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When installing a new pharmaceutical manufacturing process, the design and implementation of hygienic fluid control systems is integral to performance. Separate procurement, delivery and commissioning suppliers can lead to a complex approach to project management. Alternatively, a specialist project partner, such as Bürkert Fluid Control Systems, can help resolve inefficiencies and provide the necessary expertise across mechanical, electrical and control automation aspects. Damien Moran, Bürkert’s Field Segment Manager for the hygienic & pharmaceutical sector, discusses the benefits of the combined project management approach.

A pharmaceutical manufacturing system project, typically managed by an engineering design consultant, often has to specify, procure, commission and support automation, valve and instrumentation component packages, as well as systems that span a variety of expertise. This ranges from automation, including control panels and pneumatic valve islands, to electrical and instrumentation, such as flow meters, sensors and electro-pneumatically actuated valves, to mechanical components, including manually operated valves. The end user might specify from an authorised supplier list, and the system integrator may suggest preferred brands. However, the design consultant has the responsibility to select fluid control components that integrate effectively, not only to ensure an optimised process but also to maximise efficiency of commissioning and reliability of operation in the field.

From fieldbus communications to certification approvals, the design consultant needs to handle the challenges associated with the integration of diverse brands for the automation, electrical and mechanical areas of a pharma project. Reasons for selecting multiple brands could range from cost to individual component preference, however this approach requires greater resources in management and coordination. Alternatively, the design consultant can work with a valve and instrumentation partner that assures effective integration of components across all areas. Such a partner can also provide project management and support from start to finish, including ongoing field support.

Fluidic design expertise

This starts with a design consultation and is potentially the area of greatest benefit to the overall effectiveness of a project as it provides the opportunity to check and optimise the system design using input from specialists in hygienic fluid control solutions. In Bürkert’s case, typical examples of providing design consultation and designing customised solutions include combining individual valves into a single, multi-port block valve solution to reduce the overall footprint, maintenance requirements and costs. System performance can be improved by minimising areas of dead volume with a manipulated drainable design alternative. In terms of automation, design advice can be provided on automation concepts such as centralised and decentralised control through to integration of digital communication protocols and the information/diagnostics which can be communicated.

Crucial to the design phase is the integration of valve and instrumentation models, into the piping and instrumentation diagram (P&ID) in order to create a full 3D model of the plant. This requires 3D CAD STEP files of all components that the designer can import into their plant model. A project partner like Bürkert will make these models available for simple and free access, downloadable from a website or provided directly. Useful input to design plans can also include a virtual fluidic simulator model that demonstrates a proof of concept. This can be used to resolve design queries and helps to qualify system performance pre-installation and create a more efficient roll out long term.

Global expertise & collaboration

Implementing the design requires careful and effective project management based on technical competence as well as commitment in support throughout, particularly to overcome the challenges presented in the real world. Bürkert’s model includes a local account manager plus the support of a dedicated pharmaceutical sector specialist, with direct access to a central Hygienic Competence team that coordinates global expertise. Many projects are international, based for example around a UK design consultant with various OEM’s and Contractors from around the world. These are supported by Bürkert’s international network of pharmaceutical project managers that enable easy communication for global projects and installations.

A key to design and project management includes ensuring that all required documentation, including certificates and approvals, is available. Due to the critical nature of approvals for the pharmaceutical sector, it’s vital that a project partner has the knowledge and experience to advise on the requirements of individual products, as well as if and how those approvals are met.

Support in commissioning – and beyond

During project installation, physical space is typically at a premium. Scheduled delivery of components staggered to match the project timeline is therefore important. While working with several individual suppliers can make this more of a challenge, a single project partner can efficiently manage this process. Deliveries need to include palletising with storage designations for specific areas of an end user’s plant, as well as customised tagging, labelling and packaging for easy identification in a potentially crowded installation environment.

While the engineering consultant tends to rely on an installer, technical support in set up may also be required, usually for electrical or automated aspects, such as a valve island or control valve commissioning. Providing this assurance alongside the handover of the project to the end user, as well as offering additional field support, is not only of practical value but also provides peace of mind.

To optimise hygienic pharmaceutical fluid control system design and implementation, the optimal approach is holistic project management, as opposed to treating the separate components as procurement commodities. This is particularly the case for systems that involve higher degrees of electrical and automation complexity. Delivering the successful integration of mechanical, electrical and automation packages is essential, and the support of a pharmaceutical specialist project partner throughout a project will ensure a more efficient process delivery as well as an optimised outcome for the end user.

An innovative digital approach that combines the simplicity and speed of a smoke probe with the quality of a 3D-measurement scan has launched in the UK.

ProCap from Swiss manufacturer streamwise, provides real-time visualisation of a 3D velocity vector and its interpolation to a complete flow field, providing instantaneous understanding of the quality of aerodynamic measurements.

Simply by guiding the probe in the flow region of interest. The probe’s instantaneous position is precisely tracked with a camera system, the measured data is interpolated and the flow field is instantaneously visualised to the user. This is essentially an intuitive scan-and-paint approach of the flow in real-time.

The ProCap system drives the user towards area of interest and naturally improves the quality of measurement, saving costly and precious measurement time in the wind tunnel.

This exciting system includes a calibrated digital multi-hole probe with markers, tracking camera and software, and a laptop with ProCap software pre-installed. Alongside the system, a service & support package is available from UK channel partner, Evolution Measurement.

Evolution Measurement will manage UK and Northern Europe customer enquiries for the ProCap product range which includes ProCap Compact and Professional.

Andrin Landolt, Partner at streamwise said, “We are incredibly excited at this new venture. The team at Evolution Measurement are wholly solution focused and our products complements their existing range of aerodynamic measurement solutions.”

Evolution Measurement’s Managing Director, Paul Crowhurst said, “We are thrilled to bring ProCap to our customers as it will add enormous value for our existing aerodynamic measurement solutions customers.

The ProCap merges data streams from position tracking and flow field measurements, reduces data, interpolates and predicts the flow field for integrated validation, essentially helping aerodynamicists to maximise their time in the wind tunnel. Combining the ProCap system with our pressure scanners and custom flow probe range, we are able to provide a fully customisable aerodynamic solution which complements our wide and world-class range of fluid dynamic instruments and systems.”

For more details on the ProCap visit: www.EvolutionMeasurement.com

Compressor Controls LLC (CCC) and Yokogawa have announced that they have concluded a commercial agreement for the sale of a jointly developed solution, CCC Inside for Yokogawa CENTUM VP, that integrates Yokogawa’s process control technology and CCC’s turbomachinery control technology. It is being released on November 30. Process control and turbomachinery control can be performed with the same system, which contributes to efficient staffing, engineering, procurement, and maintenance in plant operations.

Development Background

Until now, plants have typically relied on separate systems with different logic for the control of processes and the control of turbomachinery. While purpose-built hardware provides best performance and diagnostics for the turbomachinery, it requires the management and operation of multiple systems, resulting in additional complexity. To support diverse end user needs, CCC, the number one company in the turbomachinery control market, and Yokogawa, a leader in the process control market that has delivered process control systems for more than 30,000 projects globally, have jointly developed CCC Inside for Yokogawa CENTUM VP, which integrates process and turbomachinery control in a single system.

In preparation for the release of this product, the two companies have concluded a commercial agreement under which Yokogawa will supply the hardware and software for the CENTUM VP integrated production control system, one of Yokogawa’s core products in its OpreX Control and Safety lineup, and CCC will provide the CCC Inside for Yokogawa CENTUM VP software by leveraging its control algorithms, global engineering and technical support for turbomachinery controls. In addition, the two companies will cooperate in global marketing and maintenance.

Main Features

The CCC Inside for Yokogawa CENTUM VP software enables the CENTUM VP to execute CCC’s control logic for controlling compressors, which are the most commonly used types of turbomachinery found in plants. By equipping CENTUM VP with a dedicated compressor control interface (faceplate), both process control and compressor control can be done from the same human machine interface (HMI). And by enabling the use of the same hardware, this solution reduces spare parts inventory and maintenance costs, and allows for more efficient maintenance planning.

Major Target Markets

Oil and gas, petrochemicals, chemicals, electric power, etc.

About CCC Inside

CCC Inside was developed to deploy CCC control algorithms and expertise into DCS platforms. The control algorithms are based on the same code structure of CCC Pro Built platforms, maintaining consistency and reliability. CCC Inside is delivered with native human machine interfaces for the DCS operator station and direct integration with the alarm system. CCC Engineering Utilities further facilitate configuration and tuning, with high-resolution recording capabilities. CCC Inside is engineered and commissioned by CCC global project and field service teams.

About the CENTUM series

Yokogawa released its CENTUM distributed control system (DCS) in 1975, a world first. CENTUM VP is the ninth generation in the CENTUM series. Known for their rugged performance, CENTUM systems set high standards for engineering and technology excellence while ensuring backwards compatibility with previous system versions and support of the latest technology applications. Knowledge-driven engineering lies at the heart of CENTUM, a Yokogawa flagship product that has been proudly serving the process industry over the past 40+ years.

Powelectrics technology allows you to identify issues remotely, protecting your livestock, crops and assets, optimising maintenance, cutting costs and freeing up human resource.

Powelectrics offers over 30 years of expertise and practical experience in instrumentation and digitalisation. Please click here to see the brochure, which describes the company’s range of solutions and details real application cases.

Powelectrics IIoT solutions can be battery and solar-powered, making them ideal in remote and rural environments.

The company’s sensor expertise encompasses level, temperature, flow, pressure, vibration, humidity, CO2 and many more. Please talk to us about:

• Tank & silo level monitoring (fuel, fertiliser, feed, waste, milk) to understand usage, recognise anomalies & avoid run-outs or overfills.
• Water level monitoring & management for livestock & crop protection.
• Condition monitoring of plant & processes to perform maintenance before a breakdown occurs
• Supply chain management & Vendor Managed Inventory
• Metering & energy management to identify inefficiencies & as part of ISO 50001.
• Pumping station monitoring & control
• Monitoring gas emissions & effluent to protect people & environment & comply with industry legislation. 

Whether you need to know your chickens are warm, your cows have water, your generator has fuel, your waste needs collection or your plant needs maintenance, Powelectrics can help you!

More:  Powelectrics Remote Monitoring IIoT Kit For Agricultural Applications

Powelectrics’ well-proven, versatile MetronView cloud collects data from a vast array of sensors, machines and IIoT devices. It gets your data flowing … fast … from your first step towards digital transformation to an international estate of connected assets!

What can Powelectrics do for you?

Please browse the Powelectrics website and get in touch with any queries you have or applications you would like to discuss. Call +44 1827 310 666, email sales@powelectrics.co.uk or use this contact form.

RS Components (RS) has invested in a major expansion of its Molex interconnect product range. RS can now offer designers, installers and maintenance engineers over 1,000 additional Molex products, ranging from state-of-the-art antennas and harsh-environment industrial connectors to an enhanced range of D-subs and cable connectors.

Significant introductions include antennas for applications across a wide range of industries, including automotive, industrial connectivity, infotainment systems, smart meters, wearables and telecommunications.

Newly introduced Molex Brad industrial connectors include key products from the Micro-Change M12, Nano-Change M8 and Ultra-Lock ranges. Designed to withstand harsh industrial environments and weather conditions, Micro-Change M12 connectors provide reliable connections and allow fast, simple replacement of sensors, encoders, switches and other I/O devices in industrial machinery.

RS now offers an expanded range of Molex FCT standard, mixed-layout and high-density D-sub connectors, including hoods and cable assemblies for multiple applications. Also, available is an expanded range of Molex’s versatile Easy-On FFC and FPC connectors, with terminal pitches ranging from 0.20mm to 2.00mm for use in everything from medical to automotive applications.

Additionally, the RS range of Molex Premo-Flex cable jumper products has increased to 200 products, ranging from standard products with various pitches, cable lengths, thicknesses and formats to custom assemblies with multiple capabilities.

The extended Molex range is shipping now from RS in the EMEA region.

As the UK hosts the UN Conference on Climate Change, Titan Enterprises determines it a fitting time to report on the success of its long-term OEM customer, Green Fuels Limited.

With decarbonisation, circular economy and sustainability hitting the top of the agenda around the world, Green Fuels advances biofuel technologies and joint ventures to achieve its contribution to the global net zero target.

For over 13 years, Titan’s Oval Gear (OG) flow meters have been an intrinsic component within Green Fuels’ biodiesel plants converting bio waste into sustainable biofuels.  Green Fuels’ award-winning research and pioneering process plants have powered buildings with sustainable fuel from used cooking oil, and most recently developed a process to convert fish oil and sewage sludge to biofuel.

Jason Askey-Wood, Green Fuels’ UK Managing Director, commented: “Accuracy of measurement in our chemical processes is critical and Titan’s range of oval gear flowmeters provide just that. Simple, accurate and chemically resistant, Titan’s OG flow meters, with the addition of the Namur switch, were the ideal solution for precise batch dosing within a potentially hazardous environment.”

Titan’s OG Series flow meters are designed to give reliable, high performance across a wide range of applications. Almost immune from the effects of varying liquid viscosity, density and temperature, the measurement performance of oval gear flowmeters improves as liquid viscosity increases.

Titan offers intrinsically safe options for its Oval Gear measurement devices to ensure safe operation in potentially explosive atmospheres, such as those encountered in the chemical, biofuel and petrochemical industry. As well as being constructed from durable materials including Stainless Steel, Hastelloy and PEEK, a fully certified NAMUR Proximity Switch can be installed into the Oval Gear flow meters. The NAMUR Proximity Switch is an intrinsically safe sensor specially designed for use in hazardous locations, enabling the OG series flow meters to deliver highly accurate flow measurement in explosive atmospheres.

Jeremy Thorne, Titan Enterprises’ Operations Manager said: “Titan is privileged to play a cameo role in the technological advancements that Green Fuels is achieving within the sustainable fuels market. The OG flow measurement devices are ideal for use with aggressive chemicals, combining durable materials, robust design and proven technology to ensure they will have a long product life with reliable, accurate operation throughout.”

Jason adds: “It’s an exciting time for Green Fuels with carbon reduction and climate change at the top of the worlds’ agenda. We have seen a shift in our business in developing joint ventures with both advanced economies such as Oman and developing countries, working together to find sustainable fuel solutions for the Transport and Energy sectors as they look to decarbonise and reduce harmful emissions.”

For further information on Titan’s oval gear flowmeters please visit  https://flowmeters.co.uk/oval-gear-swept-volume-positive-displacement-flow-meters-overview/. To discuss an optimised flow measurement device for your OEM application please contact Titan Enterprises on +44 (0)1935 812790 or email sales@flowmeters.co.uk.

For information about Green Fuels visit www.greenfuels.co.uk.

Silicon Designs, Inc. today announced the global market launch of its Model 1525 Low-G Series of MEMS DC accelerometer chips, with stock quantities now available for immediate customer shipment.

The Silicon Designs Model 1525 Low-G Series is designed to offer reliable, accurate, and repeatable low-frequency (including seismic) vibration and acceleration measurements within a variety of inertial- and industrial-grade applications, and particularly so, where high-repeatability, premium performance, ultra-low noise, and maximum stability are required.

The key distinguishing features of the Model 1525 Low-G Series, among comparable industry models, include its highly favorable price-for-performance ratio, excellent in-run bias stability, zero cross-coupling by design, and Allan Variances from 5 µg. With availability in five unique full-scale ranges, each MEMS DC accelerometer chip within the Model 1525 Low-G Series incorporates one of Silicon Designs’ own high-performance sense elements, together with a ±4.0V differential analog output stage, internal temperature sensor, and integral sense amplifier. The MEMS DC sense element and internal components of the Model 1525 Low-G Series are housed together within a hermetically sealed, Nitrogen damped, 20-pin JLCC surface mount package (U.S. Export Classification ECCN 7A994) which measures just 0.35 square inches.

Each Model 1525 Low-G Series MEMS DC accelerometer chip is designed to be relatively insensitive to wide temperature changes and gradients, including over its standard operating temperature range of -40° C to +85° C. Each device is further marked on its top and bottom surfaces with a serial number for traceability. A calibration test sheet is also supplied with each unit, showing the MEMS DC accelerometer chip’s measured bias, scale factor, linearity, operating current, and frequency response performance values.

Since 1983, Silicon Designs has been recognized as industry experts in the design, development and manufacture of highly rugged MEMS DC accelerometers and chips with integrated amplification. All products are designed, developed, and manufactured in-house at the company’s own state-of-the-art facility located just outside of Seattle, Washington. In addition, as the OEM of its own MEMS DC accelerometer chips and modules, including in-house wafer production, Silicon Designs can ensure that each accelerometer within a particular series is made to be virtually identical, thereby allowing for seamless performance upgrades. The company’s fully U.S.-based manufacturing operations, including with ISO9001:2015 certified quality management systems, further allow Silicon Designs to ensure that its products remain of consistently high-quality, are easily customisable to customer exacting standards, and can be offered with some of the industry’s most competitive pricing and lead times.

 For additional information on the Model 1525 Low-G Series, or other MEMS DC accelerometer technologies offered by Silicon Designs, please visit www.silicondesigns.com.

Click here to download the Model 1525 Low-G Series product datasheet.

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Teledyne FLIR preparation course for a qualification as a category 1 certified thermographer explains the basics of infrared, how to operate an infrared camera under different conditions and for various purposes, how to appropriately judge a measurement situation in the field and how to identify potential error sources to enable participants to undertake infrared inspections following written guidelines and report the inspection results.

In this course covers:

• Introduction to thermography
• Camera operation
• Basic physics of heat
• Basics of infrared physics
• Thermal pattern recognition and infrared applications
• Infrared temperature measurement techniques
• Qualitative and quantitative thermography
• Inspection routines and reporting
• Hands-on laboratory sessions
• Examination

A complex cross-border quality inspection by leading quality management provider has involved visiting five countries and inspecting 44 cars with potential mechanical issues.

Not only this, the project was completed in just 3.5 days by two of G&P’s highly-skilled vehicle technicians using an electrical measuring device to inspect the potentially faulty component.

Thankfully, all the components passed the test. However, had the tests on the potentially faulty components not taken place then there was a risk of vehicle noise and drive failure.

The manufacturer could not take the risk of any damage to their reputation by allowing the deliveries to go ahead without the additional quality checks.

Geoff Cousins, chairman at G&P, said: “This particular project required a very tight schedule for a round trip to Belgium, Germany, Poland, Sweden and Switzerland to plan the appointments in each country so that deadlines could be met.

“Added to the mix was that the cars had already been built and were distributed in these countries ready to go to market. It needed, and had, military style precision planning.”

Even before the project started, G&P only had 24 hours to plan for the challenge which involved specialist training for the two vehicle technicians.

Geoff added: “The importance of the project was that it protected the brand reputation of the car manufacturer as it had the reassurance that all of its vehicles had passed the test and, subsequently, that no faulty vehicles were released for sale.

“It also clearly demonstrated G&P’s capabilities of being able to react quickly and efficiently to resolve potential quality issues, no matter where they are.”