01-2020

12 COVERLONG LIFE SPAN

RUPTURE DISCS

16 SMART PRODUCTION

MAKING THE WEALTH OF

DATA USEABLE AT LAST

20 INDUSTRIAL SECURITY

UPDATE MANAGEMENT

FOR THE PLANT NETWORK

40 OFF TO THE CLOUD

DIGITAL SERVICES IMPROVE

PLANT AVAILABILITY

PROCESS TECHNOLOGY FOR THE CHEMICAL INDUSTRY

WWW.CPP-NET.COM

easy handling with tactile HMI and wizard

www.effi ciency-to-the-i.com

cpp 01-2020 3

cpp EDITORIAL

Hannover Messe and Ifat postponed

In the April issue of cpp, the emphasis is normally on pre-fair re-ports linked to the Hannover Messe, which takes place every year around this time. A comprehensive Special Subject section was also planned for this year. However, the global developments surround-ing the coronavirus have completely overturned both our plans and those of the exhibitors and organisers. Like many other exhibitions and events, the Hannover Messe has now been postponed from the original April date until the week from 13 to 17 July in consultation with the Hannover regional health authority, the Exhibitor Advisory Committee of Hannover Messe and VDMA and ZVEI, the HMI’s partner associations. From the health and safety point of view, this is undoubtedly the only right option for exhibitors and visitors alike; it remains to be seen whether the new July date which has been fixed for the Hannover Messe is an equally good decision. Against this background, the April issue of cpp has been amended to take account of current developments and the Special Subject section put off until the June issue. In view of the recommendation by the German Federal Ministry of Health and the Bavarian state government, Messe München felt similarly compelled to postpone Ifat 2020. The world’s leading trade fair for environmental technologies should have opened its doors on 4 May. Modern water and waste water technologies are key themes of this exhibition, which will now be staged from 7 to 11 September 2020. Our Special Subject section on Ifat has also been dropped from this issue for this reason. The coronavirus is causing considerable disruption all over the place and maximum flexibility is called for. We hope you enjoy reading this issue in spite of it and that you remain healthy throughout the coming months!

Günter Eckhardt, Editor-in-Chief

Metering Box – The universal controllerThe PLC for any kind of pump control loop. High precision metering or filling of liquids at the press of a button.

• Intuitive user interface needs no programming ability

• AUTO-TUNING to determine PID parameters

• Freely selectable instrument and control parameters

• Integrated wear alarm

www.gather-industrie.de

pumpe@gather-industrie.de · +49 2058 89381-23

Pump/Metering/Coupling Technology

Rapid delivery

Made in Germany

ISO 9001

OUR ENGINEERING IS YOUR SYSTEM SOLUTION

4 cpp 01-2020

PROCESS ENGINEERING

30 Constant temperature in all processes High-end circulators for demanding tasks in the laboratory and industry

ENVIRONMENTAL TECHNOLOGIES

36 Radar as real alternative to ultrasonic Compact level measurement in the waste water industry38 F-Gas Regulation forces action Future-proof drying in compressed air treatment

PLANTS, APPARATUS, COMPONENTS

40 Off to the cloud How digital services improve plant availability44 Keeping cool when controlling cryogenic media Optimised cryogenic valve46 Pump and product are a perfect match Positive displacement pump transfers viscous suppository masses 48 Nothing but air and water Mobile pipe cleaning system for BASF

cpp CONTENTS 01-2020

SAFETY, SECURITY

8 Lightweight explosion protection Future-proof alternative to enclosure encapsulation in zone 110 Smart safety storage cabinets Safe storage of lithium-ion batteries

12 COVER Long life span rupture discs Process safety in demanding applications14 All-rounder for hazardous areas Multi-function process calibrators with explosion protection

FOCUS: INSTRUMENTATION, CONTROL, AUTOMATION

16 Making the wealth of data usable at last With enhanced connectivity for smart production20 Update management for the plant network How to improve industrial security in large brownfield plants24 PRODUCTS

26 Step by step into the future Valve islands as electro-pneumatic all-rounders28 Distillation column trimmed for efficiency Control loop analysis reduces energy use

20 BASF has a large number of PLCs that need to be automatically up-dated. But with multiple firewalls to navigate and many third-party devices involved, integrating them into a single net-work is a challenge.

30 The Magio series complements the Julabo product range with bridge mounted circu-lators, refrigerated circu-lators and circulators for most demanding tem-perature applications.

12 Cover CPX rup-ture discs provide excep-tional performance bene-fits while eradicating common industry con-cerns associated with traditional, mechanically scored discs.

cpp 01-2020 5

COLUMNS

3 Editorial 4 Contents 6 News32 PRODUCTS

43 PRODUCTS

50 List of Advertisers50 Contact to the Editors50 Imprint

38 For businesses that rely on refrigeration dryers for their com-pressed air treatment, there will be no getting around the new F-Gas Regulation. This new standard will be the end of many dryers in use today.

40 Thomas Knecht and Kevin Nietupski, both staff members of Auma at Service Center Cologne, explain the advantages of the Auma Cloud.

More news, facts, products and

solutions for the process technology

in the chemical industry can be found

on our internet page!

www.cpp-net.com

WWW.CPP-NET.COM

Industrie

17 media brands for all major sectors of industry

Information, inspiration and networkingfor professionals and industry executives

Practical knowledge spanning all media channels: Trade journals, websites, events, newsletters, whitepapers, webinars

Thenetwork of

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Discover the appropriate media for you and your specifi c industry sector:

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expertise

6 cpp 01-2020

cpp NEWS

cpp NEWS TICKER

Wacker extends the contract of Tobias Ohler Wacker Chemie AG’s Supervisory

Board re-appointed Chief Finan-

cial Officer Dr. Tobias Ohler (49)

to the Executive Board for an-

other five years. Ohler’s current

contract expires on December

31, 2020. He joined the Executive

Board in 2013.

Ohler studied economics, busi-

ness administration and industrial

engineering and took a doctorate

in economics at the University of

Pict

rure

: Wac

ker C

hem

ie

Bilfinger reduces the size of its Executive BoardBeginning with the next financial

year, the size of the Executive

Board at industrial services pro-

vider Bilfinger will be reduced

from four to three members.

Michael Bernhardt stepped down

Pict

ure:

Bilfi

nger

from the Executive Board as of

December 31, 2019. His responsi-

bilities, including his role as Labor

Director, will be assumed by Chief

Executive Officer Tom Blades (on

the left). Bernhardt was appoint-

ed member of the Executive

Board and Labor Director at Bil-

finger SE sinceNovember 1, 2015.

Business to focus on intelligent and sustainable technologies

BOSCH PACKAGING TECHNOLOGY BECOMES SYNTEGON

Syntegon Technology is the new name among the market leaders in the processing and packaging industry. Known as Bosch Packaging Technology until late 2019, the

former Bosch division today presents itself as an independent enterprise at the com-pany headquarters in Waiblingen (Ger-many). Syntegon Technology’s business focus is on intelligent and sustainable technologies for the pharmaceutical and food industries. Ex-tending the service range is a priority for the company that employs 6100 people at more than 30 locations worldwide. It post-ed 1.3 billion euros in sales in 2019. Bosch disclosed its plans to sell the packaging ma-chinery division to a newly incorporated entity managed by CVC Capital Partners, a leading private equity and investment advi-sory firm, in July 2019. The sale of Bosch Packaging Technology was completed on

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Synt

egon

The new Syntegon flags in front of the company headquarters in Waiblingen

January 2, 2020. A new corporate brand was developed over the past few months. The name Syntegon stands for synergy, technology, and focus on the future. The corporate colour green underscores the im-portance of sustainability and health. The square in the logo symbolises a package as well as packaging technology’s ability to protect products. This newly gained independence enables Syntegon Technology to be even more flex-ible. And newly added departments at the headquarters such as Purchasing and IT shorten the distances between in-house units and facilitating interaction with cus-tomers and suppliers.

Acquisition of ultrafiltration membrane business finalised

BASF SELLS INGE GMBH TO DUPONT

Dupont now signed all agreements to acquire the Ultrafiltration Membrane business from BASF – Inge GmbH – including ultrafiltration and membrane technologies. The acquisition is now in place. „As a global leader of inno-vative water solutions committed to investing in specialty solutions, the integration of Inge’s technologies extends our water purifi-cation capabilities and helps meet growing customer demand for ultrafiltration,“ said Rose Lee, President, Dupont Safety & Con-struction. „Inge is an ideal fit for enhancing

our ability to design tailored, integrated so-lutions for drinking water, and industrial and wastewater treatment applications.“ Inge's multi-bore PES ultrafiltration technol-ogy complements Dupont’s portfolio of water purification and separation capabil-ities. The product lines will join Dupont’s trusted Filmtec Reverse Osmosis and Nano-filtration Membranes, Integraflux/Integra-pac Ultrafiltration Portfolio, and Amber series of Ion Exchange Resins to provide more options for customers.

Pict

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ont W

ater

Sol

utio

ns

The Inge multi-bore PES ultrafiltration technology now complements Dupont’s portfolio of water purification and sepa-ration capabilities

Oldenburg. Following his studies,

he was a consultant at McKinsey

until 2004 and joined Wacker

Chemie in 2005 as head of Cor-

porate Controlling.

Ifat is postponed to SeptemberDue to the increasing spread of

the coronavirus (Covid-19) in

Pict

ure:

Mes

se M

ünch

en

Europe and based on the re-

commendations of the German

Ministry of Health and the Bavar-

ian State Government, Messe

München as oganizer feels com-

pelled to postpone Ifat 2020.

This measure is taken in consul-

tation with the Executive Board

of the Exhibitors’ Advisory

Board, the conceptual partners

and in responsibility for the

health of exhibitors and visitors.

IFAT will take place from Sep-

tember 7 to 11, 2020.

Purchased tickets and redeemed

vouchers will of course remain

valid for the upcoming event.

cpp 01-2020 7

Nouryon uses technology from Semiotic Labs

BOOST PLANT RELIABILITY

Nouryon has signed a framework agreement to implement self-learning technology developed by Semiotic Labs that helps predict when to maintain and replace pumps and other rotating equip-ment. Semiotic Labs was one of the winners of Nouryon’s 2018 Im-agine Chemistry open innovation challenge.The technology uses electrical waveforms that can accurately pre-dict 90 % of upcoming maintenance needs in rotating equipment such as pumps, compressors, and conveyors, up to five months in advance. This gives time to repair or replace critical equipment dur-ing planned stops, preventing unexpected interruptions to produc-tion and improving reliability of supply and process safety. The technology has been successfully implemented at Nouryon’s chlor-ine plant at Ibbenbüren, Germany, and will now be rolled out to seven other sites in Europe. Nouryon and Semiotic Labs will also look at ways to generate more value from waveform analysis by de-veloping features that will enable significant reductions in CO2 emissions. The first large-scale implementations are planned for early 2020.

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Sem

iotic

Semiotic dashboard for waveform analysis

Neste and Ravago join forces

COLLABORATION IN CHEMICAL RECYCLING

Neste, provider of renewable diesel, renew-able jet fuel, and an expert in delivering drop-in renewable chemical solutions, and

Ravago, distributor and recycler of poly-mers, are joining forces to develop chemical recycling of plastic waste with the aim to reach significant industrial scale. Neste and Ravago have set a joint target to reach an an-nual capacity to process over 200,000 t of plastic waste. Through collaborating in chemical recycling, Neste and Ravago wish to accelerate circularity of materials and im-prove resource-efficiency in the petrochemi-cal industry. The two companies also want to provide more sustainable alternatives to pri-mary fossil feedstock. Chemical recycling of plastic waste will enable the petrochemical industry to meet its recycling targets and de-velop a more sustainable, climate-friendlier offering. “Our aim is to process annually more than

Pict

ure:

Nes

te

Neste has set a target to process annually more than one million tons of plastic waste from 2030 onwards

one million tonnes of plastic waste from 2030 onwards. With this, we could con-tribute to increasing the annual recycling rate of post-consumer plastic waste by 25 to 30 % from the current level in Europe,” says Mercedes Alonso, Executive Vice President, Renewable Polymers and Chemicals at Neste. Chemical recycling will enable the com-panies to upgrade even coloured and mixed plastic packaging waste into high-quality raw material for the production of new plastics, chemicals and fuels. Unlike me -chanically recycled plastics, chemical re -cycling enables waste plastic to be used as raw material even in the most sensitive ap-plications, such as in primary food packag-ing as well as pharmaceutical and healthcare applications.

Group increases profit in 2019

ENDRESS+HAUSER STILL ON COURSE FOR GROWTH

Endress+Hauser remains on course for growth. In 2019 the Group increased its net sales by almost 8 % to over 2.6 billion euros. The Swiss measurement and automation technology specialist created 400 new jobs worldwide. At the end of the year the com-pany had more than 14,300 employees. “We have grown across all fields of activity, indus-tries and regions,” said Matthias Altendorf, CEO of the Endress+Hauser Group. Strong impetus came from Asia. Europe, the Ameri-cas, Africa and the Middle East developed positively, but at a much slower pace. “With good product innovations, we have set a clear benchmark in the industry,” emphasised Altendorf. In 2019, order entry rose faster than sales. Endress+Hauser expects slower development in 2020. The Group anticipates sales growth in the mid-single-digit percen-tage range and aims to maintain profitability at a good level.

Pict

ure:

Endr

ess+

Hau

ser

Matthias Altendorf, CEO of the Endress+Hauser Group

8 cpp 01-2020

Future-proof alternative to enclosure encapsulation in zone 1

Lightweight explosion protection

The Expressure concept from R. Stahl is a far superior solution to the existing enclo -sure encapsulation methods for many appli-cations. This concept enables the construc-tion of large yet lightweight Ex d switch cabinets that allow standard electrical and electronic components to be safely used in zone 1. Besides power distribution boards and control systems, Expressure switch cabi-nets can also house large pieces of equip-ment, such as transformers or frequency converters, providing reliable explosion pro-tection for everything installed within them.

Pressure relief for zone 1The PTB- and Dekra-certified Expressure switch cabinet series features a unique

pressure relief system. Special stainless steel wire mesh on both sides of the enclosure ensures that the pressure within the enclo -sure can be reduced effectively, serving as a flameproof barrier that allows for controlled flow of gas combined with heat absorption. If an explosion occurs inside the enclosure, the energy released is absorbed swiftly, safely and effectively. Regardless of where the ignition source is located, only harmless incombustible and non-explosive gas/air mixtures are able to exit the enclosure. The special mesh is also designed to absorb a significant amount of the heat energy that has been generated by the chemical reaction thereby safely lowering the internal pressure within the enclosure. These features effec-

tively reduce the internal pressure in the event of an explosion to a maximum value of less than 1 bar; sparks that might other-wise cause an explosion are safely contained inside the enclosure thanks to the special mesh structure. The maximum surface tem-perature falls under temperature class T4. Covering the Expressure enclosure‘s pres -sure relief elements are explosion vent pa-nels with a target pressure of 0.1 bar; these panels seal the enclosure and, under normal operating conditions, offer IP 66 protection.

More capacity, less weightThis innovative, Ex d-certified pressure re-lief technology offers up to 50 % space and weight savings compared to conventional Ex d solutions. Expressure is a highly efficient, cost-effective alternative to Ex p pressurised enclosures. Moreover, the new protection concept makes it much simpler to install switching and control units in zones 1 and 2, near to the machinery that they control, rather than having to position them far away in a non-hazardous area. R. Stahls‘s Expressure technology comes in a choice of four enclosure sizes, ranging from 300 x 400 x 200 to 1000 x 1400 x 700 mm, and with either a single-leaf door or a double door. With walls just 2 mm thick, these stainless steel enclosures are extraordi-narily light, making transportation, handling and installation much easier. Their optimised design also benefits from a smaller footprint. The large, undivided space inside the enclo -sure provides easy access for installing and wiring switching components and for per-forming maintenance and inspection work. The volume available within the enclosure

Quintessential explosion protection requires comprehensive expertise of various types of protection especially with the increase of highly networked switching, control and communication systems that are incorporated in hazardous areas. The Expressure technology for Ex-protected enclosures is a solution that boasts a whole host of advantages over conventional enclosure encapsulations.

The Expressure technology leads to more compact and lightweight housing designs. As a result, Expressure is up to 50 % lighter than conventional Ex-d solutions with the same internal volume.

Pict

ures

: R.

Sta

hl

cpp SAFETY, SECURITY

cpp 01-2020 9

for installing equipment is comparable to that of many conventional industrial switch cabinets and control boxes, and allows the switchgear layout used for non-hazardous areas to be used unchanged for hazardous areas without any additional engineering work. Thanks to the futureproof design of the enclosure concept, even last-minute changes to the order can be accommodated with little difficulty at the commissioning and SAT stages. Cable entries can easily be retrofitted at any point in time, and new components can be added to pre-installed equipment. Control elements that have been approved for use with Ex d solutions, e. g. rotary switches, pushbuttons, mushroom buttons, key-operated switches and control lamps, can all be used without modification. Additional accessories include Ex e connec-tion shafts and inspection windows that are available in six different sizes.

Light and easyIn terms of weight and size, as well as the amount of maintenance, conversion and retrofitting work required, Expressure en-closure combinations are often a better choice than conventional Ex d enclosures. The most widely used types of protection are flameproof enclosures. These are usually incredibly bulky structures which are built this way to withstand extreme explosion pressures in the region of 7 to 12 bar. To achieve the necessary pressure resistance properties, very thick walls of 10 to 20 mm are required. Realistically for economic and for technical reasons, this limits the enclo -sure capacity to not more than around 500 l. Large, complex electrical control pa-

nels and distribution boards must therefore be divided between a number of smaller flameproof enclosures. Compliance with the applicable explosion protection require-ments complicates the production and in-stallation processes for these flameproof bushings, which are required in order to es-tablish the necessary electrical connections. All joints running through the enclosure wall must be flameproof; this is to ensure that sufficient energy is removed from any flames or hot gases in the area to prevent them from causing an explosion. The encap-sulation also makes operation, maintenance and repair more difficult. Any subsequent changes to the internal electrical wiring in-evitably require extensive, time-consuming and costly modifications, which must normally be accepted by an explosion pro-tection expert before the equipment can be put back into service. With the advent of the new Expressure technology, complete switchgear assemblies and distribution boards can now be housed in a single en-closure, saving significant amounts of space and cost, and making maintenance a whole lot easier. The amount of planning required is also considerably less. Additionally, com-ponents can be retrofitted, modified or re-placed quickly and without additional costs.

Spacious without pressurisationIn order to house complex control and dis-tribution systems within an explosion-pro-tected enclosure alongside large-scale equipment and special machinery, solutions using pressurised enclosures (Ex p) have been required to this date. Enclosures with this type of protection have air or an inert

gas forced through them. The positive pres -sure created prevents explosive gases from entering the enclosure. To start operation in-side Ex p pressurised enclosures, inert gas must be flushed through the enclosure to force out gas mixtures that have entered from hazardous areas and to create the posi-tive pressure required for operation. This takes time – frequent maintenance, replace-ment and conversion requires significant down time. However, installing equipment in line with EN 600792 requires various in-spections and tests for positive pressure, leakage, test gas supply and pre-flushing time, which makes Ex p structures particu-larly complex. Compared to this protection concept, the Expressure is by far the more cost-effective alternative. Firstly, it elimi -nates the need for many expensive design and test steps. Secondly, the Ex protection remains intact at all times – during equip-ment start-up and after maintenance and retrofitting work – without additional time consuming procedures. And of course, there is no need of equipping Ex p enclosures with a control unit, a feed air station and a pressure monitoring system.www.cpp-net.comOnline search: R. Stahl

AUTHOR:HARALD WASKOWProduct Manager,R. Stahl

The Ex d-certified Expressure enclosures boast a large internal capacity

Explosion vent panels with a target pressure of 0.1 bar provide IP 66-rated protection; in the event of an explosion, these blow open to relieve pressure

10 cpp 01-2020

cpp SAFETY, SECURITY

Smart safety storage cabinets from Düperthal can be used for the safe storage of lithium-ion batteries

Pict

ures

: Düp

erth

al

Safe storage of lithium-ion batteries

Smart safety storage cabinets

Although lithium-ion batteries are relatively safe in regular operation, they are not designed for temperatures above 60 °C, among other things. As the temperature rises, lithium-ion batteries react with pres -sure build-up in the cell, intensive emission of flammable gases, cell fire, and even ex-plosive burning of the battery (thermal run-away). The dangers result, among other

things, from deficiencies in production or improper handling of the storage medium. A further risk arises if, for example, the re-spective ingredients are released due to thermal stress. According to the technical data sheets of the manufacturers, corrosive, toxic, carcinogenic, but also flammable haz-ardous substances can escape. Accordingly, preventive measures for fire protection and

early detection of damage are important building blocks to ensure safe workplaces.

Safety storage cabinets In the classical solution, Type 90 safety stor-age cabinets according to DIN EN 14470-1, the stored media are shielded from external thermal influences, e.g. fire generation out-side the safety cabinet, and are regarded as a fire-resistant separated area (fire compart-ment). They offer 90 minutes of fire resist -ance – sufficient time for evacuation and a safe buffer for fire fighters to intervene. This prevents uncontrollable fires and explosions and, as a result, increased personal injury and material damage if a fire occurs – ex-clusively – outside the cabinet.Düperthal safety cabinets of the Battery line Type 90, on the other hand, are specially designed to meet the high requirements for the safe storage and charging of lithium-ion batteries. In the event of a malfunction, li-thium-ion batteries can ignite themselves and the thermal load or fire then occurs in-side the cabinet. In this scenario, the cabinet doors will close automatically and a special mechanism will lock them. This prevents employees from igniting a possible flue gas explosion (backdraft), by simply opening the doors. Only authorised persons and fire brigade experts will be able to unlock the doors in this case. With the classification Type 90 and the explosion-like burning of the batteries in the cabinet interior, tested by the independent Fraunhofer Institute, the Battery line offers double fire protection – sufficient time for evacuation and a buffer for extinguishing the fire.

Lithium-ion batteries are an integral part of everyday life and, with good manufac-turing standards and proper handling, are also a sufficiently safe technology. How-ever, handling lithium-ion batteries is a risk that is difficult to determine in hazard assessment. This is because new findings and the rapid pace of development make it necessary to continuously review preventive fire and hazard protection measures, re-evaluate them if necessary and adapt them to the state of the art.

In the event of burning lithium-ion bat-teries, the cabinet doors close automatically and a special mechanism locks the doors

cpp 01-2020 11

Early detection The success of extinguishing a fire is essen-tially dependent on the fire brigade being on-site as early as possible in the fire phase. For the storage and use of lithium-ion bat-teries, early detection and automatic trans-mission of thermal events, e.g. fires, is therefore almost indispensable. With the in-telligent Smart Control assistance system with touch display, temperature sensors can be used as an early warning system to detect thermal events inside the cabinet, e.g. threshold value adjustment to detect devi-

ations from normal cases. For preventive risk management, in addition to monitoring temperatures using sensors for door status and ventilation, fault messages can also be sent by SMS, e.g. to the fire brigade and to those responsible. Individual connection to fire alarm systems is also possible. The Bat-tery station models are additionally pre-pared ready to plug in with Schuko sockets and a fused power supply for chargers. The Battery line’s prepared ventilation system can also safely dissipate the heat energy generated by the charging process.

State of the art safety at workWithin the framework of a risk assessment, operators are obliged to assess the dangers which may emanate from technical equip-ment and devices and to implement the re-sulting protective measures in accordance with the state of the art. The Battery line and the additional systems for early fire detec-tion with automatic alarm forwarding capa-bility ensure sustainable process safety. The resulting danger containment in case of self-ignition of the batteries can be considered as state of the art in the hazard analysis. The use of the Battery line also helps to meet legal requirements, in particular the guide-lines for storage in accordance with the GDV data sheet on loss prevention for lithium-ion batteries of the VdS and FM Global.www.cpp-net.comOnline search: Düperthal

AUTHOR:CHRISTIAN VÖLKHead of Marketing,Düperthal

For preventive risk management, fault messages can be sent by SMS

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12 cpp 01-2020

Process safety in demanding applications

LONG LIFE SPAN RUPTURE DISCS

Using advanced, precise, in-house technology, the German manufacturer Rembe has developed a performance-improved range of rupture discs. CPX rupture discs provide exceptional

performance benefits while eradicating common industry concerns associated with traditional, mechanically scored discs.

Pict

ures

: Rem

be

cpp SAFETY, SECURITY

AUTHOR:CLAIRE LLOYDTeam Leader, Process Safety Europe, Rembe

process media or in polymerisation processes, the CPX range of rup-ture discs is compatible with the most diverse process conditions, even in processes which must comply with strict hygienic standards.

Increased life-cycling capabilityPrecision manufacturing techniques ensure greater accuracy during the manufacturing process, allowing predefined – and lower – burst pressures as well as tighter tolerances to be achieved. Rupture discs manufactured with such technology are known to be more robust than discs manufactured using alternative scoring methods, meaning individual chemical processes can be challenged. Pushing the pro-cess operating pressures closer to the rupture disc’s opening pressure without risk of the rupture disc bursting prematurely produces a positive outcome – greater efficiency and output, helping to im-prove the overall competitiveness of the facility. Not only is increased life-cycling capability achieved through these manufacturing tech-niques, it is also possible to manufacture rupture discs with lower burst pressures. Fewer rupture disc designs are consequently needed site-wide, so that a greater number of process points can benefit from this technology, all while simplifying purchasing routines.

Wide range of applicationsRembe’s CPX rupture discs not only offer direct cost benefits over rupture discs which are prone to fail prematurely; their reliability also allows a reduction in, and simplification of, maintenance schedules as well as – even more importantly – less costly down-time. From the most accurate and consistent burst openings to smooth surfaces and robust constructions, the CPX range consists of advanced forward and reverse acting rupture discs. There is a CPX solution for even the most demanding applications in the chemical industry. The IKB, IKB-X and SFD cover an extensive range of burst pressures and specifications to meet most operational requirements. www.cpp-net.comOnline search: Rembe

With chemical manufacturers focused on maximising output, reducing energy costs and ensuring that plants reliably conform to strict safety and environmental regulations, there is increased pres -sure for plant engineers to source components that will provide long-term stability and improve overall operational competitive-ness. Recognising the challenges faced by the industry has driven rupture disc manufacturers to upgrade their designs. The German company Rembe has taken an approach to further develop its prod-ucts, leading to serious technological and operational benefits for customers in the chemical sector. Rembe uses Contour Precision manufacturing to enable highly accurate digitalisation of the rup-ture disc surface while high cutting speeds ensure excellent surface quality, resulting in the manufacture of very accurate, consistent and high performing rupture disc solutions.

Advantages of Contour Precision manufacturing The precision manufacturing methods – Contour Precision Lasering (CPL) and Contour Precision Profiling (CPP) – permit high quality, accurate burst control even in the harshest of chemical manufactur-ing environments. When used as an alternative to traditional rup-ture disc scoring methods, this technology can provide many ad-vantages, as it does not influence or weaken the material structure during the manufacturing process. The move from traditional mechanical scoring to such advanced manufacturing methods elim-inates most common industry concerns associated with earlier rup-ture disc designs such as pin holing, corrosion build-up and low life-cycling capability. Switching to precision manufacturing eradi-cates the main causes of premature failure to offer a longer lifespan solution and less downtime for customers.

Pin-holing – a common concernPin-holing on rupture discs has been a common concern for the chemical sector for decades. Due to the highly corrosive nature and harsh operating conditions within the chemical manufacturing pro-cess, it was not at all unusual for process media to weaken the score lines on the installed rupture disc, leading to an unwanted leak path in the process and ultimately to the disc’s premature failure. Fre-quent premature failures are costly problems for chemical manufac-turers, with unplanned downtime impacting on production and overall output. The move to precision manufactured rupture discs provides a more long-term, cost-effective solution with superior performance behaviour even in harsh operating conditions. Addi-tionally, as chemical operators face increasing pressures to conform to strict regulatory and environmental standards, the need to install a rupture disc which does not create an unwanted leak path in the process is critical. Eradicating the risk of pin-holing, in turn, elim-inates the risk of such leak paths and thus reduces the loss of costly or hazardous process media into the environment.

No fear of corrosionIrrespective of the material, size or burst pressure, no heat is applied to the rupture disc during the manufacturing process when preci-sion manufacturing techniques are employed. These techniques cre-ate the most accurate lines of sublimation across the rupture disc surface, resulting in the most precise opening upon burst and en-abling improved process control for plant operators. Furthermore, the opening pattern, unlike scored opening patterns, is completely smooth – no witness marks, notches or indentations on the rupture disc surface facing the process, meaning it is not prone to being af-fected by corrosion or product build-up and ensuring the longest lifespan capability of any rupture disc solution. Ideal for aggressive

Rembe uses Contour Precision manufacturing to enable highly accurate digitalisation of the rupture disc surface

cpp 01-2020 13

14 cpp 01-2020

Multi-function process calibrators with explosion protection

All-rounder for hazardous areas

In processes in the chemical industry, safety and efficiency go hand in hand. This is why the process control functions are almost al-ways based on electronic measuring instru-ments such as pressure transmitters. In order to determine whether the monitoring instrument is doing its job properly and with the necessary precision, it must be calibrated regularly. However, even if the in-strument check is not required to be DAkkS compliant, calibration processes can often be a time consuming affair. Inspections in

an external laboratory result in significantly more downtime because apart from any-thing else, the instruments have to be shipped there and back again.

On-site calibrationA growing number of firms today choose on-site calibration for this reason. One Ger-man chemical company, for instance, adopted this approach for a multi-purpose plant in its agricultural segment. Amongst other things, the plant, whose various sec-

tions can be flexibly interconnected de-pending on the process, is equipped with more than 200 pressure transmitters. Since the operator feeds it with different, fre-quently changing media, the pressure measuring instruments require regular cali-bration. Such checks are carried out before and after every process. By comparing key parameters, it is possible to verify the measurement quality throughout the pro-cess. If a production process lasts for a very long time, the transmitters are also cali-brated in-between as a kind of functional check. A considerable amount of equipment is generally necessary for conventional on-site calibration. Apart from the actual calibrator, this entails a means for producing the pres -sure as well as – in the case of transmitters – a power source. Handling such a wide range of devices is not only complicated; it also costs time and holds many unknowns due to the numerous manual activities. Against this background, the above-men-tioned company decided to check the pres -sure transmitters using Wika’s CPH7000 portable multi-function calibrator, which combines all the equipment needed for the on-site calibration process in one instru-ment. In addition to a highly precise refer-ence (0.025 % FS), it also features an elec-trical voltage and current supply module, so that the values can be read out automati-cally, and a mechanical pressure pump.

Hand-helds with Atex approvalThe intrinsically safe calibrator version required for this application is Atex ap-proved (Ex ib IIC T4 Gb classification). This

Anyone who has to calibrate intrinsically safe pressure transmitters on site in a plant obviously needs test equipment that is approved for use in hazardous areas. Yet explosion protection is much more complicated to ensure when using the new hand-held generation of portable multi-function calibrators than when using conventional devices.

The chemical industry places specific requirements on measuring devices

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rules out any risk of explosion, regardless of whether the ignition temperature is reached because a surface overheats, an ignition spark is produced owing to static charge on the case or a fault occurs during electrical operation. A more complex design compared to other hand-helds was necessary to obtain this ap-proval, especially where the battery was concerned. The capacity of the CPH7000’s “powerhouse” must match the instrument’s multi-functionality and enable eight hours of operation as a minimum. The lithium-ion cell is specially cast in a protective sheath, which prevents overheating in the event of a short circuit or other fault, so that the battery cells are neither destroyed nor can they leak. An emergency interrupt function limits the power if it rises excessively. The battery never supplies more than the maximum 24 mA of current and 30 V of voltage which are output via the integrated electronic module. An additional safety cutout feature was installed as a condition of the Atex ap-proval. The test pressure needed for calibration can only be produced using a hand pump be-cause electrical alternatives would not meet the Atex requirements for explosion protec-tion. There were two other reasons why a mechanical component was integrated: the battery power is protected and the final value is approached faster owing to the larger stroke. The hand pump has Atex com-pliant conductivity: all metal parts are per-manently connected to one another, so that they cannot become charged. This simulta-neously prevents matchstick effects due to friction from trapped particles such as chips. Furthermore, the pump’s piston-cyl-inder system is fine-tuned so that there is virtually no self-heating during pumping.The CPH7000 and the calibration processes are parameterised and controlled on an in-tuitive touch screen similar to a smart-phone. The big GUI permits easy navi-gation. It is made from shatterproof glass because it could otherwise break if the in-strument were to be dropped, resulting in exposed electrical cables in the hazardous area. More severe impacts than a simple fall might cause the screen to splinter, but it would still form a closed surface.The pressure transmitters in the multi-pur-pose plant are calibrated on site with the CPH7000: the measuring instruments are integrated in the process by means of

monoflanges with an Ermeto coupling as the test connection. An external CPT7000 reference sensor is mounted to the coupling for the duration of the test. It is supplied with the same pressure as the transmitter and transfers the value to the calibrator as a digital signal. The result of the calibration is instantly recognisable: it appears in a green frame if the test item meets the class accu-racy or in a red frame if it does not.

Other testing tasksAlthough calibrating pressure measuring in-struments is the most important of the CPH7000’s functions, this portable device can also carry out other testing tasks in a single step, for example those linked to voltage and current with the electrical mod-ule. Switch tests and sensor simulations are just two possibilities here. Temperature measuring points can also be checked with the help of an Atex approved Pt100 sensor. An external atmospheric module and an in-tegrated barometer moreover provide in-formation on atmospheric pressure, relative humidity and ambient temperature. Due to its small surface, this module in miniature format does not require an intrinsically safe design. A data logger stores all measured values and parameters for documentation purposes. The logger also shows pressure and temperature cycles on a live graph in

real time, so that any deviations are detected immediately. The CPH7000 is thus equally suited for leak-testing. The data recorded by the calibrator can be transmitted wirelessly to a host computer or a notebook for further processing. In the opposite direction, calibration routines can be uploaded in this way, so that testing pro-cesses in sensitive areas are even safer. If the CPH7000’s “partner” device is within the range for Bluetooth, operators can transmit all relevant information without even leav-ing the hazardous area.www.cpp-net.comOnline search: Wika

AUTHOR:JENS ROLLMANNProduct Manager Calibration Technology,Wika

Wika‘s CPH7000 portable process calibrator with Atex approval provides highly flexible on-site calibration for process transmitters and pressure gauges. Due to its equipment, the CPH7000 also fulfils test tasks for the measurement parameters of temperature, voltage and current.

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With enhanced connectivity for smart production

Making the wealth of data usable at last

All too often on the journey to Industry 4.0, the second step is taken before the first. For some time now, promising scenarios have shown the type of potential that can be achieved if industrial companies were to use cyber-physical systems. The basis for this is selected automation data, especially from the field level. A considerable amount of this data is already being generated, but only a small proportion is actually evaluated and pro-cessed into information. Before this data can be fully utilised to create added value for

digitalisation, it needs to be properly ex-ported from the field or process control level (via a side channel) to higher levels, such as a cloud. Concepts like NOA (Namur Open Architecture) illustrate how this can be done in large plants without compromising system availability and the safety of core processes. Another prerequisite on the journey to smart production is that it should be as straightforward as possible to read this data. Only then will it be possible for this data to be widely used, for example, for monitor-

ing and optimisation systems in process automation. These and other challenges as-sociated with the contextualisation of data have not yet been adequately addressed.

Reduction of complexityUsing the NOA interface, based on OPC UA, data such as diagnostic data from existing field devices and data from any other low-cost sensors and controllers should be made accessible, so that it can then be utilised by various applications through read-only ac-

The chemical industry is preparing to tap further optimisation potential for its pro-duction processes by implementing various concepts from Industry 4.0. This is based on (diagnostic) data which, for example, intelligent field devices supply in addition to the primary measured variables. A NOA-compliant, open architecture and methods of enhanced connectivity make this data usable with manageable effort.

Existing plant data can be read in an easy, secure, and impact-free way and utilised for additional services, such as predictive maintenance, or for sustainable process optimisation

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Tel.: 0800/50 30 300 (gebührenfrei)IBAN DE22 4306 0967 2222 2000 00BIC GENO DE M1 GLS

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safety. In addition, open system interfaces are required, as is the use of existing stand -ards. However, those familiar with the grad-ually evolved and therefore heterogeneous landscape of process plants in Germany alone will know that finding solutions that work in equal measure for both existing and

cess to not impact the actual core process. Although they may appear relatively straightforward at first glance, the NOA core requirements formulated by Namur only hint at the complexity involved. The most important requirement concerns consist-ently high system availability and system

new plants is no small matter. But above all, as Namur states in its Guiding Principles for NOA: “Usability, reduction of complexity, and economic efficiency are the main suc-cess factors”.

No unstructured collection of dataThe aim must be to ensure connectivity as easily and inexpensively as possible, and to implement all general conditions such as IT/OT security within this context. Despite the wide range of transmission protocols in-volved, the integration effort should be near non-existent. In view of these requirements, one thing must be avoided: the unstruc-tured collection of data. Phoenix Contact therefore recommends an architecture in which data read via a process interface is contextualised first. This means that it is made available in an aggregated and struc-tured format before it is used in the actual information processing level. All this is en-sured by the “enhanced connectivity sys-tem” (Ecosystem). Without a system of this type, the integration effort largely depends on process interfaces and protocols. At the process interface level, this inte-gration is largely handled by the Ecosystem, for example, through the impact-free auto-mated reading of Hart data. At present, this is only possible with significant engineering effort, as the Hart information is available as raw data and makes little sense without context. Initial solutions are available in the form of Hart IP gateways or Hart IO cards, which can be used to read the raw data col-lected from field devices.

Download of functionalityTo reduce the engineering effort for users, the Ecosystem provides support at the con-textualisation level, as it carries out the pre-processing via a gateway on the edge, for example. Data mapping with the aid of de-vice-specific description (EDD, FDI) trans-forms raw data, process data or diagnostic data into valuable, usable information. PA-DIM (Process Automation – Device Information Model) will be the standard used for this. Users will no longer have to deal with the complex process of data mapping; in future, they will be able to download the functionality in the form of an app from the Phoenix Contact app store. The app makes the data available in context for further evaluation or aggregation of information. At this level, it is also possible for an open runtime system, such as the PLCnext Ecosystem, to analyse the in-formation “on the edge” and, using com-

Principle of the enhanced connectivity system (Ecosystem) in combination with cloud solutions and the PLCnext Store

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The field data read via a process interface is contextualised using an open architecture

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Even in existing plants, it is possible to tap Hart data with no ill effects; the field data required for this is available in OPC UA format

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plex algorithms (high-level languages via Matlab or C++), utilise this information for predictive maintenance or to optimise processes. Connectivity with other systems is supported at the information processing level with cloud connectors, various cloud applications, and software as a service (SaaS), which can be accessed via an online platform.

Hart data to be stored in a cloudAs mentioned, the data diode model requires the Hart protocol to be used solely as a one-way street, i.e., write access is pre-vented. In addition, secure routes, e.g., using a security router, are recommended for reading Hart signals. The Hart signals that are obtained can be collected in a local database or a cloud. In principle, it is easier to use a cloud: data cannot be lost, accessibility is optimised by the provider, and cloud services are con-vient. In practice, a Hart gateway with OPC UA interface acts as the link between the field and the higher-level system. OPC UA supports various security measures. The data stored on the OPC UA server can be used for suitable and authorised higher-level sys-

tems, where each system can select the data it requires. Up to 40 sensors can be connected to the Phoenix Contact Hart gateway extended with the OPC UA server. The information (such as identifiers or diagnostic values) is read cyclically – without any configuration effort. This opens up various possible appli-cations for the operator, such as plausibility checks, predictive maintenance or use by external specialists.

Optimised connectivityAs explained, data can be made usable with manageable effort. IoT gateways direct diag-nostic information and other information to a cloud or server where it can be evaluated, for example, by web services – better than in standard maintenance tools. In future, de-vice manufacturers will support this with big data analysis based on a huge amount of data from their worldwide database. The NOA concept in conjunction with various web services opens up significant potential for increasing the efficiency of plants. The effort involved on the part of the operator will decrease further. Those who want to ensure (enhanced) connectivity will be able to benefit from Industry 4.0 and artificial intelligence in future without having to in-vest excessive resources. New technologies like 5G and Ethernet to the Field, in process automation specifically APL (Advanced Physical Layer), will play an important role. With its higher bandwidth and availability, 5G communication enables new wireless applications. APL, as a pre-requisite for using Ethernet (Profinet) in the Ex area, makes it easier to implement big data applications, as large volumes of diag-nostic data can be transmitted from the field at high speed. The restrictions imposed by previous fieldbuses no longer apply and the handling of promises is also easier. All in all, both 5G communication and APL will pro-vide optimised connectivity that supports the specific requirements of Industry 4.0 and smart production more effectively than current solutions. www.cpp-net.comOnline search: Phoenix Contact

Unlock the wealth of data available in exist-ing plants (brownfield) with relatively little effort: read Hart data in an impact-free way using Hart IP gateways and make it available for further processing via OPC UA in com-pliance with NOA

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AUTHOR:WILFRIED GROTEDirector Industry Management Chemicals and Pharmaceuticals, Phoenix Contact

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At BASF’s Antwerp site, PLCs that were spread across 6 km² had to be updated manually

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How to improve industrial security in large brownfield plants

Update management for the plant network

An industrial network is a production plant’s backbone. As long as it’s strong, se-cure, and reliable, productivity can run at full steam. But should a network error occur, devices may become inaccessible or stop communicating. In a worst case sce -nario, production may halt altogether.

At its Antwerp site, BASF had 350 devices controlled by Simatic PLCs from Siemens. This included PLCs running compressors, energy meters, charging stations, and other mission critical devices. So keeping all PLCs updated with the latest security updates was vital to protect them from malware, unau -

thorized access, and other threats. But the PLCs had yet to be connected to a single network. This meant Siemens’ on-site auto-mation team had to update every device manually. With the site spanning 6 km2 and updates taking several hours, this was a pro-cess that could take a full year to complete.

In industrial plants, PLCs run the show. The chemical giant, BASF, has a large number of PLCs that needed to be automatically updated. But with multiple firewalls to navi-gate and many third-party devices involved, integrating them into a single network would be a challenge. Until the solution Sinema Remote Control from Siemens was brought to the table.

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BASF knew it needed an automation net-work. But installing one hadn’t been feasible for two key reasons. Firstly, the site housed 16 plant clusters with their own firewalls and third-party devices. Secondly, the site’s vast size meant installing a new fiber optic network, which was not financially viable. BASF approached Siemens for new ideas.

Experts in complexityWith its track record of successfully imple-menting networks in complex industrial en-vironments all over the world, BASF was confident Siemens could devise an effective solution. And upon receiving their request, Siemens jumped into action, bringing in network specialists to assist its on-site auto-mation team.This BASF Antwerp team says, “We are fam-iliar with networks, Siemens and PCS 7, but our team was short on technical know-how for developing a concept that could meet the stringent requirements imposed by the IT department. So, we joined forces with product and service specialists from Siemens to create the concept.” In addition to improving security and relia-bility, BASF wanted a network that would be easy to manage and master. They also wanted to be able to create user groups, so every plant cluster could manage their own devices. After assessing all the requirements, Siemens’ team planned the rollout of a se-cure, dedicated network with Sinema Re-mote Connect at its core.

Connections via VPN tunnelsThe first challenge was devising a network that could securely connect technicians and devices across 16 plant clusters. A challenge Sinema Remote Connect easily solved.Using Sinema Remote Connect, Siemens created VPN tunnels, connecting every PLC and user through the Sinema Remote Con-nect server. An inventory of the security cer-tificates for every device and user was also created in the server. This meant that when-ever a connection was requested, the certifi-cates would be checked and verified before the connection was approved. Sinema Remote Connect further improved security by en-crypting all communications using OpenVPN. Another advantage of Sinema Remote Con-nect is that it can provide remote access to Scalance M-800 as well as Scalance S-600 Industrial Security Appliances and dedicated CPs and RTUs. This allows each device to be configured and integrated automatically,

eliminating an otherwise complex and time-consuming task.Providing technicians with central access to the PLCs in all parts of the BASF plant was realised by Sinema RC Client. Once all groups and rights in the Sinema Remote Connect server were configured, Sinema RC Client’s address book function enabled every technician to see the parts of the network they have access to.

Transparent processesTo fulfill BASF’s requirements for central network monitoring, the Sinema server was

implemented. Siemens’ team created one user group for each plant cluster so they could access their own devices and monitor their performance in private. In addition, the Sinema server’s network monitoring software would provide BASF with around the clock monitoring, and diagnostics, in-cluding diagnostics for SNMP, Profinet, and Simatic.

Putting it to the testBefore rolling out the network, Siemens ran a proof of concept project in the lab. This project was to verify how devices would re-

Sinema Remote Connect and Simatic Rack PCs enable a secure and centrally managed VPN connection

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Sinema Remote Connect with Field PG connects to every PLC and user

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spond when added to the network and whether firewall rules needed to be modified.“We wanted to ensure we developed a net-work that would meet the stringent require-ments for security, seamless implemen-tation, and ease of use,” says BASF Antwerp. “The proof of concept project translated into significant time savings, while for the businesses on-site, it meant better service.” Along with saving time and lowering risk, the proof of concept project enabled Siemens to develop workflows for installing and managing devices. Siemens trained BASF’s technicians these workflows through a workshop, so they could manage the net-work independently.“Good preparation is the key to success,‘‘ says Bert Vanstraelen, Service Engineer at Siemens Customer Services in Belgium. “Giving BASF’s technicians training in the new system will ensure they can perform

AUTHOR:MAXIMILIAN KORFFProduct Sales Development,Digital Industries, Process Automation,Siemens

Scalance S615 Industrial Security Appliances made controllers accessible from the central Sinema Remote Connect server

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their own maintenance in the future with-out IT support.”

Rolling outFollowing the successful test project, Siemens built out the network in stages. Close cooperation between BASF and Siemens’ team ensured the network’s central elements were completed within one month. The PLCs were then linked to the system step-by-step, allowing the network to grow organically. With the successful im-plementation of Sinema Remote Connect, BASF now has the reassurance knowing all PLCs across 16 plant clusters can be moni-tored and updated around the clock by their central maintenance team using the TIA Portal – the engineering platform for auto-mation from Siemens.At a ground level, desktop access through Sinema Remote Connect means Siemens’ automation team no longer has to travel around to the different plants. This has freed Siemens’ technicians to focus on providing high quality services across BASF’s site.

Future upgrades plannedThere are now plans to further improve the network monitoring with Siemens’ Network Management System, Sinec NMS. This will further enhance transparency and ease of use by providing BASF’s technicians with desktop access to devices for prompt fault resolution, security monitoring, and device configuration with hardening. The project’s success also reinforced the value that BASF has for both Siemens’ technology and its expertise, especially when overcom-ing complex challenges. In fact, the project has been such a success that the company is now planning to upgrade their logistics sys-tems. The new system will be completely in-tegrated into the Sinema Remote Connect architecture. Siemens’ team will be there to support them on every step of the way.www.cpp-net.comOnline search: Siemens

The automation solution from Siemens integrates 16 plant clusters with differ-ent network infrastructures

• BASF’s Antwerp site had PLCs spread across 6 km², which had to be manually updated

• The PLCs belonged to 16 plant clusters with different network infrastructure

• The Sinema server enabled the creation of user groups for each plant cluster and pro-vided desktop access to devices and diagnostics

• Scalance S615 Industrial Secur-ity Appliances made both

Siemens and third-party con-trollers accessible from central Sinema Remote Connect server

• Sinema Remote Connect en-abled the creation of secure and centrally managed VPN tunnels

• A proof of concept project was completed before rolling the entire system out

• A task that would have taken a year to complete, can now be done automatically

AT A GLANCE: PROJECT BASF ANTWERP

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Explosion proof thermostat

Larson Electronics, released an explosion proof thermostat rated for use in Class I, Divisions 1 and 2 hazardous locations. This thermostat is ideal for tem-perature control in industrial fa-cilities where flammable gases, vapours and dust may be pres-ent. The EXP-TSTAT-250V-86F- 20M-CE16 explosion proof thermostat is rated for use in Class I, Divisions 1 and 2, Groups C and D; Class I, Zones 1

and 2, Groups IIA and IIB; Class II, Division 1, Groups E, F and G; Class II, Division 2, Groups F and G; and Class III hazardous locations. This unit features an SPDT snap action switch and is rated at 250 V(AC). It can be ad-justed via a set point knob to set the thermostat within a range of 2 to 28 ̊ C. The explosion proof thermostat is made of precision die-cast and corrosion resistant compo-nents and does not contain any exposed copper, brass or mer-cury. To improve the accuracy of the temperature readings, this unit must be secured five feet above the floor and can be mounted to walls or compatible surfaces via four cover bolts. www.cpp-net.comOnline search: Larson

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Level switches for all silo types

Emerson has introduced a range of Rosemount solids level switches designed to optimise operations, increase safety and reduce waste. The vibrating fork, paddle, capacitance and vibrating rod switches within the range ensure reliable monitoring of solid materials such as powders, grains and pellets in all silo types across industries. The switches can be used to provide stand-alone point level monitoring to help optimise filling and empty-ing cycles. They can also be de-ployed within an overfill preven-tion system. In applications in-volving light, fine-grained and powdered materials where high measurement sensitivity is required, Rosemount 2511 and 2521 vibrating fork switches

provide a cost-effective solution. Atex certification permits instal-lation in explosive areas, and all wetted parts are made from cor-rosion-resistant stainless steel. The 2501 rotary paddle switch for example can be used as a full, demand or empty detector in storage silos or process vessels and the 2555 capacitance switch can be installed in pipes.www.cpp-net.comOnline search: Emerson

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Paving the way for modular production

To meet growing demands for modular systems, Wago added the “Module Type Package” (MTP) to its range of auto-mation solutions. Similar to printer drivers from the Office ecosystem, MTP works as a standardised interface and func-tional image of entire system modules. The MTP creates the basis for the automation of versatile production systems. MTP is based on the 2658 Di-

rective adopted jointly by Namur, ZVEI and VDMA. It can be used with both Wago Con-trollers PFC200/PFC200 XTR and Wago Touch Panels (600). For module engineering, the Wago e!Cockpit Engineering Software provides a library with many preparatory functions. It also contains a control image description, which can be used to easily build a library of reus-able modules. Once the module has been created, the MTP is automatically generated with one click and can be read into a wide variety of process visual-isation and control systems (Process Orchestration Layer, POL). www.cpp-net.comOnline search: Wago

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Pluggable power distributors

Phoenix Contact has expanded the application range of its PRC plastic circular connectors with pre-assembled power distributors. The distributor boxes are weather-proof and designed with an IP 69 degree of protection. This makes the product series particularly suitable for supplying power to devices used indoors or outdoors.The single-phase designs have a 3-pos. input and two 3-pos. outputs. Three-phase distributors provide one 5-pos. input and three 5-pos. outputs. A phase splitter, which enables a three-phase input to be split into three single-phase outputs is also supplied. The entire series is designed for rated currents up to 32 A and rated voltages up to 400 V(AC).www.cpp-net.comOnline search: Phoenix Contact

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T +49 2961 7405-0 | info@rembe.de Gallbergweg 21 | 59929 Brilon, GermanyF +49 2961 50714 | www.rembe.de

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EXPLOSION SAFETY and PRESSURE RELIEF

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Updates for frequency converter portfolio

With numerous innovations, Siemens is extending its drive portfolio, improving user-friendliness and offering space-saving installation options. The Sinamics G120X converter, de-signed specifically for use in water/waste water applications and in HVAC systems, is now also available in a three-phase 3AC 200V voltage variant in the power range up to 55 kW. This means that the converters can now be integrated seamlessly into applications in the USA and in Latin America. Due to its ro-bust construction and the coat-ing of the PCBs according to 3C3 standard the converter is suitable for harsh environments. The module for extending the digital and analogue inputs and outputs increases the flexibility and the optimal control of con-

verter-guided applications. The Sinamics G120X now also sup-ports the communication proto-cols Profibus, Modbus RTU, USS and BACnet MS/TP. It is equipped with extensive inter-faces and can be easily inte-grated into existing or new sys-tems. The Sinamics G120 modu-lar frequency converter com-bines with the Sinamics control unit adapter kit CUA20 to pro-vide an option for simple and flexible cabinet design. Power modules and the control unit can be separated physically and thermally, making the converter even more flexible and custom-isable. A new Sinamics V20 con-verter size has been added in the 2.2 to 3 kW power range. www.cpp-net.comOnline search: Siemens

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Intrinsically safe pressure transmitters

The Keller D-line boasts a combination of highly robust industrial pressure transducers and the I2C interface. This series has undergone further development and an intrinsically safe version is now available too. The D Ei series is approved for gas group II applications and can be used to measure absolute and relative pressures in zone 0. With its modular structure, the series permits numerous combinations, making it the ideal compo-nent for customisations using an I2C interface:

• OEM pressure transmitters for fitting directly into a system’s existing drilled holes

• OEM pressure transmitters with ultra-flexible pressure connection for screwing into existing pressure systems

• Pressure transmitters with a pressure connection and cable gland

• Level sensor for measuring the contents of a tank up to a maximum fill level of 3 m

www.cpp-net.comOnline search: Keller

Glass-free pH sensors

The Isfet sensors made of un-breakable Peek from End-ress+Hauser offer high product safety, accuracy and improved CIP stability. The sensors made of unbreakable Peek are avail-able with three different refer-ence systems. The Isfet sensors Memosens CPS47D and CPS77D are perfectly equipped to meet the strict demands of hygienic applications. Thanks to their de-sign with an increased chip sur-face, they are even easier to clean than their predecessors. They deliver stable and reprodu-cible measured values, even after sterilisation and autoclav-ing up to temperatures of 135 °C, come with USP, EHEDG

and 3A ap proval, and are TSE-/BSE-free. They can outlast at least 25 CIP cycles and have therefore significantly improved CIP stability . In addition, the Memosens CPS77D offers maxi-mum bacteria tightness thanks to its microporous ceramic dia-phragm. Even at low temperatures, Isfet sensors such as the Memosens CPS97D have a fast response time and are chemically stable thanks to their Peek stem. Also, their open diaphragm means that they do not become clogged even in the case of high solids concentrations. www.cpp-net.comOnline search: Endress+Hauser

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Central processing unit with high scalability

A new hardware and software platform is being used in the Jumo Varitron 500 central pro-cessing unit. During its develop-ment, scalability had the highest priority. The result is modular, flexible, and, above all, sustain-able. The basis of the Vari-tron 500 is a hardware platform with an 800 MHz processor which can be used as a single, dual, or quad core variant de-pending on the application. The software has a modular structure based on a Linux plat-form and enables scalability for performance, memory, and in-terfaces. Another special feature is a customer-specific configu-ration and process data editor. Several operator stations can be integrated into the system via Codesys Targetvisu or Codesys Webvisu as well as up to 64 in-telligent connection modules.In the future, Jumo will provide visualisation libraries for indi-

vidual customer-specific oper-ation via Codesys Targetvisu or Codesys Webvisu. Flexibility is also made possible by the inte-gration of all important fieldbus systems via Codesys, such as Modbus RTU or TCP master and slave, Profinet IO controller, Ethercat master, and OPC UA server. A Profinet IO device in-terface will allow an alternative connection to higher-level con-trol systems via Modbus TCP. www.cpp-net.comOnline search: Jumo

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Enclosures for Zones 1 and 21

Pepperl+Fuchs is now offering more and more customised solutions for zones 1 and 21 that feature sensor technol-ogy from factory automation and can be used in a huge range of applications. Sensors from Pepperl+Fuchs are housed in pressure-resistant enclosures, allowing processes to be further automated even under harsh conditions.The GR series of GRP enclosures caters perfectly to the needs of electrical installation in process plants. The prod-ucts are designed to offer maximum flexibility for a wide range of applications. The mounting grid makes the addi-tional mounting base obsolete, while also enabling ter-minals and switching elements to be planned and installed quickly and easily. It also means that any DIN mounting rails can be mounted using self-tapping screws. An inno-vative spacer system allows components to be installed at different levels within the enclosure. Different enclosure sizes and depths ensure that the enclosure series with IP 66 expanded silicone seal offers high flexibility. The series can be used in environments up to -60 °C in zones 1/21 and zones 2/22.www.cpp-net.comOnline search: Pepperl+Fuchs

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Pressure switch with IO-Link and display

Wika's PSD-4-ECO program -mable pressure switch enables pressure monitoring in ma-chines which is as uncompli-cated as it is reliable. With IO-Link version 1.1, the instrument − in a space-saving design and with a two-colour display − is a flexible automation solution. The plug-and-play principle en-ables the pressure switch to be commissioned quickly, either through individual factory pre-configuration or via IO-Link. Its display can be set so that the op-erator receives on-site in-formation without any prior knowledge about the status of the current pressure or the con-dition of the instrument. For example, a measured value with-in the defined pressure range is displayed in green, a measured value outside the limit in red. For the best possible view of the

display, the case head can be ro-tated and the display tilted elec-tronically through 180°. The PSD-4-ECO has been de-signed for installation in tight spaces. With a diameter of only 29 mm and a vertical orientation of the electrical output, it can be fitted almost anywhere. The pressure switch is also suitable for harsh environments: it is de-signed for medium temperatures between -40 and +125 °C and shock resistant up to 50 g.www.cpp-net.comOnline search: Wika

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www.jumo.net

Welcome to JUMO.

JUMO digiLine O-DO S10 Digital optical sensor for dissolved oxygenin aqueous solutions

Visit us Hall 11, Booth C28

Precise measurement with long-term stability

Suitable for fresh and salt water

Immediately ready for use due tofactory calibration

No minimum inflow

Easy connection to field devices andprocess control systems due to analogand digital interface

Extremely easy to maintain due to robustand easily replaceable sensor

Fluently digitized.

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26 cpp 01-2020

Valve islands as electro-pneumatic all-rounders

Step by step into the future

More than 20 years ago, the initial com-bination of a valve island and a powerful distributed I/O system paved the way for the success of valve islands in the process engineering environment. The Bürkert valve island Airline Type 8644, for example, has long since become the industry standard and can still be found in many applications to this day. Thanks to these devices, it was now possible for the first time ever to con-trol electrical and pneumatic signals via just

one bus line and to transmit the in-formation to a higher control level. Users were able to integrate pneumatics and elec-trics into a single control cabinet and the number of bus participants within networks was reduced significantly.

Valve islands for Ex atmospheresSince many users, particularly in the phar-maceutical and chemical industries, also have potentially explosive atmospheres

within their plants, an intrinsically safe valve island variant was subsequently devel-oped that can be seamlessly integrated into the Siemens ET 200 iSP distributed I/O sys-tem. Thanks to the valve island Airline Ex Type 8650, it was possible to use a uniform concept in both potentially explosive and non-hazardous atmospheres and also to carry out maintenance and diagnostics in potentially explosive environments. The in-tegrated pneumatic hot-swap function allows the valve to be changed during oper-ation under pressure and – thanks to the in-trinsic safety in potentially explosive atmo -spheres – even when energised. Fail-safe signals can also be processed in potentially explosive atmospheres and correspondingly safe shutdown can be implemented for the pneumatics.

Growing requirementsAlthough the principles of valve islands have not changed drastically over the years, they still have to perform an increasing number of functions within a production line and meet high demands in terms of safety and operability. For example, safety functions must be easy to integrate. Addi-tionally, integration into higher-level control systems or process control systems is required, as are diagnostic options, both on-site and remotely. Components must be quick and easy to replace or add on, and compact dimensions are also an issue.

Distributed integrationThanks to experience and close cooperation with customers and users, these require-ments have been implemented in the cur-rent valve island Airline SP Type 8647. Its in-

Valve islands in process automation have, step by step, become an integral part of process engineering plants. Now Bürkert is taking the next step: Seamless inte-gration into distributed peripheral systems has created a future-proof platform that offers users maximum security, including redundant Profinet topologies.

More than 20 years ago, the initial combination of a valve island and a powerful distributed I/O system paved the way for the success of valve islands in the process engi neering environment

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tegration into the distributed peripheral sys-tem ET 200SP from Siemens also offers users the added advantage of working within the familiar Siemens programming environ-ment. For the first time, they can now read the status of the valve island, faults or pro-cess parameters directly on a locally installed LC display without the need for additional peripheral devices. In addition, the switch-ing position of the pilot valves and the as-sociated process actuators can be displayed graphically directly at the valve island. This mapping of digital input and output signals facilitates start-up, maintenance and troub-leshooting. All the information generated at the valve island can also be processed in the controller, for example diagnostic data such as defective coils, open outputs or pressure fluctuations in the intake air. Two indepen-dent switching cycle counters generate messages that enable preventive mainten-ance. The new valve island also has a lot to offer when it comes to safe pneumatic shut-down. The valve modules can be de-ener-gised via the optional EVS function. In this case, the supply circuit for the load voltage of the valves is interrupted by a potential-free contact. As soon as the safety function is active and the valve supply circuit has been interrupted, this informa tion is shown on the local LC display and, if required, sent to the controller. Since internal communication is not affected by this emergency stop func-tion, there is no loss of control in the plant at any time and users are always aware of what is happening in the field.

Saving space in the control cabinetThis simple but robust and safe solution offers users the option of emergency stop

circuits directly at the valve island. If, for process-related reasons, it is not possible to implement block-by-block shutdown, i.e. simultaneous shutdown of several valve functions, users can utilise safety valves with a second electrical connection which can be retrofitted at any time, and shut them down individually via potential-free contacts. Safety functions can thus be retro-fitted at all Bürkert valve islands without too much effort. A valve change under pressure during operation is enabled by the inte-grated P-channel shut-off. The built-in check valves protect the downstream pro-cess actuators against unintentional switch-ing in the event of pressure surges or ex-haust air build-up. To meet the demand for smaller sizes and more compact systems, the valve islands combined with the Siemens modules can be installed directly on the control cabinet wall or floor thanks to the universal Airline Quick floor instal-lation plate. Up to 48 valve functions can thus be accommodated in a particularly space-saving fashion, and small distributed units with high signal density can be imple-mented directly on-site.

Maximum availabilityAlthough valve islands have previously also been operated in redundant Profinet topol-ogies, the current generation of the valve is-land Airline SP Type 8647 now goes one step further. It is seamlessly integrated into the Simatic ET 200SP HA (High Availability) distributed I/O system, i.e. combined in a compact yet powerful automation system. Compared to its predecessor, this new level of integration further enhances plant avail-ability. Now, for the first time, valve islands

in highly available and up to R1 redundant Profinet environments can be operated di-rectly in a distributed peripheral system. In addition, thanks to complete software inte-gration in the Siemens process control sys-tem PCS7, all diagnostic information and process parameters of the valve island can be monitored. This allows preventive and wear-oriented plant maintenance to be initi-ated and downtime to be minimised.www.cpp-net.comOnline search: Bürkert

Valve island Airline SP Type 8647: users can now read the status of the valve island, faults or process parameters directly on a locally installed LC display without the need for additional peripheral devices

The valve islands can be used in combination with Siemens modules and stainless steel control cabinets in the immediate process environment

Fit for the future: now, for the first time, valve islands in highly available and up to R1 redundant Profinet environments can be operated directly in a distributed peripheral system

AUTHOR:HEIKO KURTZField Segment Manager Hygienic,Bürkert

28 cpp 01-2020

Control loop analysis reduces energy use

Distillation column trimmed for efficiency

Distillation columns are one area within a chemical plant that offer considerable po-tential in terms of improving energy effi-ciency. In the United States, there are more than 40,000 distillation columns within the refining and bulk chemical industries, and according to the US Department of Energy they consume approximately 40 % of the total energy used to operate these plants. Because they are very high users of energy they are obvious candidates for closer in-spection with a view to making perform-ance improvements that lead to greater energy efficiency. However, reducing the amount of energy that distillation columns consume is not al-ways straightforward. Columns will have different operating objectives and different

configurations which will produce different behaviours. The operation of these processes typically involves a trade-off between ener-gy usage and product recovery, and setting the appropriate operational targets involves careful evaluation of the relative economic value of these two factors. Another factor is the complexity of the distillation process, with multiple process parameters interact -ing strongly, making straightforward control difficult. An example of this occurred with a distillation column operated by Clariant at one of its sites in Germany. Not content to limit itself to compliance with current directives, Clariant aims to minimise the environmental impact of its operations. The company has developed an extensive energy efficiency programme

called eWatch, which uses analysis to identify potential savings in energy consumption, via the optimisation of machines and processes across all its global production sites. This is supplemented by training programmes for employees, to sharpen their awareness re-garding energy-saving possibilities.

Reducing steam usageAs part of its eWatch programme, Clariant wanted to improve energy efficiency at its chemical facility in Frankfurt, Germany. The facility produces azo pigments, highly specialised high-performance pigments and polyolefin waxes, which are further pro-cessed into automotive and industrial paints, inks and plastics. Clariant wanted to reduce the amount of steam used by a dis-tillation column which separates water from acetic acid, before returning the acetic acid back to the process. Key to achieving this was to optimise the performance of the col-umn. One major obstacle to achieving this was that many of the column’s PID con-trollers were not able to run in automatic mode. This meant that they were being manually controlled by operators, which was not only a labour-intensive and time-consuming process, but also made it ex-tremely difficult to optimise activities. Clariant turned to Emerson, who is a major supplier of instrumentation at the plant and had worked with the company on other energy reduction projects. Members of Emerson’s lifecycle support team, specialis-ing in process optimisation, were invited to investigate the distillation column to see if they could reduce energy usage. The initial approach to the problem was to conduct an

The energy efficiency target presented by the German government in December 2019 provides for a 30 % reduction in primary energy consumption compared to 2008. Com-panies are therefore obliged to make further energy savings. The example presented below shows how energy consumption can be reduced and the process improved at the same time by means of a precise control loop analysis of a distillation column.

By means of a precise control loop analysis energy consumption of a ditillation column can be reduced and the process can be improved

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energy saving study, including analysis of historical process data. This identified that the column had not been performing at op-timum levels, leading to higher steam usage than necessary, loss of product due to too much acidic content in the reflux water, and subsequently higher water treatment costs due to the removal of that acid trace.

Investigation of the control loopsEmerson provided its Advanced Loop Ser-vice, during which a process optimisation team investigated the layout of all the col-umn’s PID control loops to check that they were working properly and being controlled in the best way possible. PID control loops present an excellent opportunity for opti-misation. There can be several hundred ac-tive in some chemical plants and it’s not un-common for as many as two-thirds of these to be underperforming, due to deficiencies in design and tuning. This is a recipe for chronic process inefficiency and places a heavy burden on experienced operators who must continually control major aspects of the process manually, adjusting set-points locally and reacting to changes. A loop tun-ing sequence was performed as well as manual output step tests to detect problems and measure process dynamics.In addition to this, all measurements and control valves were evaluated, to ascertain whether they were correctly designed and performing as they should. Distillation col-umns feature several critical control valves, such as a feed valve to control the rate of feed flowing into the column, a reflux valve to adjust the purity of the overhead prod-uct, bottom and overhead product valves that regulate the level in the bottom of the column and in the overhead receiver, pres -sure control valves, and a re-boil valve that controls the amount of heat put into the column by the re-boiler. The sizing and per-formance of these valves are crucial, as any discrepancies can affect both product purity and energy usage.Finally, a complete appraisal of all installed instrumentation was performed, checking to ensure that the right measurement methodology was being used, every device was working correctly and installed in the correct position as well as identifying where additional measurements would help pro-vide a greater understanding of the process leading to greater process optimisation.

Revised control strategyAfter completing testing, Emerson’s team produced a comprehensive report with de-tails about which control loops, valves and

equipment were performing sub-optimally and therefore affecting process perform-ance, process optimisation and subsequently increasing the energy use of the distillation column. The report highlighted various op-portunities for improvement and a complete revised control strategy was provided which would contribute directly to reduced energy usage. Clariant implemented all the recom-mendations, with Emerson providing sup-port by tuning all the PID loop controllers, enabling them to run in automatic mode.Critically, the changes implemented meant that set-points could be controlled with an accuracy of ±0.5 % compared with ±2.5 % previously. Greater control helped to make significant improvements in terms of energy usage. The target of Emerson’s performance-related contract had been to achieve a 2 % reduc-tion in steam usage resulting from its Ad-vanced Loop Service. The actual result was a 6 % saving, which was an outstanding suc-cess, especially considering how previous attempts had failed to generate any signifi-cant reductions.

Fast return on investment Previously, the distillation column used ap-proximately 6,1 GWh/a, amounting to ap-proximately 1 million euros per year in energy costs. The 6 % steam usage reduction achieved amounts to 5,7 GWh/a and there-fore a saving of 80,000 euros per year. Based on the target figure of 2 % steam usage reduction, Clariant had expected that it would take approximately one year to achieve a return on investment (ROI), but the actual 6 % saving meant that ROI was achieved in less than four months.

The improvements made to the distillation column also produced other significant benefits. Greater control and a more opti-mised distillation process enabled a reduc-tion in product loss in the form of acetic acid content in water removed from the dis-tillation column. Subsequently there was also a reduction in water treatment costs to remove the acid, which further improves profitability.

Switch to automatic modeFollowing Emerson’s work, operators are now able to run all the distillation column’s control loops on automatic mode, rather than relying on manual control as before. This means that operators who previously had to watch and control the steam input and make manual adjustments every 30 to 60 min are now freed up to concentrate on other roles, therefore improving both worker and plant efficiency. Clariant was so satisfied with the increased energy reduction and process optimisation achieved on this two-month project that it is now looking to review the performance of other distillation columns at its other production sites.www.cpp-net.comOnline search: Emerson

At the Clariant site in Frank-furt, Germany, the steam consumption of distillation columns could be reduced by 6 % using the Advanced Loop Service Pi

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AUTOR:JÖRG WIERZ Advanced Process Control Consultant, Emerson

cpp FOCUS INSTRUMENTATION, CONTROL, AUTOMATION

30 cpp 01-2020

High-end circulators for demanding tasks in the laboratory and industry

Constant temperature in all processes

As a supplier to almost all manufacturing companies, the chemical industry relies on efficient and safe processes to meet its pro-duction requirements. Since most chemical reactions are either exothermic and release heat, or endothermic and absorb heat, a re-liable temperature control application plays a central role in the chemical industry. Julabo has developed the high-end circu-lators of the new Magio series with new fu-ture-oriented technologies, especially for such requirements. They are manufactured in Germany to the highest quality standards.

Especially the refrigerated circulators of the Magio series offer the ideal conditions for precise external temperature control as required by the chemical industry, for example, in reactor temperature control.

Reactor temperature controlIn both chemical and biological processes, the conversion of substances often takes place in reactors, which make it possible to create consistent conditions and a safe space for the reactions. This requires temperature control systems with fast and precise com-

pensation and a wide temperature range. This is why temperature control systems such as the Magio circulators are used, which react dynamically to temperature changes inside the reactor and compensate for them quickly and reliably. The reactor type, its size and the material (e.g. glass or metal) as well as the wall thickness, and the thermal conductivity associated with the material are, among other things, decisive parameters. In addition to the process hav-ing to be temperature-controlled, these pa -rameters also influence the choice of the

Julabo circulators are renowned for their reliable technology. Now, the new Magio series complements the product range with bridge mounted circulators, refrigerated circulators and circulators for most demanding temperature applications and maximum flexibility in the laboratory and industry.

The Julabo circulators of the Magio series are predestined for demanding tasks

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temperature control system. Pump capacity, pressure build-up, heat exchange rates, and the efficiency of the components in the temperature control system must precisely cover the individual requirements to guar-antee process reliability and effective ma-terial conversion. For special requirements outside the standard temperature control, specially-developed temperature control solutions are also considered. In most cases, however, this is not necessary because tem-perature control systems available on the market can be easily and efficiently adapted to individual requirements.

For temperatures from -50 to +300 °CWith the Magio series, Julabo offers prod-ucts of the highest performance class with a working temperature range from -50 to +300 °C and a heating capacity of up to 3 kW. Due to the high heating and cooling capacity, the models guarantee short heat-up and cool-down times. In combination with the high-performance power pressure/suction pump with output values of up to 31 l/min or 0.92 bar (pressure) and -0.4 bar (suction), the Magio units are ideal for the most demanding external appli-cations. The pump is not only powerful, but it is also continuously adjustable, making it easy to adapt to pressure or volume sensi-tive external applications. Furthermore, samples can also be temperature-controlled in the internal bath. To ensure maximum re-sistance to chemical substances, all parts in contact with the medium are made of stain-less steel. The high-quality insulation of all relevant components supports energy effi-ciency during operation.

Functional operationThe high-resolution TFT touch display offers a multilingual user interface and

stands for simple, intuitive operation and optimum visibility of relevant functions. The modern display shows all important in-formation at a glance. Three pre-defined, generous main screens clearly show data and graphics with different application fo-cuses. The menu navigation is self-explana-tory and arranged according to relevance in the daily work. All display functions can be operated at the touch of a finger. This allows even complex applications to be controlled easily and safely. The support function assists with further detailed questions at any time.The sophisticated operating concept of the Magio series allows quick and convenient access to the most frequently used func-tions. All operating elements, as well as safety functions, can be easily operated from the front. The main switch on the top of the circulator simultaneously switches the circulator and refrigeration unit on and off. With the bright and extremely robust touch display, it is visible from afar and can be read easily even from a distance. The cir-culator fully controls the connected cooling unit during operation. Inclined pump con-nections on the back of the model facilitate the connection of external applications. Modern interfaces such as USB, RS 232, and Ethernet support a simple remote control.

Safety through automatic shut-offFor optimum process reliability, critical states are indicated visually and acoustically at an early stage. The automatic shut-off in the event of high temperature or low liquid level additionally provides maximum safety. Classification III according to DIN 12876-1 enables safe operation, even with flam-mable fluids. The fill level of the tempera-ture control medium can be read at any time on the display.The bath fluid is drained without special

tools, comfortably and cleanly via the drain tap. The magnetic front grid of the refriger-ated circulators can be removed easily for time-saving care and maintenance of the model. As usual with Julabo, all Magio models do not have vent slots on the sides of the sys-tem. Thus, they can be placed directly next to other devices and applications or against walls to save space. Depending on the model, the refrigerated circulators from the Magio series have handles or castors for easy transport. In combination with the ergonomic handles, the models can be easily and comfortably moved to a different location.

Individual solutionsIn chemical reaction and process engineer-ing, a precise temperature control appli-cation has a decisive influence on produc-tion output, product quality, and process re-liability. The requirements placed on tem-perature control systems are strongly appli-cation-related. Due to the extensive range of accessories, the wide temperature range, and the extraordinary dynamics, the circu-lators of the Magio series can be adapted modularly and individually to almost any application. Modern interfaces and an inte-grated programmer complete the intelligent design. www.cpp-net.comOnline search: Julabo

AUTHOR:SILJA MOSER- SALOMONMarketing & PR,Julabo

The Magio circulators are ideal for flexible temperature control of reactors in the laboratory and industry

The Magio circulators have no side ventilation slots and can therefore be placed directly against a wall or next to other circulators like Corio or Dyneo

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cpp PRODUCTS

Graphical analysis of mixer and process data

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Modular orbital cleaner

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Stationary acid dosing unit

For the extractive analysis of process and emission gases the reliable and constant reduction of the sample gas moisture is indispensable. The solution for moisture reduction by cooling leads to the problem of loss of concentration of the water-sol-uble sample gas component (e. g. SO2). This effect is also called the leaching effect. In order to minimise this leach-ing effect, Bühler Technologies developed the stationary acid dosing unit. A premixed acid is metered into the heat exchanger

at a constant flow rate to satu-rate the precipitated water con-tent. A plate holder allows the complete unit to be mounted on the wall. The modified cover fa-cilitates the connection to the acid tank. The specifically de-signed connection adapters on the metering pump and the heat exchangers ensure a short lead time of the acid feed in the me-tering line. A capacitive sensor for level monitoring of the acid is also available.www.cpp-net.comOnline search: Bühler

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Quick couplings according to ADR/RID

The quick couplings of the Clean-Break CN series from Walther Präzision meet the requirements of the directive RL 2010/35/EU on transport-able pressure equipment in con-junction with ADR/RID 2017 and DIN EN 14432:2014 for hazardous goods. This approval permits the use of CN quick couplings for transfer processes of liquid chemical products classified as hazardous into/from ADR/RID-approved con-tainers as a secondary product shut-off valve downstream of the bottom valve and as a pri-mary shut-off valve for peak use in road and rail vehicle tanks. In the case of tanks intended for the transport of these dangerous goods, the fittings can thus be used for filling and removal op-erations. The locking device is not placed in the flow coupling

for hygienic and cleaning rea-sons. The CN couplings there-fore have excellent hygienic properties, are easy to clean and SIP-compatible. All these quick coupling systems can be coupled against high differential pressures and are insensitive to transverse loads (forces acting at 90° to the axial direction). www.cpp-net.comOnline search: Walther

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The modular OC200 orbital cleaner from GEA offers distinctive advantages in terms of cleaning performance and efficiency. The orbital cleaner’s normal operating pressures are 4 to 10 bar and can easily deliver high im-pact liquids for tanks with a diameter of up to 35 m. The OC200 is particularly suitable for large process tanks and storage vessels for industries. It can be individually configured. The modular system allows interchangeabil-ity of key components – rotors, nozzle carriers and nozzles – in various standard options whilst the main cleaner assembly simply remains in place. This modular-ity offers flexible adjustments of impact values, cleaning diameter, dwell time and insertion size, as well as re-duced consumption of cleaning media, according to the application requirements and customers’ priorities. www.cpp-net.comOnline search: GEA

Proview process data visual-isation from Eirich is a universal tool that is not tied to any spe-cific platform, enabling efficient analysis of operating data. It can be used on a PC in the office or on a tablet or smartphone while on the move. In many indus-tries, monitoring the mixing process is necessary for reasons of quality assurance, particularly if plants are working automati-cally, without direct control by a designated member of staff.

Proview enables simple and quick analysis of the process values in such situations.As browser-based software Pro-view works with any con-trollers, whether from Siemens, Rockwell or Mitsubishi. Instal-lation on the company network is easy. The programme is pre-configured for each machine or plant, but can also be adjusted by the user at any time. www.cpp-net.comOnline search: Eirich

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Sanitary filter housings

WS Sanitary housings from Wolftechnik are designed for use in sterile production. Depending on the product requirements, depth filter types can be used in the car-tridge filter housings for clarification, as can pleated el-ements and membrane filter cartridges for sterilisation. The housings are made of stainless steel AISI 316L (1.4404) and have a mirror polished surface inside and outside. The surface roughness (Ra) is <0.6 μm on the inside and 0.8 μm on the outside. Filter cartridges with bayonet adapters are provided for use. The standard range extends from a filter housing for a single filter cartridge in lengths of 10, 20 and 30" up to filter housings for seven filter cartridges in lengths of 10 to 30". WS Sani-tary housings offer a variety of applications depending on the filter used. Filters differ in terms of filter material, pore structure, retention rate, and dirt absorption. www.cpp-net.comOnline search: Wolftechnik

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Tare-compensated feeder

Gericke’s tare-compensated hy-brid loss-in-weight feeders are well known for their combi-nation of high accuracy feeding and robustness. The DIW-E-Star weighing system in conjunction with GAC feeders now covers the mid-range of feed rates in

the gravimetric hybrid feeder portfolio, typically from 10 up to 2000 kg/h (depending on bulk density). The DIW-E-Star is available with hopper sizes ranging from 50 to 200 l net volume. Due to the modular ap-proach, all hopper sizes fit into one weighing frame. All hoppers are equipped with ver-tical agitators to ensure mass flow even for cohesive powders. The weighing frame itself has been designed to combine high -est mechanical stability with a lightweight construction. Due to the tare-compensation mechanism the load cell only measures the actual product weight, and vibrations are fil-tered out mechanically before even reaching the load cell. www.cpp-net.comOnline search: Gericke

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Intelligent liquid ring vacuum pump

Edwards Vacuums developed the Elri series of liquid ring pumps for applications which are wet, humid as well as corrosive. The stainless steel impeller, end-plates, liquid reservoir and heat exchanger makes this pump highly resilient against cor-rosion and harsh process gases. The internal injection channels reduce the risk of leakage while the horizontal motor flange ar-rangement saves time on main-tenance. The use of mechanical seals also ensures reliable oper-ation by preventing leaks as well as extending service intervals. The Elri is equipped with two VSD. While the main VSD matches the speed of the pump to vacuum level by adjusting its

speed, the second VSD regulates the water flow through the cen-trifugal pump according to the operating conditions to avoid risks of cavitation. A special algo-rithm always maintains a perfect harmony between the two VSD’s. The Air logic control ler not only enables the monitoring of im-portant features and parameters of the pump, but also offers the option of set-point control. While the Econtrol box even allows to connect and control multiple Elri pumps, the Icon Box enables smart monitoring and remote controlling ensures optimal servicing to get maxi-mum uptime with the pumps. www.cpp-net.comOnline search: Edwards

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Drum emptying system with follower plate

The drum emptying system with follower plate from Lutz is supplied on a mobile trolley. A simple and convenient control system enables the commission-ing. The manual, infinitely vari-able control of the FDA-com-pliant hydraulics gently deposits the follower plate on the medi-um. The conveying speed is infi-nitely variable and the con-tainers are emptied almost pul-sation-free. Sealing lips made of EPDM (also available in FKM or PTFE) adapt perfectly to the con-tainer. Due to the pressureless guidance, the pumped medium is not pressed out at the wall. Only a small amount remains in the container after emptying.

Depending on the pump size and the drive motors that can be combined with it, flow rates of up to 120 l/min can be achieved. www.cpp-net.comOnline search: Lutz

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Facelift for IE3 asynchronous motors

The facelift of the IE3 asyn-chronous motors from Nord Drivesystems involves no change of electrical data and outer dimensions. They can be seamlessly used without adjust-ments in any existing appli-cation with Nord IE3 motors. The optimised cooling fin shape, an assembly-optimised fan and a modern fan cowl en-able a better heat dissipation and assembly. The fan cowl can be simply assembled in case a motor-mounted frequency in-verter is used. The special cool-ing fins design enables an un-

hindered airflow around the ter-minal box. The revised terminal box is without sharp edges and corners and has reinforced feet for a better motor stability. An-other important detail is the op-timised incremental encoder mounting. Due to the fan cowl, the encoder is fully shock-resis-tant and not within the airflow, which further improves the cooling power. Retrofit mount-ing is also possible due to a plug-on shaft.www.cpp-net.comOnline search: Nord

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Visualisation app for pumps

Lewa has developed an app that presents a virtual, freely scalable ecoflow process diaphragm pump on an iPad and allows malfunctions to be simulated. This makes it unnecessary to provide a demo model at trade shows, for example, and technicians at the customer’s facility can be trained more effectively. Also augmented reality smart glasses are available from Lewa for remote main-tenance and initial diagnostics of malfunctions in oper-ation. With the smart glasses, a connection to a service technician can be established to support the on-site em-ployee with their repair and maintenance work. www.cpp-net.comOnline search: Lewa

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Metering and drainage station for IBC

The Dulcodos Safe-IBC from Prominent is a special metering and drainage station for Inter-mediate Bulk Containers (IBC) with almost complete residual drainage. The customer positions and fixes the IBC on the slightly forward-tilted installation sur-face of the collecting pan. Using leak-proof safety couplings and hoses, the IBC is connected to an interim tank of approximately 200 l fitted to the left side of the collecting pan. Optionally, the station can be equipped with a standpipe and a tank volume of approximately 60 l.This buffer volume ensures an uninterrupted process when changing the IBC. The visual level indicator and a level measurement function with alarm message also allow more efficient planning of IBC changes. The station is equipped with an inspection opening for

maintenance purposes.To ensure reliable metering, a compact metering station can be integrated in the front of the in-terim tank according to process requirements. This is equipped either with one or two solenoid metering pumps or with one motor-driven metering pump. Larger metering stations can be configured as required and de-signed for side mounting on the wall or installation on the floor.www.cpp-net.comOnline search: Prominent

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Mixer for continuous processes

The continuous Ploughshare mixers of the KM series are particularly suitable for envi-ronmental engineering appli-cations. This low-maintenance mixer model is intended for processing powders, fibrous or granular solids, but also fluids and pastes. The continu-ous mixer even performs gran -ulating processes with mini-mum retention times. It is char-acterised by excellent repeat-ability, maximum homogeneity of the final product, short re-tention times and great econo -mic efficiency.The sophisticated mixer concept also includes universal applica-bility of the machine. Beyond

processing of dry, powdered, granular or fibrous solids, it can also be equipped for numerous other mixing tasks. Adding fluids to moisten product com-ponents is just as possible as processing pastes and fluids. A broad range of different mixer sizes allows for even more ver-satility. The smallest model with a drum volume of 5 l boasts a feed rate of 0.25 m3/h based on retention time and degree of filling. The feed rate of the larg -est model to date with a 57,000 l drum volume is 1300 t/h.www.cpp-net.comOnline search: Lödige

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Valves with electric drives

Gemü has expanded its selection of motorised valves with the launch of the Gemü Esystep and Esydrive valves.The Gemü Esy -step valves are designed for standard open/close and simple control applications. With regard to the actuator, this is a compact spindle actuator with step motor. Via the interface in the

housing cover, the valve can be extended with additional acces-sories such as diverse electrical position indicators or travel sen-sors to provide extra functions.The Gemü Esydrive valves are available for variable and com-plex open/close and control ap-plications in conjunction with high requirements on perfor -mance and service life. The ac-tuator is based on the hollow shaft principle. Both the Ether-net-based Esy-web interface, in conjunction with an integrated web server, and the Modbus-TCP communication interface, enable the exchange of parametrisation and diagnostics data and the networking of several devices.www.cpp-net.comOnline search: GemüPi

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Jacket-cooled submersible motor pumps

The Amarex KRT range of submersible motor pumps are available with drive ratings of 10 to 30 kW and are suitable for vertical or horizontal dry installation. Since the pump motors remain fully operational when not submerged, the pump sets can also be used in pump sumps when water lev els have dropped. Thanks to IP 68 enclosures, the pumps also offer trouble-free continuous operation when flooded. The pump sets meet all explosion protection requirements set out in the Atex, FM and CSA standards.The motor is cooled via a closed circuit which avoids con-tact between the circulating water-glycol mixture and the fluid handled. This also rules out any risk of contaminants in the fluid handled impairing the cooling of the motor. The cooling liquid is circulated by a special impeller which the pump’s design engineers have integrated into the cartridge seal.The pumps are able to transport fluids with a temperature of up to 40 and operate in environments with a tempera-ture of up to 55 °C. www.cpp-net.comOnline search: KSB

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Ultrasonic clamp-on flow and energy meter

The ultrasonic clamp-on flow-meters and energy meters TFX-5000 are available in two versions:

• a flowmeter for water delivery, raw sewage, cooling water, sea water, deionised water, water-glycol mixtures, alcohols, chemicals and many caustic fluids

• a heating/cooling energy flowmeter used in conjunction with dual clamp-on Resistance Temperature Detectors (RTDs) for temperature measurement in hydronic processes and HVAC systems

Users can select up to eight pa -rameters to log, including flow rate and total, signal strength, and alarms to an 8 GB microSD card. Users are alerted to out-of-specification flow conditions and can access a history with the most recent alarm, error and event codes. The TFX-5000 meter features a large, easy-to-read graphical display and provides Modbus RTU, Modbus TCP/IP, Bacnet MS/TP, and Bacnet/IP connec-tivity. www.cpp-net.comOnline search: Badger Meter

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Smart actuator in protection class IP 67

The Profox from Auma is not only cunning and adaptable but also extremely hardy. The smart actuators are suitable for process and water applications. Adjust-able speed ensures fast and pre-cise positioning. Operating costs are low, thanks to high mechan-ical efficiency and low standby consumption. Special diag-nostics ensure long-term avail-ability and future-proof Profox for IIoT applications.Auma Profox actuators work with gate, butterfly, ball and globe valves. There are multi-turn versions for torques of 10 to 100 Nm and part-turn ver-sions delivering 32 to 600 Nm. A linear actuator will follow soon. Modular design ensures flexible configuration, rapid de-livery and consistent operation. Host system integration is equally flexible, the most com-mon communication protocols are supported. IP 67 protection

(IP 68 optional) and Auma’s corrosion protection ensure that Profox actuators have a long life even under the toughest process conditions, at temperatures from -30 to +70 °C.Profox actuators are simple and easy to use, with rapid instal-lation and commissioning via pushbuttons or an app. Actuator status is always clearly visible, even from a distance.www.cpp-net.comOnline search: Auma

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Compact level measurement in the waste water industry

Radar as real alternative to ultrasonic

In sewage treatment plants, one treatment stage immediately follows the next. Each of these processes must be perfectly coordi-nated with the previous and the subsequent one so that the overall system can work op-timally. To control the various process stages automatically, precise measurement data are required. But accuracy is not everything. Smooth, trouble-free operation is only pos -sible with robust, durable sensors that can withstand wind, weather and the challenges posed by dirt and contamination.

Compact and highly accurateFor decades, the Schiltach-based company Vega has been supplying a wide variety of level and pressure sensors to sewage treat-ment plants all over the world. At the begin-ning of this year, a new compact series of radar level sensors was introduced to the market. The beating heart of these new sen-

sors is a radar chip newly developed by Vega and specially optimised for the requirements of level measurement. And thanks to its small size, very compact sensors are now possible. Moreover, these new instruments are so in-expensive that they can replace previously-used ultrasonic sensors in almost all appli-cations. Vegapuls series C 11, C 21 and C 22 sensors have a fixed cable connection and are designed in protection class IP 66/IP 68. In accordance with the requirements in the waste water sector, the sensors are also suit-able for use in Ex hazardous areas up to zone 0. And for the typical zone 1 in the wastewater industry, Vega has come up with something special. By means of a special en-capsulation, which is new for radar sensors, operation in Zone 1 is possible even without an intrinsically safe power supply – making installation much easier for the user.In addition to being unaffected by tempera-

ture fluctuations, vacuum or changing gas overlay, radar sensors are, most importantly, non-insensitive to soiling. These are all fac-tors that often lead to malfunctions in ultra-sonic level measuring devices. The Vegapuls series measures with a frequency of 80 GHz, which enables very good signal focusing. With this advanced technology, measure-ment signals can be better separated from interference signals − the measuring process itself thus becomes much easier and more precise than other measuring methods. Be-fore its official market launch, the new sen-sor series was tested in over 400 applications in 30 countries. Several application examples in the wastewater industry show where the new sensor can really unleash its strengths.

The basis for calculationsWaste water and rainwater are transported to the waste water treatment plant via

Radar technology has established itself as a real problem solver in the field of level measurement. So far, however, the price of the devices has prevented their general use in standard applications. Now, the compact radar sensor Vegapuls is also gaining the upper hand in price-sensitive applications in the waste water industry.

The compact radar level sen-sors Vegapuls and the control unit Vegamet offer a real al-ternative to the ultrasonic sensors commonly used in sewage treatment plants

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AUTHOR:JÜRGEN SKOWAISAProduct Management Radar, Vega

widely branched sewer networks and measured in open channels on the way to the plant inlet. An important job, since measuring the amount of water flowing in and out of the plant provides the basis for calculating service rates and fees as well as operating costs. The Vegapuls C 21 delivers these measured values reliably with an accu-racy of ±2 mm, regardless of the ambient temperature and the type of medium.The sensors are also used at another point on the way to the waste water treatment plant – in pumping stations. If the natural gradient from the households to the plant is not steep enough, various pumping stations are required to create sufficient height dif-ferences along the way. Level measurement with Vegapuls C 11 in the inlet shaft of the pumping station, together with a controller, ensures economical operation of the pumps.The rain overflow basins, which protect waste water treatment plants from overload during heavy rainfall, are also an ideal lo-cation for the new sensor series. The precipi-tation is stored there temporarily and then released to the plant at a slower rate. If the basin cannot hold the accumulating quan-tities of water, part of the water is dis-charged. Due to legal requirements, such im-pounding events and discharged water quan-tities have to be measured and documented. Vegapuls C 22 stands out here due to its compact design and simple ceiling mount-ing, delivering the required measured values reliably – even in the event of flooding.

Controlling the cleaning processesIn the precleaning stage, floating materials are mechanically removed with rakes or sieves. This protects later process steps from buildup, clogging, and abrasion. Solids with diameters greater than 25 mm are trapped in the coarse screens, compressed in the screenings press, and then disposed.The fine screen removes smaller residual materials from the waste water. Measure-ment of the water level difference between the front and the back of the screen is used to determine the degree of contamination and initiate the cleaning of the screen. This is where things get particularly rough and dirty. An ideal task for the fully encapsulated Vegapuls C 11. Reliable level measurement is also required in the containers where the solids, sand and sludge sorted out through coarse and fine raking are collected. Here, the measured values, which are also sup-plied by a Vegapuls C 11, give the signal to

start the automatic exchange of the con-tainers.Through the addition of chemicals, phos-phates in the wastewater are precipitated out in primary sedimentation, in aeration systems or in special precipitation and post-clarification pools. Precipitants like ferric chloride bind the phosphate chemically and deposit it in the sludge. In each chemical storage tank, a level measuring system as well as a limit level detector are deployed for continuous inventory monitoring and optimal dosing. Vegapuls C 21 is also used here. The sensors are approved as overfill protection systems according to WHG (Water Resources Act in Germany) and thus reliably protect the environment from an overfilling of the tanks.

Displaying the essential readingsThe sensors are supplemented by Vegamet controllers. These supply the connected 4...20 mA sensors, process the measured values and display them, all without com-plicated programming. A large display for data visualisation is integrated in the hous-ing designed for harsh field conditions. Vegamet enables simple implementation of pump controls, flow measurement in open channels/weirs and totalising counters as well as the calculation of difference, total and average values. Limit values can be monitored and relays switched, e.g. for overfill protection according to WHG.The compact Vegapuls series is ideally suited for a wide range of applications in the waste water industry. It is a real alternative to ultrasonic sensors not only because of its low price, but also because of its high relia-bility and long service life. All sensors and controllers can also be adjusted via a smart-phone or tablet with Bluetooth functional-ity. This makes everyday work easier in the harsh environments of the industry – es-pecially since many sensors are often lo-cated in virtually inaccessible places.www.cpp-net.comOnline search: Vega

With the Vegapuls C 21 a flow measurement in open channels can be carried out at the inlet of the waste water treatment plant

The level measurement with the Vegapuls C 11 in the inlet shaft of the pumping station ensures economical operation of the pump

The new Vegapuls series is also well suited for level measurement in rainwater over-flow basins

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Future-proof drying in compressed air treatment

F-Gas Regulation forces action

Compressed air drying and production go together hand in hand. Virtually every com-pressed air station uses refrigeration dryers, for the simple reason that virtually every compressed air application requires dry compressed air. The F-Gas Regulation EU 517/2014 aims to minimise emissions of fluorinated greenhouse gases (F-gases) in order to mitigate the effects of global warm-ing. Set in place since 2015, this regulation

is now only just beginning to cause ripples in the industrial sector. Operators of com-pressed air stations count amongst those now feeling the effects, owing to the fact that F-gases are used as a refrigerant in many refrigeration dryers. Any company wishing to service or repair their existing refriger-ation dryer, or to purchase a new one, must do so within the confines of the regulation. Refrigerants that have until now been freely

available will henceforth gradually be with-drawn from the market – partially by means of outright bans, but also by a deliberate tightening of the supply of refrigerants with high global warming potential (GWP).The hitherto ubiquitous refrigerant R404A now finds itself firmly in the regulation’s sights. As of this year, the release to market of new refrigeration dryers that use R404A are prohibited. Existing stocks of this refrig-erant are only permitted for maintenance purposes in larger systems until 2030, whereupon it will become banned from ser-vice altogether. The result is clear to see: R404A will henceforth be difficult to source in large quantities, and will only be available at great cost. And it does not end there …

Shortages aheadOther commonly used refrigerants with high global warming potential are also being targeted, such as R407C and R410A. Quotas have been assigned to the individual manufacturers and distributors of these re-frigerants, limiting the volumes which they are legally allowed to produce and sell. The quotas will gradually be reduced to just 21 % of their initial volumes. The lower the global warming potential of a refrigerant, the higher the volumes that may be pro-duced and sold; as a result, manufacturers are rushing to switch their product ranges over to refrigerants with the lowest possible global warming potential values. Access to refrigerants with high global warming po-tential will consequently become much more difficult. Many such products cur-rently on the market will no longer be avail-able for maintenance and servicing work, or if they are, only at very high prices. Operators of compressed air stations would be well advised to check up on which re-

For businesses that rely on refrigeration dryers for their compressed air treatment, there will be no getting around the new F-Gas Regulation. This new standard will be the end of many dryers in use today – operators should be wary.

Future-proof refrigeration dryers not only save operators both energy and space, they also use a climate-friendly refrigerant

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frigerant their system currently uses and, if necessary, seek advice on possible alter-natives. Stockpiling large quantities of re-frigerant for later use is not an option for most; operator certification is a prerequisite for purchasing new stocks and the only al-ternative – sourcing unofficial supplies on the black market – is fraught with danger from a technical point of view, not to men-tion highly illegal. As a starting point, all operators of refrigeration dryers – particu-larly older units – should have them ser-viced by a certified technician as soon as possible, to ensure there are no leaks in the refrigerant circuit that could waste precious supplies. There are also new regulations re-garding mandatory leak testing that must be adhered to.

Not a feasible alternativeUnfortunately, in many cases, simply con-verting an existing dryer to use a new re-frigerant is not a feasible alternative. It is not always technically possible to do so and even when it is, it can be prohibitively ex-pensive. In such cases a better option in the long run would be to invest in a new dryer altogether. The enormous strides recently taken in the development of dryer technology mean that there are several advantages to this option. The latest generation of dryers are designed for the highest levels of efficiency and ener-gy-saving, and frequently take up much less space than their older counterparts. On top of securing their future supplies of refriger-ant, operators will also benefit from re-duced energy and servicing costs.

Think about the futureAny operator planning to invest in a new re-frigeration dryer should first ensure not

only that refrigerant supplies for it are cur-rently available, but that they will continue to be available for service purposes over the entire lifecycle of the machine. By far, the safest choice is to go with a refrigeration dryer that already operates using a refriger-ant with the lowest possible global warming potential, or at the very least, one that is ca-pable of being converted inexpensively for use with it at a later date.Some manufacturers continue to use refrig-erants that, whilst currently unrestricted, are bound to be either banned completely or gradually withdrawn from the market in the near future. Inevitably, operators using these systems will find themselves in trouble sooner or later. The most proactive manufacturers of re -frigeration dryers are already offering prod-

ucts using a new generation of refrigerants such as R-513A, which has the lowest GWP value of all refrigerants on the market today, thereby ensuring the most future-proof and climate-friendly solution cur-rently available. www.cpp-net.comOnline search: Kaeser

The new refrigerant R-513A offers the most future-proof solution currently available on the market

Thanks to a frequency-controlled radial fan, Secotec TG refrigeration dryers can be connected directly to the central exhaust air ducting

High-performance TG-series re-frigeration dryers from Kaeser not only impress with their latent heat storage system, fu-ture-proof use of climate-friendly R-513A refrigerant and relatively small footprint – they now also benefit from a new ex-haust air system, which elevates these high performers to an en-tirely new level of cost efficien-cy when it comes to compressed air treatment.Designed for large-scale indus-trial operations, these compact powerhouses are capable of de-livering flow rates of up to 98 m3/min and ensure stable pressure dew points, even under the most challenging conditions

– all whilst guaranteeing maxi-mum reliability and minimal lifecycle costs.When installed in a location that is less than ideal, energy con-sumption can increase due to a build-up of heat inside the dryer. The frequency-controlled radial fan fitted to TG-series dryers is designed to allow the dryer to be connected directly to a facility’s central exhaust air ducting – making this potential issue a thing of the past. Fur-thermore, thanks to space-sav-ing component layout, the new units are smaller than their pre-decessors, meaning operators save on space as well as operat-ing costs.

REFRIGERATION DRYERS: TG-SERIES

AUTHOR:DANIELA KOEHLERPress Officer,Kaeser Kompressoren

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How digital services improve plant availability

Off to the cloudAsset management and predictive maintenance on the basis of data stored in the Auma Cloud. This is Auma‘s way to increase actuator availability. Thomas Knecht and Kevin Nietupski, both staff members of Auma at Service Center Cologne, explain the advantages for the users and how classical and digital services are further merged.

Mr Knecht, which are the milestones Auma has achieved in terms of digitisation?Thomas Knecht: The topic of digitisation is not new to us. In 2002, we had introduced the first generation of our software-based actua-tor controls. This was the AC.1. The actuator controls made it consi-derably easier to integrate our actuators into digital fieldbus proto-cols. One year later, COM-AC software for AC.1 configuration was launched. In 2005, data matrix codes were introduced on the actua-tor name plates. At first, this was purely for production reasons. La-ter, this code was used to store device data which can be read out today using the Auma Assistant App.

The year 2009 was also a very important milestone.Knecht: That is correct. It was the time when AC.1 actuator controls were replaced by the new AC.2 actuator controls, which are still in-tegral part of our product portfolio. The Commissioning and Diag-

nostic Tool, in short CDT, is used for device configuration, replacing the previously used COM-AC software. In 2014, we launched our first App, the Auma Support App, enabling quick and easy access to the device documentation by means of mobile end devices. This App was then integrated into the Auma Assistant App which was in-troduced to the market in 2017.

If I remember correctly, Auma showed a first idea of the Auma Cloud on the Achema in 2015?Knecht: At that time, it was just an idea. We needed more than three years to turn a mere idea into a complete solution. In September 2018, the Auma Cloud went online. A few weeks later, we presented our new service scheme with the Auma Cloud as central “hub”. Moreover, the latest version of the Auma Assistant App was launched. The App enables to download data from AC.2 actuator controls to the Auma Cloud.

Thomas Knecht, Director Service of Auma Riester GmbH & Co. KG, and Kevin Nietupski, who works for the company as Product Manager Service (from left)

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of all actuators and actuator controls is created. The data is stored in a structure which has been previously defined by the user. They may also be concentrated into subgroups and therefore appear in a hier -archical structure. Once complete, the list is transferred to the Auma Cloud by simply pressing a button.

If I understand you correctly, the plant structure includes a list of all actuators and actuator controls within the plant?Nietupski: That’s perfectly right. It is a structured serial number list to which short notes can be added.

This sounds very straightforward. Still, I believe that filling the Auma Cloud with data is quite time-consuming. Do you offer any support?Nietupski: Only recently, we have been offering to load data to the Auma Cloud as an actual customer service. Once our service engi-neers are on-site at the customer’s premises, they scan the data matrix codes within the plant and set up the plant structure for the Auma Cloud.

Can you please explain by means of an example how the AC.2. actuator controls and the Auma Cloud work together?Knecht: The AC.2 actuator controls provide the event reports. They list all relevant events and faults or failures within the MOV with a time stamp. The data is continuously stored within the Auma Cloud and analysed by means of an algorithm. This way, we obtain valid figures allowing qualified statements on plant availability.

When talking about cloud applications, we are actually talking about data security. How do your customers deal with this issue?Knecht: Indeed, data security is always a focus during discussions with customers, even if the advantages of our new service scheme has been described in detail beforehand. To ensure maximum secu-rity to our customers, we have decided in favour of Azure, the cloud computing platform of MS Microsoft. A renowned name, pro-ven technology and a leading product – this creates trust among our customers.

Mr Knecht has mentioned several products which we will explore in detail. Mr Nietupski, let us start with the AC.2 actuator con-trols.Kevin Nietupski: The AC.2 can be considered as the brain of the MOV package, i. e. the system consisting of valve, actuator and actuator controls. Actuator controls collect a large quantity of data such as operating and status data allowing statements on the actua-tor status. At the same time, critical operating states are recorded and archived. Thus, our service technicians can quickly provide the user with straight-to-the-point solutions in case of failures.

You mentioned the CDT software. What do you need this software for?Nietupski: As referred to by its name, the Commissioning Diagnos-tic Tool, the software is both used by our service as well as by our customers for commissioning, configuration and diagnostics of the actuators. The diagnostic function is extremely useful since it ena -bles a sound analysis of data packages and event reports, which can be downloaded directly from the AC.2 actuator controls to a mobile end device, e. g. a laptop.

And what is the function of the Auma Assistant App?Nietupski: The App is the light version of the CDT software. In its initial version, the complete device documentation could be downloaded by scanning the data matrix code on the actuator name plate. With the latest version of the app, you can also modify the device settings. Furthermore, the intuitive app can also be used to take snapshots.

What is a snapshot?Nietupski: Snapshots are documents containing all relevant device data including serial number and operating data, which can be uploaded to the Auma Cloud.

Which operating system do you need?Nietupski: The app runs on both Apple and Android devices.

Mr Nietupski, let us talk about the Auma Cloud. What does it do?Nietupski: All the systems that my colleague just presented were not initially connected within a network. And this is exactly what we did with the introduction of the Auma Cloud. It links both de -vice and operating data as well as information on the respective applications, enabling centralised management of all Auma devices within one site, applying the same system which complies with the site setup. Both users and our service personnel may access the Auma Cloud. In fact, it is a platform on which the users can manage, edit and analyse the operating and device data.

This means the plant layout is stored in the Auma Cloud. How does this work?Nietupski: You use the „Create a serial number list“ function of the Assistant App. The user scans the data matrix code of all Auma actuators on their tour throughout the plant. Thus, a complete list

The company Auma Riester GmbH & Co. KG with head-quarters in Muellheim, south of Germany, can look back on 50 years of active business. Founded in 1964, the com-pany counts among the worldwide leading manufacturers of electric actuators for industrial valves, actuator controls as well as gearbox combinations. The prime customers for their products are traditionally water and waste water companies as well as power plants of any kind. A further important market segment is the oil and gas industry start-ing with oil production and refinery. Not to forget appli-cations in the chemical industry and concrete production.As a medium-sized company, operating at 30 locations, Auma employs approximately 2,600 people, whereby around 1,200 of the employees are working in Germany (as of 2018). More than 15 % of the Auma staff work in the service sector. This figure shows the substantial cus-tomer orientation of Auma. In 2018, the company turn-over was 420 million Euros.

AUMA: FACTS AND FIGURES

„Cloud-based Auma services cater for intelligent asset management and the launch of predictive maintenance.“

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obtains the complete device-specific documentation, i. e. device data, documentation, wiring diagrams, etc.

Will the cloud-based services replace on-site service staff in the future?Nietupski: Definitely not. But we would like to make full use of the cloud-based services. At the same time, face-to-face contact for con-tinuous customer care is indispensable, especially when it is used as a source of information which is later included in our algorithms.

What is the outlook for the Auma Cloud and the adapted services?Knecht: We have different approaches. One major keyword is con-nectivity. Our actuators shall become IIoT ready for automated data transfer to the Auma Cloud. The Auma Cloud as such will undergo enhanced development based on the feedback we receive from our users. Furthermore, our R&D is working on expanding our digital services portfolio while combining them with our standard main-tenance options.www.cpp-net.comOnline search: Auma

And has Azure met your expectations?Knecht: More than initially expected.

How do you protect the data stored within the Auma Cloud against unauthorised access?Knecht: On the one hand, we have uncompromisingly implement -ed the security specifications of our customers. On the other hand, we apply a special user management. It includes registration via two-factor authentication and multi-stage validation process. After this initial step, access rights for the individual users are defined. User management enables the respective functions for the individ -ual users.

Is the use of the Auma Cloud free of charge for your customers?Knecht: Basic services are free of charge while additional functions have to be purchased.

Can you give an example?Knecht: Among others, we charge for continuous live data trans-mission directly from the field level via OPC UA to the Auma Cloud. I would like to take this opportunity to emphasise that our main-tenance services will also work for discontinuous data transmission to the Auma Cloud. However, continuous transmission will result in more accurate data analysis. Once defined escalation levels are ex-ceeded, the Auma service will automatically be notified. Or even de-vice monitoring can completely be assigned to our service staff.

Mr Nietupski, which advantages do the cloud-based Auma services provide for the user?Nietupski: They cater for intelligent asset management and the launch of predictive maintenance. Eventually, plant availability is considerably improved. In addition, business processes are accelerat ed, transparency reigns on all levels and information is quickly available: Without any research on our website, the user

THE INTERVIEW WAS CONDUCTED BY: LUKAS LEHMANNAssistant Editor-in-Chief

With the intuitive Auma Assistant App, com-plete device documentation can be down-loaded from the Internet, device settings can be changed and snapshots can be taken

Plant structure: the user walks through the plant with his mobile phone and scans the data matrix codes on each Auma actuator. In this way, a list of all actuators and controls is generated

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Filling system for the chemical industry

The form fill seal system Fillpac FFS forms bags from a prefabri-cated tubular PE film and fills them with the product. The cus-tomers can select the optimal machine performance class from the Beumer product family depending on their require-ments. To palletise the bags, bar-rels, canisters, cartons or buckets, the Beumer Robotpac is used. Depending on the pack-aged items, it is equipped with the appropriate gripping tool

which can be easily and auto-matically changed, if the pack-aged items change. The fork gripper for example was de-signed specifically for palletising cardboard boxes, the finger gripper for bagged goods. For maximum performance, a double gripper for both types is offered. Moreover, there are par-allel grippers for dimensionally stable packed items.www.cpp-net.comOnline search: Beumer

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Seventh model for screw compressor series

The screw compressor VM 100 from Aerzen is designed for a volume flow range from 1500 to 7620 m3/h and covers a maximum differential pressure of 3.5 bar. Aerzen is thus re-sponding to specific practical requirements in the low-pres -sure range and the constantly growing demands for high-per-formance and efficient technol-ogy. All in all, the product range of E compressors includes sizes in the volume flow range from 330 to 7620 m3/h and drive ca-pacities from 30 to 630 kW.

A special feature of the VM 100 is the already integrated acoustic hood fan. Oil-free operation is certified according to ISO 8573-1/Class 0. The principle of the built-in reflection silencer protects against contamination and ensures process reliability over the entire service life of the system. Various equipment op-tions and a comprehensive range of accessories complete the VM 100’s operational capa-bility.www.cpp-net.comOnline search: Aerzen

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Easy to install pail filling station

The pail filling station type 14 from Feige Filling uses the Feige weighing technology to fill cans, pails or can-isters with liquid or pasty products in a highly accurate, rapid and cost-effective way. And all that for filling vol-umes ranging from 1 to 30 kg or 3 to 60 kg, depending on the customer or market requirements. Further bene-fits: The pre-configured station is easy to install. Control and operating elements are located directly at the filling station, easing the operation of the filling station. The optional LID Roller closes the pails with lids.www.cpp-net.comOnline search: Feige Filling

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High-speed turbocompressors

The HST 30 high-speed turbo-compressor from Sulzer offers more flow and pressure at a higher efficiency than its prede-cessors. This translates into sav-ings in the energy consumed by low-pressure air compression, both in waste water treatment and industrial processes. HST 30 introduces updated ver-sions of the active magnetic bearings. It also includes a per-manent magnet motor design, built specifically for this duty.

Almost unique for this size of a machine is that it is cooled with air only. All cooling air filters are well protected by the front door, but can easily be exchanged in sec-onds. Thanks to the horizontal shaft and inlet direction, the replacement of integrally-geared turbos and multistage centrifu-gal machines is also straight -forward. The flexible pipework configuration is helpful for the designer and builder as well. With filter boxes for wall or floor mounting as well as si-lencers and valves for all rel-evant flange sizes, HST 30 is one of the most flexible machines of its kind. The HST 30 has a maxi-mum input power of 300 kW and a maximum flow of 12,000 Nm3/h.www.cpp-net.comOnline search: Sulzer

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44 cpp 01-2020

Optimised cryogenic valve

Keeping cool when controlling cryogenic media

Cryogenic liquefied gases are stored and transported at very low (cryogenic) tempera-tures and, if necessary, high pressures. To maintain these conditions, the employed valves must have a special design. The ma-terials used to manufacture wetted compo-nents, such as the valve body and trim, must be capable of withstanding the extreme tem-peratures of the process medium, which may drop to near absolute zero. Even after longer periods in service, the materials must show no signs of embrittlement. In terms of appearance, cryogenic valves stand out from other valves due to their long

insulating section or extension bonnet, which creates the necessary distance between the valve body that carries the process medi-um and the valve bonnet. This cryogenic ex-tension bonnet ensures that the cryogenic process medium does not damage sensitive components. To prevent an exchange of ener-gy between the inside of the cryogenic valve and the warm environment, cryogenic valves are often insulated (e.g. in offshore instal-lations) or mounted in a so-called ‘cold box’. These installation specifications make it diffi-cult to access the valves. As a result, working on them is time consuming and compli-

cated, which calls for low-mainte nance de-signs with a long service life.Even stricter requirements apply to cryo-genic valves used as throttle valves in gas liquefaction. If gases are liquefied using tur-bines and/or valves, the process takes ad-vantage of the Joule-Thomson effect. This means that the gases are depressurised below their inversion temperature, which causes them to liquefy – contrary to their behaviour above the pressure-dependent in-version temperature. Joule-Thomson valves are expected to handle high pressure drops between the compressed medium at the

The Type 3598 cryogenic valve by Samson was carefully tailor-made for use at cryo-genic temperatures, high operating pressures and high pressure drops: optimised features include the materials used for the valve bodies and trims, the design engin-eered to master cavitation and flashing as well as the well-thought-out temperature distribution across the insulating section. Together with the top-entry design and standard pressure balancing, these benefits add up to lower cost of operation and quicker maintenance.

The Type 3598 cryogenic valve is suitable both as a throttle valve for gas liquefaction and as a control valve for offshore tank farms

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valve inlet and the relieved medium at the valve outlet. Severe pressure differences across the valve favour the occurrence of cavitation and flashing. This results in high noise levels, severe vibrations and erosion on valve components.

For larger volume flow ratesFor many decades, Samson has been devel-oping and manufacturing cryogenic valves in compliance with applicable specifications. Different valve versions in small and medi-um sizes for moderate pressure drops at cryogenic temperatures were added to the product range long ago. With the newly de-veloped Type 3598 valve, Samson responds to the trend that has also taken hold of the industrial processes to produce and dis-tribute cryogenic gases: plants are becoming ever larger while constantly higher flow rates and differential pressures need to be handled. During the development process, Samson brought together the thorough on-site experience gained over many years by plant operators with the corporate know-how acquired through CFD (computational fluid dynamics) simulations and experi-ments conducted at Rolf Sandvoss Innovation Center. The product management and R&D departments focused on reducing the total cost of ownership by achieving greater relia-bility, ease of service and energy efficiency.

More reliabilityThe Type 3598 valve for cryogenic process media is capable of handling high pressure drops and also available in large valve sizes. This makes the valves suitable for operation in up-scaled process plants with high flow rates as well as for use as Joule-Thomson valves in applications with high pressure drops and, consequently, a risk of cavitation. In larger valve sizes, there is enough space downstream for the flow to continue with-out disturbances despite cavitation and flashing. To minimise undesired vibration and imminent cavitation damage on the sealing surfaces inside the valve, the pres -sure is let down in the clamped-in cage and not at the seating surface, as is the case in valves with seat-plug design.

Ease of serviceThe cryogenic valve has a top-entry design. This design comes with a single-piece valve body including a large-diameter cryogenic extension bonnet. As a result, service and maintenance work on the trim parts can be performed without having to remove the valve from the pipeline, cold box or insu-lation. After the actuator has been disas-

sembled, there is free access to the valve seat, piston and circulation inhibitor through the cryogenic extension bonnet. The pressure balancing assembly fitted as standard guar-antees that even large control valves are easy to service and disassemble. This is because relatively little force is required to move the piston, even in large control valves and at high pressure drops. As a result, smaller ac-tuators having a lower weight can be mounted on the valves. As a positive side ef-fect, it is also possible – depending on the valve size – to fit actuators suitable for the direct attachment of positioners or limit switches. This considerably reduces the pip-ing and hosing required for installation.

Higher energy efficiencyA circulation inhibitor is installed in the lower part of the cryogenic extension bon-net, which influences the process medium’s temperature distribution across the insulat-ing section. This offers several advantages: no icing up of the packing chamber, which is located in the valve bonnet outside the cold box or insulation. And no heat energy from the outside can heat up the process medium, which has been cooled down with great effort. The interface between the cold box and the environment can additionally be insulated by attaching an optional cover plate to the valve. So, the control valves’ total energy balance is influenced by the optimised temperature conditions as well as the required air capacity. On top, the thrust needed by the actuator plays an important role, which means that the included pres -sure balancing has a positive effect as well.

Lower actuator thrustDue to the engineered design, the cost of purchasing a Type 3598 cryogenic valve is higher than a standard valve with screw-on

insulating section. This is counterbalanced by the lower cost resulting from the lower actuator thrust and smaller actuator size required. Realistically, it would be possible to use an actuator with 1000 cm² dia-phragm area on a pressure-balanced valve instead of a 2 x 2800 cm² actuator on an un-balanced valve of the same size. A compari-son of the two actuators shows a reduction of roughly 90 % concerning travel volume and weight and of around 80 % when it comes to the actual cost of the actuator.

OutlookFurther versions of the cryogenic valves with enhanced features are already in the pipeline. This includes modular additions – such as larger valve sizes and higher pres -sure ratings – as well as angle-style valve bodies. Currently, the valves are available ac-cording to Ansi standards only, but DIN ver-sions will follow.www.cpp-net.comOnline search: Samson

AUTHORS:

MARTIN KNAACKProduct Management & Technical Sales, Control Valves Solutions,Samson

TIMO MAUSProduct Management & Technical Sales,Control Valves Solutions,Samson

ANDREAS SANDERResearch & Development, Modular Systems & Severe Service Applications,Samson

The Type 3598 cryogenic valve comes with some extras integrated as standard: pressure balancing (bottom right) and circulation in-hibitor (top right)

46 cpp 01-2020

Positive displacement pump transfers viscous suppository masses

Pump and product are a perfect match

Pharmaceutical manufacturer Dr. Pfleger Arzneimittel is behind well-known OTC brands such as Bio-H-Tin, Ipalat Neuralgin and Mykosert, and also manufactures and markets numerous prescription medicines in the fields of urology, dermatology and pain-relief. What’s less known: In the mod-

ern production facility in Bamberg, the company manufactures the products of many well-known domestic and foreign pharmaceutical companies on a contract basis and in accordance with current GMP requirements. Dr. Pfleger Arzneimittel offers services from product development, manu-

facturing and packaging through to dis-tribution. In addition to tablets, film-coated tablets, capsules, ointments and creams, the company manufactures and packages suppositories. „We are one of the leading contract manufacturers in this field in Germany,“ said Martin Schaller, Technical Services Project Manager.

Suppository manufacturingThe suppositories are manufactured in a modern moulding process. A 500 l process plant is used for this purpose, in which the suppository mass, consisting of the active ingredient and a fatty base, is melted and transferred via hose bridges to the supposi-tory moulding plant. In the moulding plant, the primary packaging is formed in either plastic or aluminium foil, and the supposi-tory mass is then moulded directly into the cavities. The suppositories are then hard -ened and sealed in a 105 m long cooling tunnel before being mechanically packaged into cartons.Production capacity is approximately 20,000 suppositories per hour. As part of this process, a 14 m long ring pipe is used. „The mass is pumped directly from the preparation tank with agitator through heated hose bridges to the suppository fill-ing station,“ explains Martin Schaller. There is no need for an additional moulding vessel, intermediate tank or product funnel. Once at the filling station however, only a small amount is moulded into the cavities; the remainder is pumped back into the preparation tank to repeat the process. Given the repetitive nature of the process, it is particularly important that the tempera-

Manufacturing of suppositories requires reliable transfer of the viscous mass from the preparation tank to the moulding plant and back in a low pulsation environment. The slightest temperature or pressure fluctuation could cause the mass to harden and product quality to suffer. At Dr. Pfleger Arzneimittel in Bamberg, Germany, a Certa sine positive displacement pump is tasked with handling this critical process.

The suppositories are manufactured in a modern moulding process

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ture is kept constant at 35 to 38 °C. At just two degrees below this value, the mass would harden and settle, and the entire pro-duction process could come to a standstill. The homogeneity of the suppository mass and thus the even distribution of the active ingredient could also be affected.

Transferring without pulsation peaksA positive displacement pump is used to circulate the suppository mass in the ring pipeline. To avoid hardening, the pump must not only be sanitary and efficient enough to process the mass at a viscosity of approximately 4000 to 6000 mPas, but it must be stable and reliable. Of upmost im-portance is that the pump transfers con-stantly and without pulsation peaks. High pressure peaks in the volumetric dosing pumps at the filling station could lead to problems with the dosing accuracy. In ex-treme cases, the uniformity of the supposi-tories and thus the product quality would suffer. Another criterion: Easy pump main-tenance and cleaning. „The pump is rinsed with purified water every night and at the end of a production cycle the pump is dis-assembled and thoroughly cleaned by a ma-chine. As a result, we require the effort for disassembly and reassembly to be as low as possible,“ says Martin Schaller. Initially, a rotary lobe pump was used for the important task of recirculating the sup-pository mass during production. “Not only did the rotary lobe pump have an annoy-ingly high noise level, but over time its maintenance costs also increased,“ reports Martin Schaller. Recurring leakages led the team at Dr. Pfleger Arzneimittel to look for a

more modern alternative. They found what they were looking for at Masosine process pumps, a brand of Watson-Marlow Fluid Technology Group. The requirements for sanitary, reliable low-pulsation pumping at high viscosity, alongside easy and quick manual cleaning meant a sine pump was the optimum solution.

Gentle conveyingIn this type of positive displacement pump, a sinusoidal rotor revolves. This results in four chambers of the same size that shift as a whole – their volume remains unchanged during the process. Inside these chambers, the medium is gently conveyed from the inlet to the discharge port. The seal between the pressure side and the suction side is made by a gate located on the rotor. This simple but effective design makes sine pumps particularly suitable for use at high viscosities of up to 8,000,000 mPas. Certa sine pumps are available in various sizes with a flow rate of up to 99,000 l/h at a maximum pressure of up to 15 bar. Some Certa pump models are self-draining and self-priming. The pump can be used in asep-tic processes as it is bacteria-proof and requires no additional steam connections.

EHEDG and 3A certifiedThanks to extensive EHEDG EL Class I Asep-tic and 3A certification as well as quick and easy cleaning through CIP and SIP, the Certa sine pump sets the benchmark for hygiene among positive displacement pumps. The pump also offers advantages over other pump types such as rotary lobe pumps, when it comes to manual disassembly and

cleaning: Designed with only one rotor, one shaft and one seal, the number of parts in contact with the product is reduced to a minimum. Disassembly and cleaning are therefore much easier and quicker. In addi-tion, this design offers significantly lower energy consumption than comparable posi-tive displacement pumps. „Compared to our previous rotary lobe pump, the mechanical seal of the sine pump is much easier to access. Unlike the rotary lobe pump, manual cleaning of the mechan-ical seal can be done with minimal effort. In addition, the static flushing of the seal is much easier to carry out and the seal is also easier to control visually,“ says Martin Schaller. During comprehensive preliminary tests, the Certa sine pump proved its suitability for use in the production of suppositories at Dr. Pfleger Arzneimittel. During a period of nine months, not a single pump failure oc-curred. Furthermore, the use of the sine pump has led to a reduction in the noise level in the preparation area. Most impor -tantly: Thanks to the virtually pulsation-free pumping of the viscous mass, the dosing pumps at the filling station work precisely and the suppositories are uniform. www.cpp-net.comOnline search: Watson Marlow

The Certa sine pump delivers the viscous suppository mass reliably and with low pulsation from the preparation tank to the moulding plant and back

The sine pump is designed with only one rotor, one shaft and one seal. Pump disassembly and cleaning therefore is quick and easy.

AUTHOR:CHRISTIAN PASCHENCommercial Manager, Watson-Marlow

48 cpp 01-2020

Mobile pipe cleaning system for BASF

Nothing but air and water

Product changes are inevitably associated with significant effort and interrupted pro-duction. The requirements vary according to the plant and the products. In any case, the pipe system has to be cleaned carefully be-fore it is used for another product. If the product is water-based (e. g. aqueous sol-utions, emulsions and dispersions), the pipeline is usually rinsed with pure water. Depending on the desired level of cleanli-ness, more or less waste water has to be discharged. Another possible cleaning pro-cess involves the use of pigs. Pig gates must

allow the pig to be inserted into the pipe-line and removed again after cleaning. Changes of geometry (e. g. changes to the pipe diameter and fittings) are highly prob-lematic for this process. Pumps, valves and backflow preventers cannot be cleaned at all using pigs and have to be removed from the piping system before cleaning.

Cleaning with air and waterThe Comprex pipe cleaning system devel-oped by Hammann is based on the con-trolled injection of compressed air into a

pipeline that is partially filled with water. These compressed air impulses lead to the formation of water blocks that are acceler-ated to high velocities of up to 20 m/s. As a result, impurities, product residues and fouling material are mobilised and re-moved.Production plants in the chemical industry often contain hazardous material. For this reason, the waste water resulting from the cleaning process is also hazardous and has to be discharged into containers prior to further cost-intensive treatments. Compared

Pipe systems require cleaning at regular intervals, especially multi-purpose product pipelines. Existing processes such as the use of pigs require complex additional installations. Intensive water rinsing results in large quantities of waste water and therefore in high costs for discharge. By contrast, the Comprex process needs only a small amount of water and can be integrated into existing pipe systems easily. Finally the compressed air is used to dry the system after cleaning process.

Prototype of the mobile Comprex unit as it is used in the BASF agricultural production plant

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to conventional water rinsing, the Comprex process needs only about one tenth of the quantity of water. Moreover, Comprex units can be adjusted to individual needs.

Development and testing periodBASF’s agricultural production plant in Lud-wigshafen has high requirements as regards the cleanliness of piping systems after prod-uct changes. Special measures are in place to prevent cross contamination by product residues or microbial growth. The piping system was traditionally rinsed using large quantities of de-ionised water. BASF there-fore decided to test the Comprex process, which promised lower water consumption. The following basic conditions had to be considered:

• Numerous product changes per year

• Different product pipelines of various lengths

• Minimal construction work on existing plants

• Mobile solution for the whole factory

• Simple process workflow with intuitive handling by operators

• Cleaning using compressed air and water from existing supply networks

• Piping system to be dried after cleaning

• Lower operating costs due to less waste water and downtime

In 2017, several tests were successfully per-formed using Comprex units. Compared to water rinsing, water consumption was re-duced by between 50 and 75 % – an enor-mous potential saving due to the thermal disposal of the waste water. Following the test period, Hammann developed and con-structed a customised prototype of the Comprex system.

Adapted to the customer’s needsThe customised unit – internally named A8700 – uses electricity, water and com-pressed air from the respective BASF supply systems. The machine’s control system is based on software developed by Hammann and adapted to the customer’s needs. Clean-ing tests verified the potential for added value and enabled refinements to the requirements for the final Comprex unit. These included:

• Mobile design for different injection points

• Components and materials according to BASF’s specifications

• Special encoded couplings to prevent con-nection errors

• Vessel size suitable for 1000 l of com-pressed air

• Internal control of compressed air and water

• Specific cleaning programmes for every pipe section at the factory

• Easy touch-screen operation based on icons and visualisation of all relevant in-formation

• Automatic cleaning with documentation of each cleaning procedure, including air and water consumption

• Option of adding cleaning agentsThe development of the specific software for the agricultural production plant as well as the engineering and construction of the components according to BASF’s require-ments were completed at the beginning of 2018, so that delivery was possible in spring the same year. A few minor software adjustments were performed together with the customer following an initial period of operation in the summer. The system has

been operating reliably and successfully since the end of 2018. The operating staff were highly satisfied after the first few weeks of operation. Thanks to Comprex cleaning, the quantity of contaminated waste water was reduced by 70 % on average – an important step to-wards sustainability. The costs for disposing of waste water were significantly reduced, as were CO2 emissions resulting from the thermal treatment of waste water. A com-parison of the cleaning results with labora-tory samples showed them to be consist-ently below the threshold. Further potential was identified for optimising water con-sumption and more fine adjustments to the cleaning process are therefore planned in the near future.www.cpp-net.comOnline search: Hammann

AUTHOR:DR. TILL SCHMIDBERGERProcess Manager,BASF

AUTHOR:HANS-GERD HAMMANNManaging Partner,Hammann

Scheme of the Comprex process: The compressed air pulses lead to the formation of water blocks that remove impurities, product residues and fouling material.

The Comprex sytem is operated by touch-screen

50 cpp 01-2020

cpp LIST OF ADVERTISERS

Fette Compacting GmbH, Schwarzenbek 2 GATHER INDUSTRIE GmbH, Wülfrath 3

Hillesheim GmbH, Waghäusel 19 JUMO GmbH & Co. KG, Fulda 25

REMBE GmbH Safety + Control, Brilon 23 VEGA Grieshaber KG, Schiltach 52

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cpp 01-2020 51

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Information, inspiration and networking for professionals and industry executives

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52 cpp 01-2020

RADARULTRASONICIS THE BETTER

695,- €VEGAPULS 31

Compact 80 GHz level sensor with in-head display

www.vega.com/vegapulsAll advantages of the radar technology: