prevention: A method that limits energy, bothelectrical and thermal, to safe levels underboth normal operation and fault conditions.Intrinsic Safety is the most representative tech-nique of this method, it being a protectionconcept employed in potentially explosive at-mospheres. It relies on the electrical apparatusbeing designed so that it is unable to releasesufficient energy, by either thermal or electri-cal means, to cause an ignition of a flammablegas. The energies required to ignite variousgas groups have been proven by experimenta-tion.

Electrical equipment that has been assessed,tested and found to be in compliance with theATEX Directive and the relevant European Har-monized Standards must be marked with the cer-tification coding as described in the standards.The product’s ATEX label and markings shouldinclude information stating that it is:

• In compliance with the relevant and applica-ble safety standard/directive.• Intended for use in hazardous or explosive at-mospheres.• Approved for certain gas groupings.• Operational in a specific ambient temperaturerange.• Assigned a certain temperature coding.

MMeeeettiinngg aallll tthhee DDiirreeccttiivveessAs a result of the combination of company in-stallation policies, public legislation and safe-ty requirements, many manufacturers and end-users must deal with issues with which they aresomewhat unfamiliar. New directives andamended directives in the European Union canbe introduced at any time. It is the manufactur-er’s sole responsibility to identify the manda-tory directives and qualify their applicableproducts for full compliance.

The degree of expertise and specialized equip-ment required to meet all the various directivesand requirements is beyond the reach of mostcompanies. Indeed, it is often not cost effec-

X Directive

Safety & Security PRODUCT FOCUS October 2008 15

Hazard Type Continuous Intermittent Abnormal

CEC/NEC Division 1 Division 1 Division 2

IEC/Europe Zone 0 Zone1 Zone 2

PCNE_14_15_16_17.qxp 9/29/08 4:25 PM Page 3


tive to hire and retain a full-time in-house spe-cialist to handle a task or a function that maybe only called on several times a year. MooreIndustries, which builds instrumentation foruse worldwide, has such a full-time special-ist because of the multitude of products itmakes and the markets it serves.

Companies may prefer to concentrate ontheir core business rather than having todeal with the constantly changing legislativeworld of compliance, approvals and certifica-tions. Instead, they outsource their compli-ance requirements.

Outsourcing is a long term relationship be-tween the manufacturer and the compli-ance service. This sort of relationship isideally suited for complex and ongoingproblems of product design and safety com-pliance. Both outsourcing and subcontract-ing are costly, time-consuming and may re-quire substantial material and human re-sources.

Design and compliance firms that provide suchservices must know products, marketplaces,and current and future compliance require-ments so they can fully assist clients from theinitial design specifications to the final list-ing or certification by a third party.

A third party is an independent certificationagency neutral to both the consumer/end-userand the manufacturer. Some of the well-known and reputable testing approval agen-cies for ATEX compliance include ISSeP (Bel-gium), SIRA (UK), LCIE (France), KEMA (Hol-land) and Factory Mutual (USA & UK).

Certification is the process of assessingthe design to the specification setdown in an applicable Standard or Di-rective. Approval or certificationagencies are generally not thestandards-writing bodies (al-though they often have astrong presence on thosebodies) but are rather in-dependent serviceswhich give a third par-ty attestation that acertain design com-plies with the re-quirements of aparticular stan-dard.

TThhee CChhaannggiinngg IInntteerrnnaattiioonnaall SScceenneeMany countries publish their own NationalStandards concerning hazardous and electricalapparatus. Some of these standards still existand others have become superseded.

There are differences from country to countryin the way in which the standards and certifi-cation procedures are implemented. WithinEurope, the Committee for ElectrotechnicalStandardization (CENELEC) produced a series ofStandards aimed at harmonizing the technicalapproach of its member countries. On the oth-er hand, North American approval agenciesadhere to the guidelines and constraints stat-ed by both the National Electric Code (USA) andthe Canadian Electric Code (Canada).

Although Canada follows the classification ofNorth America, it has close links with the IECand CENELEC. In Australia, the Standards Asso-ciation of Australia (SAA) produces NationalStandards, and offers a certification/approvalservice by which its main requirements are

very similar to the European Standards. Al-so, there exist reciprocal arrangements

assuring the acceptance of test resultsbetween European bodies and North

America and Australia.

ATEX is required in Europe, ofcourse, but because many coun-

tries follow Europe’s stan-dards, ATEX is being in-

creasingly required acrossAsia and other regions.

In summary, the fieldof industrial safe-

ty is broad andvery detail-ori-ented. Manufac-

turers are forced to adhere to numerous stan-dards, regulations and directives in order tocompete in the global marketplace and avoidliability and monetary losses caused by faultydesigns and unsafe products. Government agen-cies as well as insurance companies have strictguidelines on industrial facilities to integrate theirprocedures into the highest possible methodsof protection.

The first and primary precaution to be used isto avoid placing electrical apparatus in hazardouslocations. When designing a plant or a factory,this aspect needs to be considered and only whenthere is no other alternative should such appli-cations be allowed. The size of the apparatus,the flexibility of the system, and its cost ofoperation and maintenance are secondary butalso important facts that need to be considered.

Manufacturers of pneumatic and electrical/elec-tronic devices that are intended for use in po-tentially explosive atmospheres must investsubstantial monies in research and development,design and third party agency approvals in or-der to stay in business and compete.

Products designed and intended for installationand commissioning in hazardous locations in theEuropean Community and many other regionsmust be tested and certified in accordancewith the mandated ATEX Directive 94/9/EC, elsethey cannot be sold to the European marketplace.It is that simple: use ATEX-certified products forhazardous locations, else you’ll break the lawin the EU.

By: Gus H. Elias, Senior Certification EngineerMoore Industries-International, Inc.

MOORE INDUSTRIES SLI: enter 25181 at www.tim-info.com/pcne

PCNE_14_15_16_17.qxp 9/29/08 4:25 PM Page 4

Safety & Security PRODUCT FOCUS October 2008 17

The overall objective of functional safety is toprotect workers by reducing incidents and to re-duce risk of loss and costs associated with risk.Cost of risk is the sum of insurance premiums,claims administration fees, workers’ compensa-tion claims, risk management department costs(salary, travel, fringe benefits, and so on), legalfees, and other related costs such as state fees,assessments and consultants. Cost of risk expens-es are measurable direct costs.

Functional safety benefits users by cutting costs,but not reducing safety. It provides them with ahigh safety/failure ratio so that they can max-imise both production and safety.

Using functional safety and its applicable stan-dards requires the availability of data such as prob-ability of dangerous failure per hour (PFHd) or meantime to dangerous failure (MTTFd). This addsthe time domain because functional safety al-lows you to calculate the reliability of yoursafety system. This should not be regarded as anabsolute and certain value but more as an indica-tive and relative quantification that can preventthe use of unsuitable equipment.

Like a travel passport that authorises you to trav-el internationally, a control system that uses afunctional safety concept gives you a ‘pass-port to safety’. That is because a system usingfunctional safety meets international safetystandards, making your system compliant withsafety standards applicable in most nations. Asa result, you have significantly increased glob-al market opportunities to sell your product tonew customers.

Functional safety is the part of the overall safe-ty implementation that depends on the cor-rect functioning of the process or equipment in

response to operational safety inputs. It relatesto the physical operation of a machine orprocess. In other words, functional safety equalsthe confidence in the ability of the safety-relat-ed control system to perform its function overa specified time period.

The name ‘functional safety’ is often associat-ed only with programmable safety systems, butthis is a misconception. It covers a range of de-vices, such as interlocks, light curtains, safety relays,safety PLCs, safety contactors and safety drivesthat are interconnected to form a safety system.

An example of functional safety is an over-temperature protection device using a thermalsensor in an electric motor’s windings to de-en-ergise the motor before it can overheat. The ther-mal sensor performs a function, or action, to helpprovide safety.

Another example: Compare fixed hard guardingto electrically interlocked guarding. The hardguarding is not considered functional safety. Al-though the fixed guard does perform a safetyfunction — keeping people out and materialsin — it is not considered ‘functional safety’because there is no input to a system. The in-terlocked door, however, is an example of func-tional safety. When the guard is opened, the in-terlock serves as an ‘input’ to a system that as-sures a safe state is achieved.

Functional safety falls under the umbrella of therisk reduction process. The risk reduction processinvolves these steps: •Eliminate by design using inherently safe de-sign concepts. •Safeguarding and protective measures with hardguarding and safety devices. •Complimentary safety measures including

personal protective equipment (PPE). •Safe working practice achieved with procedures,training and supervision.

Functional safety addresses the safeguardingportion of the risk reduction process. Whenyou implement integrated safety by design-ing systems so that safety and environmentalconsiderations are fundamental elements ofdoing work, you include functional safety meas-ures as part of the safety system.

Performing a hazard analysis and risk assessmentis the first step in the safety life cycle, which hasfive steps: 1. Risk assessment or hazard analysis. 2. Safety system requirements. 3. Safety system implementation. 4. Safety system validation. 5. Maintaining and improving the safety system.

Functional safety is part of the safety life cyclebecause it is involved in steps 2, 3 and 4.When designing equipment and associatedcontrol systems, a hazard analysis will helpdetermine whether functional safety is neces-sary to ensure adequate protection againsteach significant hazard. If so, then users can in-tegrate functional safety into the machine de-sign requirements, implementation and valida-tion.

A hazard analysis identifies what has to bedone to avoid hazardous events associatedwith the operation and maintenance of themachinery. In addition, a risk assessment givesthe safety integrity required of the safety sys-tem for the risk to be acceptable.

ROCKWELLSLI: enter 25182 at www.tim-info.com/pcne

Functional safety is the part

of the overall safety that

depends on the correct

functioning of the process

or equipment in response

to operational safety inputs,

it relates to the physical

operation of a machine

or process.

Functional Safety as a Passport to Safety

PCNE_14_15_16_17.qxp 9/29/08 4:28 PM Page 5


The everyday life in machine building is condi-tioned by the following fact: If the enduser him-self is obliged to react faster and faster to chang-ing market requirements, his own demands onthe flexibility of the machinery concepts almostautomatically become greater and greater. That'swhy in the field of bottling and labelling the func-tional flexibility has always been one of the keyfactors.

It goes without saying that the market alreadyhas the appropriate answers. Meanwhile, thedifferent processes such as hot-setting adhe-sive, cold-setting adhesive, and self-adhesivelabelling on one and the same equipment canbe used not only in series but also simultaneous-ly. This has become possible by using a differentnumber of mobile labelling processes, whichare coupled to the base machine according to theso-called plug & label principle.

Accordingly to the innovative character of the vari-able machinery concepts, their safety-relatednetworking should, of course, also be state of theart technology. Instead of costly conventional wiring,automated solutions are increasingly requestedhere as well. Since their purpose is to reachmaximum efficiency, they are ideally based onSafety at Work, the safety system of AS-i (actu-ator-sensor interface), which can transmit bothsafe and non-safe signals on the same line.

All around the Pluto AS-i module, which is mas-ter and safety monitor all in one, a consistent and

attractivelypriced concepthas been de-veloped espe-cially for flex-ible bottlingand labellingequipment. Here, specialemphasis isgiven to on-c o n d i t i o nmaintenance,which is get-ting more andmore impor-tant in all industries. As an example, the on-linediagnostics function not only reduces trouble-shoot-ing to a minimum, but also the data can bevery easily transmitted via a gateway to thedownstream fieldbus system, thus allowing itscontroller to reproduce complete momentaryimages of the state of the corresponding equip-ment.

Connecting mobile operator panels in a net-work is also possible in an elegant and unprob-lematic manner by using special absolute encoderswith an AS-i interface. Thereby, a further multi-tude of cables becomes superfluous, thus avoid-ing some occasional problems which were notalways related to the very stringent hygienicregulations.

The Pluto AS-i module combines the functionsof the traditional AS-i master and AS-i safety mon-itor in a single module. It can monitor safety nodesas well as control outputs, in total up to 31safe/non-safe nodes. It is also possible to use thenew module to monitor a system in the tradition-al way with a separate AS-i master. Up to 32 AS-ior PLC models can be connected in a network viathe Pluto CAN bus.

The AS-i module can read information from theother modules and their connected safety deviceson the bus. The entire safety system can beprogrammed with the "Pluto Manager" pro-gramming tool with predefined safety functionblocks, available in the library. The module alsohas 12 regular I/O's. Four of them can work asanalogue inputs. Wiring and connection of sen-sors to the safety system has become very easyusing the AS-i bus and nodes.

JOKAB SAFETYSLI: enter 23838 at www.tim-info.com/pcne

Users expect an ever increasing

level of functional flexibility from

modern bottle-filling and labelling

machines. The machine concepts

required for this purpose, however,

make the development of networked

safety solutions a challenge.

Safety PLC Increases Flexibility of Bottling Machines

PCNE_18_19.qxp 9/30/08 1:58 PM Page 2

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with our self-sufficient and wireless footswitch, Atex autho-rised for Ex zones 1 and 2, as well as 21 and 22. Simply radio»out« of an explosive atmosphere – also possible with radioposition switches, radio pull-wire switches and radio controldevices from steute. Our radio switches transmit their signalswithout the need for cables or batteries. And all this at theno-license frequency of 868 MHz. More information from:

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Safe switchgear for demanding andcritical applications

PRODUCT FOCUS October 2008 19


flame-proof according to ATEX

RESISTANCE THERMOMETER

The resistance thermometer type TOP-Exd-PKG-230 signed Ex II 1/2 GD EExdia/IbIIA/IIB/IIC T6/T5 has been designed for tem-perature measurement in all explosion zonesof gases, streams, fogs and dusts. In zone 0 or20 can be only protection tube. Connection headcan be only in zones 1 (21) or 2 (22). Limit be-tween zones is threaded fitting and insideflame-proof protection tube can be placedonly measuring insert, working in intrinsicsafe wire configuration ia or ib. This resist-ance thermometer has been designed for tem-perature measurement in zones 1 (21) lub 2 (22)and can work with non-intrinsic safe wire con-figuration. Connection head is optionallyequipped with 1 or 2 cable inserts, and with ter-minal block or transmitter.

Alf SensorSLI: enter 25163 at www.tim-info.com/pcne

connects binary signals safely to Fieldbus

ATEX POWER I/O BOX

The Power I/O Box type 8643 is designed to con-nect binary signals to Foundation Fieldbus H1or Profibus PA in process systems – easily,cost effectively and safely. ATEX approved foroperation in Zones 1 and 21, it meets all explo-sion-protection requirements, as well as offer-ing users maximum flexibility regarding intrinsically safe actuator andsensor technology. It replaces conventional discrete cabling with a mod-ular multiplexed system, saving space, cabling costs, and time duringverification and documentation of safety procedures. The device is suitablefor use in areas subject to explosion hazards, such as in petrochemicals, oiland gas, the pharmaceutical industry, water treatment and fine chemistry.For use in these sectors, the device is available either in an aluminium orpolyester casing with IP65 protection, or as an electronic module with IP20/IP30protection for installation in Ex-e enclosures or control cabinets. The de-sign integrates 4 intrinsically safe digital outputs, making possible the con-trol of a wide range of intrinsically safe actuators such as solenoid valves.

BürkertSLI: enter 25198 at www.tim-info.com/pcne

certified for hazardous areas

PRESSURE SWITCHES

The 901 range of ATEX-certifiedpressure switches are suitable for mon-itoring overpressure, vacuum or dif-ferential pressure of both liquid andgaseous substances, including aggres-sive media, in hazardous environ-ments. The switches can be used to monitor fluid levels and filters, aswell as excessive or inadequate pressure and pressure differentials in closedsystems. The switches are available in a factory-set version, in which thepressure setting and switching differential are set by the manufacturer,or an adjustable version, the 901 Prescal, where the customer uses a scaledadjustment knob to alter the trip and reset pressure, without having touse a screwdriver. A range of switch options are available, including pres-sure connections in various materials, shapes and sizes. Customerscan also select from a diverse range of materials for seals and di-aphragms. All switches are intrinsically safe and have been categorisedas Temperature Class T4 and Explosion Group IIB or IIC.

Impress Sensors & SystemsSLI: enter 25154 at www.tim-info.com/pcne

PCNE_18_19.qxp 9/29/08 4:41 PM Page 3

“In fact, China has one of the world’s largestpotentials for wind energy with the windturbine business growing at 40% per year be-tween 2000 and 2006, and with 105% growthin 2006 compared to a global increase of 25%per year”, explains Rob van de Laarschot, NewBusiness Development Manager, at DSMComposite Resins. “China’s spiraling growthin wind energy production is further fueledby the Government’s desire to work towardsa cleaner environment”, he continues. “Whileforeign companies have taken the lead in pro-ducing wind turbines, domestic companiesare now beginning to catch up and developtheir own technologies. With both foreign anddomestic companies involved, wind energyand wind turbine blade production in Chinais an extremely promising and exciting ap-plication and market.”

In efforts to keep pace with energy demandin China and countries worldwide, largerand larger wind turbine blades are beingdesigned to transfer more and more energyfrom the wind. While some 20 years ago, a20m long blade was considered enormous,a blade of this size is small compared to to-day’s largest blade, which is over 60m inlength. According to Rob van de Laarschot,there are even bigger blades on the drawingboards of up to 70m in length. These are tobe manufactured in new types of structuralresins and adhesives based on new genera-tions of structural. “The wind turbine blademarket has largely been dominated by epoxyresins. But to follow the trend of producinglarge series of bigger blades in shorter time,fast processing times are key. Producers arelooking to adapt blade design and to changeproduction processes; they want higher fibercontent and thus greater stiffness and strengthwith a better size/weight ratio for lowerproduction costs.”

In line with these developments, a secondgeneration of unsaturated polyester resins hasbeen released recently. These resins are nowpenetrating the wind turbine blade market.When combined with glass fiber reinforcementand the right sizing, Synolite 1777 resinhas very high mechanical properties. As wellas a lower cost of the material, this newgeneration of unsaturated polyester resinis much lower in viscosity compared toepoxy and does not require post-curing. Thismakes processing faster and easier and so of-fers further cost advantages.

Another significant consideration for blademanufacturers is that these resins can be pro-duced locally in DSM’s Nanjing plant. “Lo-cal production will become even more deci-sive in the choice of resin supplier. As bladesbecome larger and larger, transport is the keyissue not only because of cost but also logis-tics. Local production is therefore a must”,says Rob van de Laarschot.

Furthermore a new sizing for the glass fiberreinforcement of the resin for wind-turbineblades has been launched. Neoxil 728 sizingwill be produced at the dedicated plant inShanghai, China. Neoxil 728 sizing is a lowmolecular weight epoxy with a high solid con-tent and has excellent mechanical propertiespreventing glass fiber from breaking andmaking the glass fiber compatible with the

Wind energy is a booming

industry in China as the

country searches for

cost-efficient solutions

to meet the almost

insatiable demand for

energy of its fast

growing economy.

Unsaturated Polyester Resins for Larger Wind Turbine Blades

Energy & Water20 October 2008 Industry Special

PCNE_20_21.qxp 9/29/08 5:01 PM Page 2

Precise Measurements.

Electronic Evaluation.

Process Optimization.Use magnetostrictive filling level sensors to get an insight from the outside. Infos at Phone +49/40/39 82 07-0 or www.fafnir.com

resin matrix. Furthermore, low migrationproperties reduce the cost of glass fiber pro-duction. For glass manufacturers in China, lo-cal production of purpose-designed Neoxil 728sizing will ensure a consistent high per-forming solution. Remko Goudappel, DSM Business Director

Neoxil Sizings and Binders, explains “DSMbelieves that local production of consistent, highquality sizing for glass fiber reinforcementwill meet a growing need of China’s burgeon-ing domestic production of wind energy gen-erators.” Up until now, most glass fiber man-ufacturers in China have produced their own

sizing in-house. It is very challenging toachieve and maintain a consistent high qual-ity sizing, which is a critical component in thestrength and rigidity of wind turbine blades.

DSM COMPOSITE RESINS SLI: enter 25183 at www.tim-info.com/pcne



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Energy & Water Industry Special October 2008 21

PCNE_20_21.qxp 9/29/08 5:01 PM Page 3

To control energy use and its

associated environmental impacts,

it is first necessary to understand

how and when energy is used.

An energy management system

allows a major manufacturer with

widely distributed site facilities,

to both understand and control

his energy use.

SCADA System Evolves to Manage Energy Usage

The SCADA-based energy management systemwas first commissioned in 2002 by a major USmanufacturing company that required a tool tounderstand electrical use in multiple buildingson its large manufacturing campus. The facilityhas a 13kv distribution system consisting ofmultiple feeders that provide electricity to mul-tiple buildings. Most feeders on the system feedmultiple transformers, so the building load can-not be determined simply by reading individualfeeder loads. Furthermore, the complexity ofthe distribution system and the building trans-formers is such that most building loads couldnot be defined simply by installing meters on alimited number of connection points.

The client had already chosen an electrical me-ter manufacturer and was installing their metersat the start of the system project. This made itnecessary that the energy management sys-tem provided an open architecture and supportfor multiple protocols. The client also requiredaccess to the system from multiple locationsaround the facility so that key personnel can checkelectrical system conditions in real-time from theirdaily work locations.

The initial system was designed using CitectSCA-DA 5.41. Communication to I/O devices wasachieved through a combination of Ethernet andserial channels. The system initially connected

20 advanced electrical meters and 2 electricutility billing meters to the power monitoring sys-tem. The meters were installed on each of the 13kvfeeders in the facility’s electrical substation andat selected locations around the plant to providethe ability to calculate individual building usage.

The original system design included: •Active plant electrical system graphic display-ing electrical conditions and breaker (switch)status in the facility’s electrical substation

•Electric energy consumption for each building •Electric demand for each building•Power flow, energy, and demand through thetwo power transformers that feed the plant

•Alarms on breaker (switch) status•Alarms on high current and low/high voltagearound the facility

•Trending of power and demand for the plant andbuildings

•Tracking electric energy delivered through theelectric utility billing meters

•Two Internet Display Clients to allow engi-neering personnel to access system data fromvarious locations in the facility

As a result of the initial system installation, fa-cilities engineering, operations, and managementpersonnel began to see benefits and identify im-provements in operations that would provide ad-ditional value.


PCNE_22_23.qxp 9/29/08 5:09 PM Page 2

AAddddiinngg NNaattuurraall GGaass aanndd SStteeaammIn 2004, facility energy managers decided to addgas and steam monitoring to the energy system.The addition was complicated by the desire to useavailable transducers to minimise installation cost.Steam lines had flow transducers; gas lines hadonly pulse outputs from the gas utility billing me-ters. The client desired to have consumption, de-mand, and flow data for high and low pressuregas connections and various steam lines feed-ing the plant. I/O devices were connected to thevarious inputs to collect this raw data, which isprocessed in a PLC to calculate the requiredconsumption, demand, and flow data. This approachsaved the client thousands of dollars, whichwould have been required for shutdowns and in-stallation of the necessary metering devices tocollect the raw data directly.

SSuuppppllyy CCoonnttrraacctt MMaannaaggeemmeennttChanges in the electrical energy market result-ed in additions to the system in 2005, when thefacility changed its energy supplier. To improveits ability to stay in compliance with the new en-ergy contract, the facility energy manager decid-ed to make two major changes to the energy sys-tem.

First, the system was modified to automatical-ly report energy usage to the energy supplier everyfifteen minutes. Total electric and gas energy con-sumption for each 15 minute interval is captured.At the end of each interval, the system automat-ically connects to the energy supplier’s serversvia an Internet connection and downloads the con-sumption data. For each interval the system re-ports total imported electric energy, total on-siteelectric generation, and total gas consumption.

Second, the new energy contract had a specifiedmonthly limit in kwh. In order to ensure that thefacility does not exceed this limit, the system tracksenergy consumption for each day and month-to-date. A calendar screen displays the daily andmonth-to-date energy use and percent of budg-et. The screen also provides visual warning whendaily or month-to-date usage is higher than thecalculated budget.

GGeenneerraattiioonn aanndd NNeett MMeetteerriinnggFurther alterations to the electrical supply con-tract, in 2007, resulted in changes to the methodof operation of two large co-generation units in-stalled by the company in 2002. The new con-tract gave the company the ability to sell gen-eration onto the electrical system. As a result, thefacility needed to be able to track energy into and

out of the plant. To achieve this, the systemwas modified to gather pulse outputs from thebilling meters for energy flow in both direc-tions, rather than only incoming energy. Thesystem tracks energy in each demand interval andcalculates demand and peak demand in each di-rection. The usage numbers are tracked month-ly and stored to provide a record of energy useand sales.

OOPPCC CCoonnnneeccttiioonnssAlso in 2007, facility managers decided thatthere was a need to integrate additional data in-to the energy system, from the Wonderwaresystem that was originally installed to monitorand control the co-generation units; and a Hon-eywell EBI system that is used for facility man-agement. The objective of this addition was toreplicate selected system views from the exter-nal systems inside the Energy System. Success-ful OPC connections have been installed to bothexternal systems.

The data pulled from the Wonderware system en-ables plant management to better monitor theconditions of the co-generation facility and theload-shed control system. As a result of this ad-dition, plant management has identified a prob-lem with the load shed system that prevents itfrom fully protecting the plant for the loss of theutility feed.

The data pulled from the Honeywell system is usedto provide plant floor views of electrical use. Thenew views also provide real-time access to elec-

trical conditions at machine tools located through-out the facility.

HHeeaatt TTrreeaattiinngg FFuurrnnaacceeIn 2008, the facility added a new heat-treat fur-nace. This furnace is fuelled by natural gas andelectricity. Plant and corporate managementdesired to track both energy inputs and the re-sults of inputs for the furnace. As a result, the En-ergy System connected to an EIG Shark electri-cal meter and a Mercury Instruments gas meter.Data from both meters has been added to the sys-tem. The system collects energy inputs to the fur-nace and calculates daily and monthly energy use.

EEnnvviirroonnmmeennttaall SSuussttaaiinnaabbiilliittyyIn addition to reducing costs and improving en-ergy efficiency, the energy management sys-tem also helps the system user pursue a policyof environmental sustainability by trackinggreenhouse gas emissions. In 2008 the first ad-ditions to the system were made enabling track-ing of the greenhouse gas impacts of electricalconsumption and of selected natural gas uses.These additions allow plant managers to trackgreenhouse gas emissions and tie them direct-ly to the energy requirements of specific produc-tion activities. The system is designed to trackdirect Scope 1 emissions, and Scope 2 indirectemissions, providing the company with the fa-cility to meet all future targets regarding green-house gas emissions.

CITECTSLI: enter 25184 at www.tim-info.com/pcne


PCNE_22_23.qxp 9/29/08 5:09 PM Page 3

The ability for pumps to operate efficiently, evenwhen storm surges and unusually high flowsoccur, is an essential requirement in many wa-ter, waste and effluent treatment applications.Critical periods are when high flows and stormsurges result in an increase in rag or other heavydebris which can cause pump failure resulting inexpensive downtime. This situation was one ofthe factors leading to the reengineering andupgrading of an Anglian Water pumping sta-tion facility, which included the installation of chop-per pumps.

The Anglian Water One Alliance facility at Gar-rison Road, Great Yarmouth in Norfolk, collectsraw domestic and industrial effluent prior totreatment, as part of its screening and transferprocess from pumping station to works. An au-to self-priming SP10R Chopper pump was sup-plied and installed by P&M Pumps for transfer-ring rag matter from a collection sump adjacentto a storm screen into a gravity main leading tothe local sewage treatment works. Prior to theupgrade, Anglian Water had relied upon macer-

ation and this lacked the required performance,for example, falling short of the flow targets re-quired for the transfer process.

In addition to improving the flow performance,regardless of heavy rag and solid matter, the com-pact Chopper pump assembly, enabled easy in-stallation on top of the existing foundationswhere working space was very restricted.

Commenting on the installation and subsequentpumping performance, Graham Rose, the Site En-gineer at Garrison Road confirmed, ‘The opera-tional problems we were experiencing with mac-eration within the transfer process have been elim-inated, thanks to the Vaughan Chopper pump’.He continued, ‘The pumps ability to handle ragmatter easily and efficiently was crucial to ourselection and an added bonus is that the pumpdoes not macerate solids and rags, it only chopswhat it need to chop to stop the pump from clog-ging’. Graham concluded, ‘The pumps perform-ance has provided the benefit down stream as in-let screens can now remove far more material thanthe previous system allowed’.

Through their experiences at the Anglian Watersite and other installations, P&M Pumps havedemonstrated that their pumps and expertise canbring significant cost-savings. In most cases,retrofitting Vaughan Chopper Pumps in the cor-rect areas to deal effectively with the process, canbe self-financing. Furthermore, payback periodsof less than one year are realistic, thereby min-imising the effect to the budget holders.

VAUGHANSLI: enter 25208 at www.tim-info.com/pcne

Pumps in water, waste and effluent

treatment applications need to

operate efficiently, even when

unusually high flows occur, so

Anglian Water installed chopper

pumps in one of their pumping

station facilities.

Chopper Pumps ImproveScreening Transfer Process


PCNE_24_25.qxp 9/29/08 6:07 PM Page 2

Capital refurbishment of the Iron and Steel fac-tory Mittal Steel in Zenica, Bosnia and Herzegov-ina, by repairing the water system and the lu-brication system of the factory enables an un-interrupted running of the manufacturing processin the plant.

The pump equipment, pipelines, steel construc-tion, water system and other equipment in theIron and Steel Factory have been amortizedand thus seriously damaged. In order to rehabil-itate the water system, many different activitieswere undertaken to completely repair the wa-ter treatment equipment. Some of the activitiesperformed were the supplying of new pumps, over-hauling of the existing pumps and repairing ofpipelines and valves; the dismantling of theold cooling tower; the repair of the electrical equip-ment and establish a new measuring system aswell as the repair of ancillary equipment.

Central lubricating system (tanks, pumps, mainlines, auxiliary lines, valves, pressure limiters and

electro-hydraulic switches) was also overhauledand tested in order to be brought back into op-erational condition.

“More than hundred of pumps and valves wererepaired or replaced with new ones. Also, repairsof pipelines with diameter from 15mm up to 1m,sedimentation tanks, measuring and controlequipment were parts of this project. Experi-ence accumulated through past years, knowledgeand dedication of our stuff was a perfect combi-nation for realization of this project.” said ZlatkoCvetkovski, Head of R&D department of MZT Pumpi.

The activities undertaken in order to rehabilitatethe water system and the lubrication system ofthe Iron and Steel Mills in Mittal Steel – Zeni-ca, Bosnia and Herzegovina enabled an uninter-rupted running of the manufacturing process inthe plant.

MZT PUMPISLI: enter 25207 at www.tim-info.com/pcne

PCN Europe, more than just a magazine!a media portfolio providing a total processing overview through:

websitewww.pcne-online.com

monthlynewsletters

and topical mails

Putting a Water SystemBack into Operation


PCNE_24_25.qxp 9/29/08 6:07 PM Page 3

Denby Pottery may be approaching

its 200th birthday, but its plant is

clearly 21st century. Automation

systems help maintain the delicate

balance of traditional quality and

contemporary productivity.

Automated Plant Keeps Pottery at Cutting Edge

26 October 2008

Clay was discovered at Denby in Derbyshire inthe early 1800s and pottery has been made onthe site since 1809. Although the principles ofproduction are the same as 200 years ago, to-day’s processes would not be recognised by Den-by’s founding fathers. What was very much ahands-on manual industry based on craft skillsand subjective assessments has become high-ly automated, with every pertinent parametermonitored and measured to ensure optimum pro-ductivity and quality.

Like cooking, quality begins with ingredients andDenby is passionate about using the best clay.This is made into slip by mixing it with waterin the cylinder house. Each mixer takes 1.3tonnes of clay and 200kg of water and is linedwith stone cobbles. It is driven through a 2.2msteel ring and nylon spur gear.

“The nylon gear teeth require a soft starting ef-fect, so we use a Mitsubishi inverter. Thereare two gear tooth sensors and a single bolt inthe ring,” explains Site Automation Engineer JohnSpriggs. “The position of these gives us an A,B& Z quatrature encoder. It sounds a bit HeathRobinson, but its spot on for a harsh environ-ment.”

The pulse train feeds into a tiny FX1S PLC (pro-grammable logic controller), the sole means ofcontrol for this mighty machine. The PLC runs themix sequence, the inverter to set the speed ofrotation and a E50 HMI (human machine inter-face) for local diagnostics.

“It amuses me that this monster of a machineis controlled by such small components,” chuck-les John. “You might think that they wouldn’t beup to the job, but they’ve been working away forsome while now – and there are no plans to re-place them yet.”

Part of the slip blending process is the aciddosing station. This was relocated in January 2008to reduce corrosion and has become relativelycomplicated because it is in fact two parallel tanksystems, yet it too is controlled by a local FX PLCand E50 HMI, a combination that gives the finerecipe control required. Next stop is an effluenttreatment panel, where a slightly larger FX2N doesthe honours alongside another E50. The slip isthen dewatered, and as John says:

“This is an energy hungry process, which is whywe try to be accurate with the initial water dos-ing. There is one more pairing in the clay prepa-

PCNE_26_27.qxp 9/29/08 6:11 PM Page 2

October 2008 27

ration process – controlling a magnetic filter thatremoves iron and cobalt impurities that if leftin would leave splots on the finished product.

“Denby is the last pottery in the country to mixits own slip, clay and glazes on site. Its criticalto our quality standards. If anything goes wronghere, we risk writing off a day or more’s produc-tion. Yet the whole process is controlled by con-trollers that would sit in the palm of yourhand.”

The glaze mixing processes are similar to theslip mixing, except the quantities are an orderof magnitude smaller and there is approaching500 different recipes to cover all the differentcolours and finished.

“We’ve got six tanks in the glaze department,all connected via MX4hmi software. Overall con-trol used to be via a PC, but that did not taketo the rigours of the shop floor, so we have re-cently replaced it with the Q series PAC (pro-grammable automation controller)

With the slip and glazes ready, its off to the mould-ing areas. Denby has dozens of ranges of table-ware, cookware, and tea sets, and each range con-sists of any number of bowls, plates, cups,mugs, trays, casseroles, tureens, lids, teapots, cof-fee pots, sugar bowls, flasks etc. Despite this manyof the processes are highly automated.

Round items are perhaps the most automatedin production. Typically the clay is extrudedand cut into precision-sized blanks with a mov-ing head wire cutter. These are lifted ontomoulds, spun and compressed into shape. Theywill then be conveyed through a microwavedryer where the pot is dried sufficiently for de-moulding. The conveyor carries on, perhaps viaan infrared dryer, to a hot air dryer.

Again it is usual to have two identical systemsrunning in parallel. This offers several advantages:two products can be handled simultaneously; largeruns can be handled at double speed, and eachside in turn can be taken down for mainte-nance, resetting or repair so that productionnever grinds to a halt.

“These discrete part moulding processes arequite different from the bulk liquid processingin the materials preparation stage, something thatis reflected in the control cabinets,” John reflects.“Typically a making machine may have a dozenaxes of motion in each side, with a mixture of

induction, stepper and servo motors, plus any num-ber of sensors, fans, switches etc. “

“For many years we have favoured all-Mit-subishi control solutions, and the A-series mid-to-large range PLCs have been the stalwarts ofour making machine control panels. Often we’llalso incorporate an FX or two for dedicatedcontrol of a particular function, such as foot pol-ishing – an abrasive process to smooth theitems’ bottoms to perfection so that they don’tscratch customers’ best dining tables.”

Tiny Mitsubishi Alpha controllers pop up all overthe factory for “relay replacement” applica-tions, often programmed by the electrician in-stalling the unit. John also likes to use Alphason the glaze spray flow lines. Once again, it’sa simple job, but critical for the level of perfec-tion expected by and of Denby.

The final stage in pottery production is firing,mostly using tunnel kilns. Denby has four tun-nel kilns, typically with one PLC controlling theburners and another controlling the haulage. BothPLCs will feed into an HMI so that the shop floorstaff are kept fully aware of every little nu-ance of control in this critical stage.

“The tech spec for a pottery kiln sounds like itcould pass muster at NASA,” says John. Ournewest one is 120m long and its expected torun continuously for the next ten years at least!Our specification for kiln use is the Q-series PAC.”

With the newest kiln coming on stream, its pred-ecessor has been taken out of service and,once it has cooled, will have its control systemupgraded.

“It was still running with its original relay con-trols, but we are going to bring it right up to con-temporary spec with a Q-series system. This isan exercise already successfully completed onour oldest tunnel kiln.”

John and his colleagues have the challenge ofreplicating the achievements of their forebearsand keeping the Denby plant up to the higheststandard of modern control engineering, whilstnever disrupting production or compromisingquality or undermining the heritage of thebrand.

“We have several plans in formulation. Wewill be integrating the different parts of the plantwith an MES (manufacturing execution sys-tem) – no doubt based on Mitsubishi kit, andwe are just discovering the delights of robotsfor a variety of tasks, including machine load-ing and unloading. We expect this to be a rolewhere Mitsubishi robots will continue to figurein the future. And of course we have to do ourbit towards the environment, so we are havinga big push on energy management.”

MITSUBISHI ELECTRICSLI: enter 25186 at www.tim-info.com/pcne

PCNE_26_27.qxp 9/29/08 6:11 PM Page 3

28 October 2008

The programme to decommission the UKAEA(United Kingdom Atomic Energy Authority) site atHarwell in Oxfordshire and transform it into aworld-class centre for excellence in science andinnovation is a complex technical process requir-ing a great deal of hard work in planning and im-plementation.

One of the companies supporting UKAEA is NuviaLimited (formerly NUKEM Limited). Nuvia offers anextensive engineering design resource for thenuclear industry ranging from new build plantfor radioactive and hazardous environments,shielded facilities and containment systems, andtreatment plants for solid and liquid active wastein addition to extensive radiation safety and con-sulting expertise.

Nuvia has been awarded a contract to designand build a nuclear waste encapsulation facility atthe site, which has included an Excel Automationconveyor system designed to transport stainlesssteel drums containing intermediate-level ra-dioactive waste (ILW) through the process.

The drums, which are 800mm in diameter, 1,200mmhigh and weigh up to 1,000kg, are loaded onto theconveyor system from an existing drum storagefacility. The conveyor system then transports the

drums through the process, which involves druminspection followed by grout filling of the drums,before transporting them back to the existingstorage facility. During the process the weight ofthe drums increases to a maximum of 2,000kg.

The Nuvia specification required the contact sur-face of the conveyors to be stainless steel. Tomeet this specification, a bespoke handling sys-tem was designed consisting of sets of poweredroller conveyors fitted with stainless steel tube rollersand side guides; and cross-chain transfer units hav-ing stainless steel pads fixed to the chains. The rec-tangular conveyor system layout carries drums in-side a ‘cell’ with a concrete roof and walls. As thedrive motors are located outside the cell, each ofthe conveyors is fitted with a through-wall driveto enable the drive shaft and coupling of the mo-tor gearbox to connect to the conveyor chains thatdrive the rollers. The support structure of the con-veyors and any equipment that is not in contactwith the drums, are manufactured from carbon steeland finished with a special paint.

Because the cell is a restricted area a drum removalsystem had to be designed and supplied consist-ing of a hand operated cable winch recovery bo-gie and hydraulic cylinder-driven drum pushers. Inthe event of a conveyor breakdown, the drumpushers are extended through the walls in orderto push drums into a position where they can betransferred to the existing storage facility.

Proving all components and the system itself off-site was also a key requirement of the contract. Thisinvolved testing a sample of the conveyor drive sys-tem to ensure that the lubricant free drive chainsused ‘incell’ were fit for purpose and could be ap-proved. The system was then made and assembledin Worcester and laid out in the company’s work-shops. Each item of equipment underwent a unittrial, which was then followed by a total factory ac-ceptance test and buy-off by both Nuvia and its cus-tomer UKAEA. The whole system was then strippeddown, packed, itemised, and delivered to site,where it was installed by Nuvia.

Commenting for Nuvia, design manager AndyBlue says: “Excel Automation was involved inthe project from the start, and the input of its de-sign and engineering team on the conveying sys-tem was invaluable. The installation itself also wentvery smoothly and we were delighted with the re-sult.

EXCEL AUTOMATIONSLI: enter 24521 at www.tim-info.com/pcne

A conveyor system designed

to transport stainless steel

drums containing

intermediate-level

radioactive waste is applied

in the programme to

decommission a site for

nuclear research.

Stainless Conveyor SystemHandles Radioactive Waste

PCNE_28_29.qxp 9/29/08 6:28 PM Page 2

October 2008 29


for use upon compressed air, gas and liquids

ORIFICE RESTRICTORS

The range of miniature orifice re-strictors for use upon compressedair, gas and liquids to pressures of125psi (8.5bar), incorporates a pro-tective stainless steel filter en-closed within precision mouldedpolysulfone housing. Ten colourcoded orifice diameters rangingfrom 0.10mm to 0.76mm are avail-able, each being suitable for in-lineinstallation within flexible tubingof 1.57mm and 3.17mm inside di-ameter. A choice of 5, 25, 43 or 73 Micron filtration is offered depend-ent upon selected restrictor orifice diameter. This product is suitedwhere precise flow is essential; they are light in weight, inexpensive andcorrosion resistant. Applications include laboratory, instrumentation,fluid power and analytical industries.

The West GroupSLI: enter 25170 at www.tim-info.com/pcne

calibrates and tests pressure devices

PRESSURE CALIBRATOR

The 719 Electric Pressure Calibrators feature a built-in electric pressure pump that makes it possibleto quickly calibrate and test pressure devices withone hand. Process technicians, plant mainte-nance technicians and instrument technicians whodo pressure calibration work often use manualpumps to pressurize transmitters and gauges. Thatrequires the use of two hands: one to pump andone to hold the pressure calibrator. With itsbuilt-in, battery powered pump controlled by athumb button, the calibrator is more convenient,faster and easier to use. The electric pump canbe programmed to set target pressures or limitpressure to eliminate over pressurization. Itscleanout port makes it easier to service the pressure calibrator withoutsending it out for repair. The cleanout port minimizes pump failures causedby accidental exposure to contaminating fluids.

FlukeSLI: enter 25172 at www.tim-info.com/pcne

for accurate, fast and easy water field testing

HANDHELD COLORIMETER

The eXact Micro 7+ handheld col-orimeter is suitable for residential,commercial, and municipal water test-ing. It reads 9 parameters directly: Al-kalinity; Bromine; Calcium Hardness;Free Chlorine; Total Chlorine; Copper;Ozone; Permanganate; pH and Trans-mission. Additionally, in transmissionthe meter tests for: Ammonia; Chloride; Chlorine Dioxide; Chromium Hexa-valent; Cyanuric Acid; Iodine; Iron; Low Range Total Hardness; Manganese;Nitrate; Nitrite; Acid pH; Alkali pH; Potassium; Sulfate; Sulfide and Tur-bidity. The meter fits comfortably in your hand, is waterproof (IP-67) andthe sampling cell is built into the meter. It is EPA-compliant for Free andTotal Chlorine regulatory testing. Its environmental friendly with a 4mlsample cell using 60% less chemicals than the ordinary 10ml test. Themeter provides reliable accuracy, minimum variation, and fast results(uses 20 second test method) at 0.01 resolution.

Industrial Test SystemsSLI: enter 25169 at www.tim-info.com/pcne

PCNE_28_29.qxp 9/29/08 6:28 PM Page 3

30 October 2008

Sierra

The Cal=Trak XL Pri-mary Standard GasFlow Calibrator is de-signed for high flowsup to 500l/min. Suit-ed for calibration ofgas measuring in-struments includingmass flow meters and controllers, it offersclass-leading accuracy of +/- 0.25% of reading.The dimensionally-based primary accuracy is su-perior to pressure-based secondary methods andis backed by a rigorous uncertainty analysis. Dueto its compact size its on any laboratory benchreplacing large bell provers with one simple, in-tegrated package. It can be used in the man-ufacture, inspection, validation and recalibra-tion of mass flow controllers, flow meters andmany other varieties of flow equipment with flowrates too high for common primary standard de-vices. In either manual or automatic opera-tion, it measures, displays and outputs theflow of gas, either in mass or volumetric units.The menu-driven configuration allows end-users to customize the calibrator to fit their chang-ing needs. The single integrated piston cham-ber of the can measure flows from 5 to 500 l/min,over a 100:1 range.

for high flows

GAS FLOW CALIBRATOR

SLI: enter 25204 at www.tim-info.com/pcneSystec Controls Mess-und Regeltechnik

Deltaflow flow metersare differential pres-sure probes whichmeasures the flowin pipes and conduitsand can be used tometer gases, steamsand liquids under al-most any operatingconditions and acrossa broad spectrum ofindustries. In power plants it meters all gaseousmedia reliably and precisely, including feedair, preheated air, recycled stack gas and fluegas. In addition, it can meter media with extreme-ly high particulate contents of <200g/m3, livesteam, low / medium-pressure steam andfeed water, all tested per PED97/23/EG with CEcertification. In chemical and petrochem indus-tries they can meter products, exhaust or fluegasses, inert or aggressive media. It is alsosuited for measuring biogases and sewagegasses in the water and wastewater treatmentindustries. The series can be used on pipe di-ameters from 3mm up to 15,000mm and pres-sure ranges can span between 0 to 100 bar, upto 0 to 690 bar. Turndown is >1:30, bi-direction-al, temperature range from -200 to 1,240ºC.

for gas, steam and liquid applications

FLOW METERS

SLI: enter 25200 at www.tim-info.com/pcneHumphrey Products

The HKL5 valveis designed foruse with reagentsand other aggres-sive liquids andgases found intypical analyticalapplications. Thisdirect-acting so-lenoid valve is acompact 12.6mmwide, with a high0.05 Cv flow rate,low 1.8 watt power consumption, a pressure rat-ing from vacuum to 2bar, and a working tem-perature range from 0 to 80°C. The valve fea-tures multiple porting configurations, can be usedas a 2-way or 3-way, NO/NC standard fill/ex-haust valve, or as a selector or diverter, and canbe mounted on a manifold or a subbase, withcustom Acrylic manifolds available upon request.It features diaphragm-poppet valve design,which has no sliding seals, no metal-to-metalcontact and requires no lubrication. The di-rect-acting solenoid has an isolated coil withminimal armature travel for a fast responsetime of 0.010/0.004 ms, and is available in 12or 24VDC coil voltages.

designed for aggressive liquids and gases

SOLENOID VALVE


uniprod

The Monitor 2 isintended for indus-trial measurementsof following pa-rameters of waterand sewages: dis-solved oxygen con-centration in water,pH, redox, conduc-tivity, turbidity and suspended solids continu-ously. This monitor is used for the quality con-trol of water in the industrial treatment plants,water pollution control stations, power andchemical industry etc. It consists of measure-ment converter and appropriate measurementsensors. The microprocessor controlled trans-mitter is provided with a 128x128mm LCDgraphic display for the presentation of measuredvalues and parameters of the system. A well de-signed menu enables total control of parame-ters of the transducer and preview of all inputsand outputs. The instrument is equipped witha 3 fully isolated, freely programmable 0/4-20mAcurrent outputs (measured values and tem-perature), alarm relay, 4 freely programmablerelays. A serial interface RS-485 is optionallyavailable to create a Bus connection (Mod-Bus, Profibus protocol or other).

for treatment plants & water control stations

LIQUID QUALITY MONITOR

SLI: enter 25164 at www.tim-info.com/pcneMoore Industries

The TCS Temperature Concentrator Systemsubstantially reduces the cost of transmittingmultiple temperature sensor measurementsby concentrating up to 32 signals onto a sin-gle twisted wire pair. The system provides a pre-cision measurement at less than 25 percent thecost of using comparable stand-alone smart tem-perature transmitters. It accepts any combina-tion of RTD, T/C, mV and resistance/potentiome-ter signal inputs, converts the inputs to the Hartdigital communications protocol, and trans-mits the data long distances from the field tothe control room on an economical Hart digi-tal data link over a twisted wire pair. All process,status and diagnostic information can then beaccessed by a Hart-based control system. Ituses Hart - or ModBus RTU with a converter mod-ule - for communication from the field to thecontrol room. One twisted wire pair replaces ex-pensive dedicated wires. The TCS, being a loop-powered device, eliminates the need to send pow-er wiring out to the field as well.

reduces the transmitting cost

TEMPERATURE TRANSMITTER

SLI: enter 25165 at www.tim-info.com/pcneApplied Measurements

Constructedfrom stainlesssteel thePi600 seriesof pressuresensors, aresealed to IP65(plug & sock-et) or IP66/68(cable). Theyhave a ceramic diaphragm, offering compat-ibility with a wide range of pressure media.Absolute and gauge versions are available andthere’s a wide choice of electrical outputsignals to meet the customer’s operationalrequirements. Three accuracy levels are avail-able down to 0.05% across a pressure rangefrom as low as 0-10mbar up to 0-700bar.The Pi600 Series also offers excellent chem-ical and abrasion resistance. Operating tem-perature range is from –20 up to 135°C,with temperature compensation down to0.01%/°C if required. The sensors are com-pact and weigh 100g. Various pressure portconnection thread options are available. Out-put options include millivolts, 0-5V and 0-10VDC, 4-20mA, plus a special ratiometric 0.5-4.5VDC.

sealed to IP66/68

RUGGED PRESSURE SENSOR


PCNE_30_31.qxp 9/29/08 6:36 PM Page 2

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Experience electric automation at its best!Come and see it all!Control Technology

IPCs

Drive Systems and Components

Human-Machine-Interface Devices

Industrial Communication

Industrial Software

Interface Technology

Electromechanical Components and Peripheral Equipment

Sensor Technology

ElectricAutomationSystems and ComponentsExhibition & Conference25 – 27 Nov. 2008Nuremberg

SPS/IPC/DRIVES/

www.mesago.com/sps


October 2008 31

Asco Numatics

The 1/4" and 1/2"ASCO ActuatorControl System(ACS) range ofstandard, explo-sion proof systemsis designed for thecontrol of actua-tors on processvalves. The rangecomprises solenoid valves, spool valves, man-ual reset valves and filter regulators and redun-dant components to prevent unplanned shut-downs. They have many applications in theprocess industry and address the growing de-mand for manifold systems, especially in appli-cations where corrosive atmospheres (for exam-ple offshore), are present. The high reliabilitymodular system uses proven technologies andis manufactured in 316L stainless steel to re-sist aggressive environments. Tested up to150bar, the system features an optimised flowpath and is lighter, stronger and more compactthan conventional panel mounting assemblies.The components are connected by means of aversatile, leak tight coupling system and mount-ed on a vibration resistant and shock proofstainless steel base plate.

explosion proof, for process valves

ACTUATOR CONTROL SYSTEM

SLI: enter 25171 at www.tim-info.com/pcneBronkhorst High-Tech

The Massview mass flow me-ters offer an economical, dig-ital alternative to convention-al VA meters (variable areameters) also known as purgemeters. The series incorpo-rates a digital bar graph of ac-tual gas flow, which is, thanksto the OLED clearly visiblefrom all angles, as well as in-dicating flow units, gas type andtotalised figures. Availablewith an optional in-built nee-dle valve for flow control duties, it is designedto mimic the straightforward features and ver-tical format of the VA meter, but with theadded benefits of an electronic output signal,high measuring accuracy, virtual independ-ence from gas temperature and pressure vari-ations, freedom from parallax error and inher-ently safe construction, with no fragile glass com-ponents in the flow path. It operates on the prin-ciple of direct thermal mass flow measure-ment and is virtually independent from gastemperature and pressure. It offers best accu-racy of ±1% FS plus ±1% RD, with flow ratingsfrom 0.01 to 200 ln/min (SLM), and handles pres-sures up to 10bar (g).

as an alternative to VA meters

MASS FLOW METERS

SLI: enter 25168 at www.tim-info.com/pcneGemü

The automatic systemfor sterile sampling ofpure steam conden-sate is designed tomonitor pure steamquality in sterile plantin the pharmaceuti-cal, food and bever-age industries where samples are regularlytaken from the steam ring mains and theircontamination analysed in a laboratory. Forthis purpose various systems have been usedto date where sampling takes place manuallyor semi-automatically. The operator of the plantor the lab technician usually had to monitor theentire procedure. As well as potential contam-ination of the sample taken, with some systemsthere is a Health & Safety issue concerning theincreased risk of scalding. This system totallyisolates the condensate sample and reduces theoperator involvement and potential injury. It con-sists of a sampling multi-port valve with pneu-matic actuators, a stainless steel samplingbottle as well as a compact control unit, eithermounted ready-to-connect on a movable standor as a static version. Parameters such as ster-ilization time and condensate volume can beindividually set via the control system.

fully automated, for pure steam

CONDENSATE SAMPLING SYSTEM


PCNE_30_31.qxp 9/29/08 6:36 PM Page 3

32 October 2008

MacroSensor

The high-pressure and seawater-resistant LVDTPosition Sensors can be used to measure the po-sition of the valves, called chokes, on sub-seaoil well control towers (called Christmas trees),located at the wellhead, as well as controllingor measuring position of robotic arms and ac-tuators. Seawater applications often require aservice life of as much as 20 years while beingexposed to seawater pressures up to 500bar, thesensors are designed from 316SS and Inconel625 for pressure and corrosion resistance.These materials enhance the high reliability ofthe LVDT assembly. To minimize the number ofpressure-sealed connections and I/Os, a 4-20mA two-wire, loop-powered I/O can be uti-lized, which is then, converted to a RS485 sig-nal for transmission to the surface. A 4-20mAI/O also minimizes any noise over long trans-mission lines. Offsets can be easily made in thedata acquisition system on the platform above.

high-pressure and seawater resistant

LVDT POSITION SENSOR

SLI: enter 25202 at www.tim-info.com/pcneWhitewater Well

The SWD3 PortableSand MeasurementUnit is an automat-ic, realtime, inlinestandalone monitorfor measuring sandand other particulateconcentrations in wa-ter lines. Designedfor continuous oper-ation without theneed for routinecleaning or mainte-nance, the device provides reliable, real-timesand concentration data in the field. Auto-matically measuring sand content as low as 0.1ppm, it delivers continuous real-time data andenables easy collection of samples for offsiteanalysis - providing a true picture of well con-ditions and ensuring that sand concentration doesnot exceed regulatory agency requirements.Requiring no manual calculations, the plug-and-play unit eliminates human error in calculatingsand concentrations. Cost-effective, durable,and corrosion resistant, it provides a user-friendly interface, enables easy single-operatoruse, and conveniently attaches to a notebookcomputer for data downloading.

for waterlines, portable

SAND MEASURING SYSTEM

SLI: enter 25209 at www.tim-info.com/pcneEndress+Hauser

Field Xpert is ahigh performancedevice configu-rator that meetsthe needs andrequirements ofthe process in-dustry. The hand-held is designedfor device con-figuration, it allows for wireless communicationvia Bluetooth or WLAN based on an industrialPDA. The Windows Mobile operating systemmakes it possible to install further software ap-plications for Plant Asset Management activ-ities such as maintenance and documenta-tion. The configuration software package DeviceXpert for field device enables commissioning,diagnosis and maintenance of all registered HARTdevices as well as automatic distribution ofDevice Descriptions (DD) via Internet or WLAN.For Endress+Hauser time-of-flight level de-vices it allows to create envelope curves. It of-fers a 3.5" transreflective TFT color display.The working temperature ranges from -10 to 60°C(non EX version) or -10 to 50°C (Ex version). Itsantistatic and non-corroding housing conformsto protection class IP65 .

for HART-based instruments

DEVICE CONFIGURATOR


Hypertac

The high speedrugged i zedcontact systemis designed forthe transmis-sion of Ether-net high-speedsignals in harshenvironmentapplications.The contact uses the company’s hyperboloid tech-nology which offers integrity and reliability,even under high levels of shock and vibra-tions. It is housed in a ruggedized shell whichenables a reliable cabling. The system is avail-able in Twinax, Triax and Quadrax versions andcan be used in many of the circular and rectan-gular modular connectors series e. g. BE-, L- andC-Series. The system meets the requirementsof Ethernet Class F (CAT 7), which is the high-est performance level. It is compliant with thelatest Ethernet standards (IEE802.3) and achievesmore than 700 MHZ DC. It can be easily removedfrom the connector insulator with the appropri-ate tooling, enabling easy maintenance. The con-tact system is designed for cables of a resist-ance of 100, 120 and 150 Ohm and of sizes from6.5 to 13 mm diameter.

for harsh environment applications

ETHERNET CONTACT SYSTEM

SLI: enter 25340 at www.tim-info.com/pcneDonadon SDD

Chemical plants,tanks, reactors, si-los and any otherequipment work-ing under pressuremay be damagedor destroyed by uncontrolled pressure rises.Protection of personnel and equipment from thisrisk is achieved with safety devices that providean adequate fluid outlet, venting the excess pres-sure. Rupture discs and relief valves are the safe-ty devices used more frequently. Their designand performance are different but both types pro-tect the equipments from high pressure. Theymay be used independently as primary safetydevices or in conjunction. If the rupture disc isinstalled upstream from the valve the posi-tive properties of both devices - leak tight sealof the disc and re-closure of the pressure reliefvalve - are combined. The disc then protects thevalve from corrosive or scaling products, reducesthe maintenance requirement of the more ex-pensive and sensitive equipment and makes itpossible to test the performance of the valve with-out shutting down the plant and dismountingthe valve. Both are normally set at the same pres-sure. The pressure build up in the space betweenthe two devices must be monitored.

protect from pressure surges

RUPTURE DISCS

SLI: enter 25341 at www.tim-info.com/pcneSwagelok

Variable areaf l o w m e t e r s(VAFs) are usedto measure liquidand gas flowrates by meansof a tapered tubeand float. Theyprovide accurate measurement with individu-ally calibrated scales and a 10:1 turndown ra-tio. The VAFs are factory calibrated and markedto indicate the specific media, flow range, andaccuracy class. In addition, the product canbe calibrated and marked to customer-specif-ic applications. Customers can choose from10 variations of variable area flowmeters fittedwith glass or metal measuring tubes. The G se-ries models feature glass measuring tubes,which enable direct view of the process read-ing and flow at the meter. For use in difficult op-erating conditions where pressure or temper-ature is a factor, M series models are equippedwith metal measuring tubes and mechanical orelectronic displays. The flowmeters are avail-able with NPT and flange end connections insizes from 1/8 to 11/4 in. Available options in-clude high/low flow indicators, transistor relays,and 4 to 20mA analog outputs.

can be calibrated to custom applications

VARIABLE AREA FLOWMETERS


PCNE_32_33.qxp 9/29/08 6:40 PM Page 2

Upcomingevents

For more information: www.pcne-online.com/events

OCTOBER

• Maintain14 - 16 October, München, Germanywww.maintain-europe.com

• Pumps & Valves15 - 17 October, Antwerp, Belgiumwww.2.fairtec.com

• ISA14 - 16 October, Houston, USAwww.isa.org

NOVEMBER

• Valve World4 - 6 November, Maastricht, Netherlandswww.valve-world.net

• Exposolidos18 - 20 November, Barcelona, Spainwww.exposolidos.com

• SPS/IPS/Drives25 - 27 November, Nuremberg, Germanywww.mesago.de

DECEMBER

• SCS automation & control2 - 5 December, Paris, Francewww.scs-automation.com

• Pollutec2 - 5 December, Lyon, Francewww.pollutec.com

22000099MARCH

• Process Management Academy Europe2 - 4 March, Düsseldorf, Germanywww.arcweb.com

• Industrie10 - 13 March, Lyon, Francewww.industrie-expo.com

October 2008 33

Hans Turck

The M25U sensor is completely enclosed in stain-less steel - including both the housing andsonic converter face - and complies with degreesof protection IP68/IP69K. Thus the ultrasonicbarrier sensor consisting of both transmitter andreceiver is particularly suitable for detection ofbottles and containers in aseptic applications,such as bottling operations in H2O2 atmospheres.It fully fulfils all demands relating to hygien-ic design in the beverage, food and pharmaceu-tical industries. The stainless steel enclosure isnot just resistant to chemicals and aggressivecleaning agents, but is also resistant to temper-ature shocks. It is possible for example, after clean-ing with 60°C hot water to rinse with 10°C coldwater without damaging the sensor. It is adjustableto two sensitivities: Objects with a minimumdiameter of 30mm are detected up to a rangeof 1m at higher sensitivity - for objects from 15mmdiameter the maximum range is 40cm.

fully encapsulated, IP68/69K

ULTRASONIC SENSOR

SLI: enter 25159 at www.tim-info.com/pcneEmerson

The two-wireMicro Motion2200S Coriolismeter, expandsthe value ofCoriolis to arange of applica-tions that require loop-powered flow devices.The meters can upgrade older loop-powered tech-nologies to ELITE Coriolis meters withoutadding more power or installing new cabling.It delivers +0.10% liquid flow and +0.0005 g/cm3

liquid density accuracy in continuous processand mass balance applications. It has no mov-ing parts and requires no maintenance. Equippedwith MVD digital processing technology, the trans-mitter delivers multivariable and diagnosticinformation via HART communications. Front-end digital processing reduces signal noiseand offers a faster response time compared toanalogue devices. It is suited for use in the chem-ical, petrochemical and refining industries, andfor continuous process and mass balance appli-cations, The transmitter has CSA Class1 Divi-sion 1 or 2 approvals, and ATEX, IECEx, NEPSIZone 1 and Zone 2 approvals. Available with an316L stainless steel enclosure it is suited for harshenvironments.

to upgrade loop-powered technologies

2-WIRE CORIOLIS METER


Amphenol Industrial Operations

The Amphe-Power GT is a 5015-style, reversebayonet coupling connector with audible, tac-tile and visual indicators of a secure attachment.Adaptable to the severe conditions encoun-tered by wind power generation equipment, agri-cultural appliances, military and other equip-ment operating in exposed environments, theGT series features more than 12 different shellstyles, high shock and vibration resistance anda rugged, waterproof construction to IP67. Thequarter-turn mechanism, allows for at least2,000 quick and easy matings in the field,without special tools. The component’s ease ofinstallation, long lifespan and quick replacementmaximises operational up-time. An extensiverange of options includes: solder or crimp ter-mination, gold- or silver-plated contacts, mil-itary or commercial finishes, Neoprene or Vitoninserts in addition to low smoke/flame retar-dant inserts, a diverse set of back-end fittings,aluminium or stainless steel components andover 250 configurations.

rugged, waterproof construction to IP67

BAYONET CONNECTORS

SLI: enter 25157 at www.tim-info.com/pcneMikster

The LGTD-R-01/K radiohumidity and temper-ature sensor is a meas-urement module,which read-out is doneby radio link. Applica-tion of this sensor isrecommended if cre-ation of wiring systemmakes difficulties. Thissensor has a self mem-ory Flash type with50kB capacity that en-ables to log humidity and temperature inces-santly till 18 months (with logging frequency- every minute). Read-out from sensor is doneby radio data logger connected to PC com-puter (with Logginet software) by RS232 con-nection and converter RS232/RS485. Systemis protected against unforeseen interferencesin radio communication thanks to tempera-ture and humidity logging in sensors directly.Communication gap may include 18 months.It protects against the loss of data because ofradio communication cutting off. Radio Logginetis applied everywhere temperature and hu-midity monitoring is required without allowingfor a possibility of data losses.

read-out done by radio link

RADIO TEMPERATURE MODULE


PCNE_32_33.qxp 9/30/08 3:41 PM Page 3

34 October 2008

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A ABB 8

Alf-Sensor 19

Amphenol Industrial Operations 33

Applied Measurements 30

ARC Advisory Group 2

Asco Numatics 31

B Bronkhorst 9, 31

Bürkert 19, 36

C Citect 22

D Donadon SDD 32

DSM Composite Resins 20

E Emerson Process Management 33

Endress + Hauser 32

Excel Automation 28

F Fafnir 21

Flexim 7

Fluke 29

G Gemü Gebr. Müller Apparatebau 31

Georgin 21

H Hans Turck 33

Humphrey Products 30

Hypertac 32

I Impress Sensors & Systems 19

Industrial Test Systems 29

J Jokab Safety 18

Jumo 7

K Knick 11-13

M Macro Sensors 32

Mikster 33

Mitsubishi Electric 26

Moore Industries 14, 30

MZT Pumpi 25

R Rembe 9

Rockwell Automation 17

Romaco Group 10

S Samson 29

Sierra Instruments 30

SPS/IPC/DRIVES 31

Steute Schaltgeräte 19

Swagelok 32

systec Controls Mess- und Regeltechnik 30

T The West Group 29

U Uniprod 30

V Vaughan 24

W Wachendorff Automation 6

Whitewater Well 32

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