chemical industry information

FMA completes another project for Coors Brewers

2007-02-28T01:27:00.003-08:00

FMA was recently involved in the process design and control requirements for the filtration, beer supply and CIP systems to Can Lines 2 and 3 for the GBP35M Merlin project at Coors Burton brewery.

FMA has a long-standing relationship with Coors Brewers - their track record spans both complete turnkey operations as well as specific control systems. Indeed, the company was only recently involved in the process design and control requirements for the filtration, beer supply and CIP systems to Can Lines 2 and 3 for the GBP35M Merlin project at Coors Burton brewery. This involved the complete re-automation of the existing two KG filters and the horizontal leaf PVPP filter, plus the addition of a second horizontal PVPP filter to create two discrete filter lines - whilst ensuring maintained production throughput for existing packaging requirements.

FMA involvement in "Merlin" also focused upon the concurrent electrical installation and control system for the new beer supplies from the BBTs to can lines 2 and 3 via the use of an existing CIP unit.

A Rockwell Controllogix solution was used to upgrade the existing PLC control system for filtration and provide control over beer supply for the can lines.

Using their considerable process knowledge, FMA was then able to provide a detailed functional specification incorporating filtration, CIP and beer supply requirements as well as operation of all new and existing process plant.

Full liaison took place with OEM equipment suppliers and thorough software simulation procedures were embarked upon.

A considerable part of the success of this complex project was down to the thorough simulation testing and operator training carried out by FMA and Coors.

New software makes gland selection simple

2007-02-28T01:27:00.001-08:00

Hazardous area equipment specialist Hawke International has introduced cable gland selection software on the latest version of their electronic catalogue.

Hazardous area equipment specialist Hawke International has introduced cable gland selection software on the latest version of their electronic catalogue. Designers can drill down, using context relevant help, to find the right gland for their needs. Operators may either specify environmental requirements and cable characteristics or use cable manufacturer's codes and product descriptions to access the data sheet for the relevant product.

"Previously, selecting the correct cable gland was a time consuming exercise - our software has changed this," explained Mike Connelly.

The software not only leads the enquirer to the right product but also shows alternative and similar products that can be considered.

"Improving gland selection achieves greater safety with a possibility of substantial cost saving in some cases," added Mike.

The CD will save time for project designers and electrical engineers.

The interactive catalogue features the complete Hawke portfolio including glands for hazardous and industrial areas complying with either European or North American standards.

Full technical sheets are called up in PDF format for previewing.

The selection software can automatically generate enquiries for printing or faxing.

Enquiries can also be saved for easy recall in the future.

There is even a simple one-button operation to export enquiry data to Microsoft Excel.

In addition to accessing data sheets and generating enquiries, users can view product certificates and obtain useful installation advice from the training videos, which are also included on the CD.

The CD is part of a programme of ongoing product development and user support.

Mike Connelly commented, "The software is a first for our industry, but we are still moving forward.

Additional cable data is being added all the time.

We will also be making these tools accessible via the web and adding multi-language capability in the near future."

Imagine your best operator always on the job!

2007-02-28T01:26:00.001-08:00

In any shift pattern, there is always a "Best Operator" at operating the plant: Startim from MTS is designed to integrate with existing plant control systems in the same way that a good operator would.

Imagine your best operator always on the job! In any shift pattern, there is always a "Best Operator" at operating the plant in normal and abnormal conditions. If only they could operate the plant 24 hours a day, 365 days a year and never retire, profits would be up and the future a little more secure. The bad news is that they can't, the good news is that Startim can.

Startim is designed to integrate with existing plant control systems in the same way that a good operator would.

However it also automates the coordination, preparation and planning best practices appropriate to current plant operating conditions and constraints to deliver a total control solution.

Startim delivers most benefit in improving plant transitions between operating conditions.

These plant transitions may be as complex as site start-up or shutdown; or for a particular processing plant, may involve grade changing, product changeover, improved recipe management or emergency shutdown or recovery.

As a manager, using a total control solution such as Startim you will know that your plant is being operated within all plant safety guidelines, with an audit trail of automated actions and manual interventions.

Experience of using Startim on a number of processing units has demonstrated the practical benefit of defining current best practice for operating procedures and automating their complete implementation.

Repeatability and reliability then become the cornerstones of delivering and improving on current best practice with all its present day financial rewards.

Additionally, a system that takes best practice and retains it as 'Corporate Memory' can significantly reduce future risk.

Rittal saves money on power distribution

2007-02-28T01:25:00.000-08:00

Rittal's new 4 pole Maxi-PLS is a fully modular partially type tested system for numerous applications such as power distribution, variable speed drives, process and the utility industries.

Rittal's new 4 pole Maxi-PLS which utilises the popular TS8 enclosure range is a fully modular partially type tested system for numerous applications such as power distribution, variable speed drives, process and the utility industries. The components are supplied ready to install, allowing fast assembly without any form of drilling, sawing or bending. When considering a conventional ACB enclosure typically taking 24-36 hours to build, 4 pole Maxi outstrips this by taking an average of just 1 day.

With options of 2000amps or 3200amps the possibilities are endless and Maxi-PLS integrates with all commercially available Air Circuit Breakers to offer maximum investment return.

With a system so simple to purchase, install and later modify Maxi-PLS not only eliminates high labour costs but also takes away the worry of having to cope with a large power distribution system.

More information can be found in the new power distribution catalogue, available from Rittal, which also contains a full range of products to accessorise Maxi-PLS solutions.

Electroless Nickel plating stops corrosion

2007-02-28T01:24:00.000-08:00

Poeton Industries Limited, a world leader in surface coating technology, has won a substantial order from its Gloucestershire neighbour Spirax Sarco thanks to investment in a new coating process.

Poeton Industries Limited, a world leader in surface coating technology, has won a substantial order from its Gloucestershire neighbour Spirax Sarco thanks to a recent 90,000 GBP investment in EDEN - a special environmental dialysis system designed to reduce waste from the coating process. Cheltenham based Spirax Sarco, a supplier of products and services worldwide for the control of steam and other industrial fluids, adheres to a strict environmental policy when selecting its supplier partners. The company placed the order with Poeton after sample coatings proved that the combination of the new Poeton semi-automated electroless nickel line and the EDEN environmental system, provided consistently high standards of corrosion protection for a range of steam traps and control and metering products.

Explains Poeton managing director Colin John: "EDEN provides continuous and very precise control of the electroless nickel solution, which means we achieve much more consistent plating rates and finer tolerances".

A spokesman for Spirax Sarco agrees: "We were impressed with the Poeton ability to deliver such a high quality, 'right first time' corrosion resistant coating, and equally impressed with the more attractive finish it provided for our cast iron components".

The steam traps are coated with Apticote 400, a nickel composite coating that combines the protection of low friction polymers with the natural hardness and corrosion resistance of nickel to provide superior wear, abrasion and chemical resistance.

To ensure on-time delivery for the Spirax Sarco monthly production schedule, Poeton also provides a weekly collection and delivery service and has the flexibility to operate its electroless-nickel lines 24-hours a day to meet any increases in demand.

To discuss surface treatments, sample part processing or technical advice call Poeton Industries now.

EDEN - Electro Dialysis for Electroless Nickel - works by continuously cleaning the process solution in the two electroless nickel plating lines.

It has reduced monthly volumes of spent process solutions by 1500 litres and virtually eliminated the generation of hazardous heavy metal waste.

Poeton believes it is the first UK surface treatment specialist to install the EDEN environmental system.

Tube clamp system suitable for many diameters

2007-02-28T01:19:00.000-08:00

The tube clamp system from Automation Supplies is a versatile approach to tube clamping, using one unit for multiple diameters of tube sizes from 20 to 50mm.

Automation Supplies is a new company offering a range of exciting new engineered products from one source, based on the popular and increasing use of established modular parts and assemblies to achieve cost effective solutions. The tube clamp system is a comprehensive range of round and square tube connection clamps and joints for making small or large frames from steel, stainless steel and aluminium. The two way connector clamp GN133 is a new addition to the range allowing a rigid 90 degree connection of two tubes which have different outside diameters.

The clamp is made from cast aluminium and is available in finishes of black plastic coated, natural aluminium, and to special order in any RAL colour.

The different combinations of tube diameters able to be used with this tube connection element are 20, 25, 30, 40, 42, 45, 48 and 50mm.

Tube clamping can be specified via the use of cap screws or adjusting handles in steel and stainless steel.

A full catalogue of the tube connection system is available for download or in print from the Automation Supplies website.

This component can also be adapted to be used with the linear adjustment system that forms part of the tube clamp system.

Invensys APV Achieves ISO 9001:2000 Certification

2007-02-23T21:24:00.003-08:00

Invensys APV is delighted to announce its certification to the prestigious ISO 9001:2000 standard for its facility based in Crawley, West Sussex.

Invensys APV is delighted to announce its certification to the prestigious ISO 9001:2000 standard for its facility based in Crawley, West Sussex. Basing the management of all business activities on the principles of the new ISO standard is helping APV improve efficiency throughout the company in order to deliver improved customer satisfaction. According to Business Improvement Manager, Paul Morley, "We are delighted to have achieved ISO 9001:2000 certification.

However, this is certainly not the end of the process.

We are committed to continually monitoring and improving our business processes, as necessary, as we continue to strive to become the world-class supplier of choice to our chosen markets".

The program is fully supported by the APV management team.

"ISO 9001:2000 provided a set of values that ideally matched our business ambition", commented Managing Director, Steve Davies.

I am very grateful for the efforts of a large number of employees, who have contributed to improvement actions over the past few months".

Significant effort has been invested in communicating the principles of ISO 9001:2000 to all employees of APV in Crawley.

This was aimed at helping them understand what is required both individually and as a group, as they work together in support of a philosophy that focuses on the need to continuously improve the quality of service to customers.

NNE has opened an office in Sweden

2007-02-23T21:24:00.001-08:00

Specialising in engineering consultancy and establishing rebuilding and optimising pharmaceutical production facilities, the company has a new Swedish subsidiary located in Huddinge south of Stockholm.

Specialising in engineering consultancy and establishing, rebuilding and optimising pharmaceutical production facilities, the company has set up a Swedish subsidiary located in Huddinge south of Stockholm. The decision to establish NNE Sweden AB was triggered by the increase in turnover in Sweden, where NNE has recorded sales running into double-digit millions (DDK). 'The new offices in Huddinge gives us an even better platform for serving existing and potential customers in Sweden,' said Kay Stendevad, managing director of NNE Sweden.

'We are both local and international players.

We aim to build an independent Swedish organisation focusing on local customers.

Coupled with our international experiences, our extensive network means we can meet all our clients' needs for consulting and engineering services.

Our skills cover a breadth and depth of disciplines'.

The NNE Swedish client base includes AstraZeneca, Pfizer/Pharmacia, Ferring, Novozymes Biopharma and Polypeptide.

The services most in demand are in the fields of automation, GMP and validation, process operations and clean room technology.

NNE Sweden AB has hired five engineers to date, all with experience from the pharmaceutical and biotech industries.

Further recruitment is underway.

The Huddinge premises will be officially inaugurated at a reception on 9 October 2003.

NNE has more than 80 years' experience as a supplier of consultancy and engineering services and process plants for the international pharmaceutical and biotechnological industries.

With a staff of more than 1,000, NNE is the largest Nordic consultancy in this segment.

NNE A/S is a wholly-owned subsidiary of the Danish pharmaceutical company Novo Nordisk A/S.

USD1.5B coal-to-chemicals design contract for AMEC

2007-02-23T21:23:00.001-08:00

AMEC has been appointed to carry out the initial engineering design for the offsite and utility facilities on a USD1.5Bn coal-to-chemical production complex in north west China.

AMEC, the international project management and services company, has been appointed by the Shenhua Ningxia Coal Group (SNCG) to carry out the initial engineering design for the offsite and utility facilities on a USD1.5 billion coal-to-chemical production complex in the Ningxia Hui Autonomous Region in north west China. AMEC has been working as the SNCG project management contractor for the overall facility since early 2006 and this latest award builds on the close and successful relationship developed with SNCG during that time. Working from their Shanghai offices, AMEC engineers will provide the basic engineering and design needed to define and integrate all the common, site-wide systems required to service the six individual process units within the facility.

These systems include power and steam distribution, water systems, flare and fire fighting, interconnecting pipework, air and gas, site-wide instrumentation, control, electrical systems, loading/unloading facilities and storage.

The new facility, which is designed to produce 540,000 tonnes of polypropylene per year and which will include a coal gasifier plant, a methanol and methanol-to-propylene unit and a polypropylene unit, is scheduled to be completed in early 2009.

Polypropylene is a chemical product usually derived from oil refining and ethylene processing but the project will use coal as the feedstock, which will come from large reserves in the Ningxia area.

'The award and successful execution of this contract will further strengthen the AMEC expertise as the leading contractor in coal based petrochemical facilities,' said Ross Gibson, president of the AMEC China operations covering Natural Resources.

'We have the skills and resources to respond to the challenge and look forward to contributing to the success of this important and prestigious project'.

FEED/PMC contract for new petrochemicals complex

2007-02-23T21:22:00.000-08:00

Foster Wheeler has been awarded a FEED/PMC contract for a new petrochemicals complex in Saudi Arabia, to produce polybutylene terephthalate at Yanbu.

Foster Wheeler Energy, part of the F-W Global Engineering and Construction Group, has been awarded a front-end engineering design (FEED) and project management consultancy (PMC) services contract by Osos Petrochemicals Company (in formation) for a planned new petrochemicals complex to produce polybutylene terephthalate at Yanbu, Kingdom of Saudi Arabia. In executing the FEED, the Foster Wheeler role will also include the basic design for the utilities and offsites of the project. The Company will provide PMC services up to engineering, procurement and construction (EPC) award and will be involved in the preparation of a project cost estimate, issuance of an invitation to bid for the EPC phase, evaluation of EPC bids and assistance with EPC award.

The new petrochemicals complex comprises four licensed technology process units plus associated utilities, offsites and common facilities.

The complex will produce 60,000 tonnes per annum of polybutylene terephthalate, a plastic used as an insulator in the electrical and electronics industries.

'We are pleased to assist Osos Petrochemicals in realizing its first petrochemicals complex, a key element of their strategic plan to build added-value petrochemical derivatives in the Kingdom,' said Steve Davies, chairman and chief executive officer, Foster Wheeler Energy.

'Foster Wheeler is playing a key role in the development of the petrochemicals sector in Saudi Arabia and is currently managing over USD20 billion of petrochemical project investments for Saudi Arabian clients'.

'Osos Petrochemicals has selected Foster Wheeler after proper evaluation and looks forward to building a relationship as we develop our petrochemicals investment in Saudi Arabia,' commented Mubarak A Al-Khater, managing director of the Osos Petrochemicals Complex.

For a sixth time FW scoops the ECITB ACTIVE Cup

2007-02-23T21:18:00.000-08:00

A team from the Foster-Wheeler UK subsidiary Foster Wheeler Energy, part of the Global Engineering and Construction Group, has won the Engineering Construction Industry Training Board ACTIVE Cup.

Foster Wheeler announce that a team from its UK subsidiary Foster Wheeler Energy, part of its Global Engineering and Construction Group, has won the Engineering Construction Industry Training Board (ECITB) ACTIVE Cup. A record field of ten teams from the UK's leading engineering and project management companies took part in this year's competition. Foster Wheeler has participated in the competition since its inception ten years ago and this is the sixth time that the company has won the award.

The popular ACTIVE (Achieving Competitiveness Through Innovation and Value Enhancement) Cup is an annual competition-based learning event in project management.

The ACTIVE initiative was launched in 1996 with the aim of improving the performance of capital projects in the process industries and encouraging the sharing of good practice.

The ACTIVE Cup uses sophisticated technology to test teams from companies within the industry on their ability to put the ACTIVE principles to work when managing a substantial project.

The annual weekend event, sponsored by the ECITB, a UK organization, is based around a dynamic and interactive computer simulation managed by Cranfield University School of Management in the UK.

Teams are set the challenge of project managing the construction, from inception to client acceptance, of an 'environmental monitoring station' located in a remote area.

'The project is executed over a 20 to 25 'week' simulated schedule, with each week lasting 15 to 20 minutes,' said Matthew Morley, leader of the winning team, and proposal manager at Foster Wheeler Energy.

'The time pressures created by the simulation required rapid and accurate progress assessment and decision-making with respect to equipment and material procurement, workforce allocation and plant hire deployment.

The competition judges assessed team performance against actual project performance, namely achieving the highest profit against a fixed-price, lump-sum contract, the ability to meet both schedule and profit forecasts at key stages throughout the project and the continuous application of the ACTIVE principles'.

'Foster Wheeler is proud of its project management and project execution expertise and proven track record in 'real life',' said Steve Davies, chairman and chief executive officer, Foster Wheeler Energy: 'It is very pleasing to see a Foster Wheeler team demonstrate these same skills and apply the same commitment and professionalism in this prestigious competition'.

'The ECITB ACTIVE Cup allows us to simulate the life-cycle of a major project within a single weekend,' commented David Edwards, chief executive, ECITB: 'This, and the competition element, puts the pressure on and intensifies the learning experience.

The teams are tested across the spectrum of project management activity, including negotiating with clients, suppliers and bankers.

In winning, the Foster Wheeler team demonstrated a thorough understanding and application of the ACTIVE principles'.

New Crane Flow of Fluids Premium software released

2007-02-14T21:42:00.004-08:00

The latest Flow of Fluids software is used by designers and operators to visualise their systems, calculate system operations, communicate the design with others and access supporting documents

The newest version of Flow of Fluids software has been released today. Flow of Fluids Premium version 2007 software simulates the operation of small piping systems, and is the companion software to the Crane Technical Paper 410. The newly released version contains significant improvements from its last release, Flow of Fluids Premium version 2005.

'If the Crane TP410 is the quintessential guide for understanding flow of fluids through pipes, valves and fittings, then Flow of Fluids Premium Software is your way of designing, simulating and visualising the whole system,' said Ray Hardee, PE and Chief Engineer at Engineered Software.

Flow of Fluids Premium calculates results for series, branching and looped systems, whether opened or closed, for up to 25 pipelines.

The programme boasts the ability to select pumps directly from more than 85 manufacturers' supplied electronic pump catalogs.

The newest features include key enhancements to new visual features such as, the option of creating piping system models as a 2-D or isometric drawing and a new Shape Editor where users can create custom shapes for pumps, tanks, components and control valves.

Other new capabilities include the ability to copy and paste between piping system models, size a flow meter or balancing orifice and insert it into the piping system in a single step, view results instantly using the new AutoCalc feature.

Users can also customize their results on the FLO-Sheet and fly-by viewer, or change the system's fluid properties in a lineup.

'When designing our software, we strive to provide users with customising opportunities so their systems can be as accurate as possible while making their jobs easier,' Hardee added: 'Flow of Fluids Premium is perfect for creating a professional looking presentation of your piping systems'.

Flow of Fluids software is used by designers and operators to gain a clear picture of their fluid piping systems.

The programme allows users to visualize their systems in a familiar format, calculate system operations, easily communicate the design with others and access supporting documents in electronic format.

Modular system for Fast-track Pharma projects

2007-02-14T21:42:00.003-08:00

"Time is of the essence" in establishing new biotech or pharma production: NNE has developed a "Modular" approach to plant construction, that has been shown to reduce overall construction timescales.

"Time is of the essence" in establishing new biotech or pharma production. Novo Nordisk Engineering (NNE) has developed a "Modular" approach to plant construction, that has been shown to reduce overall construction timescales. NNE uses multiple vendors to produce plant modules, effectively skid mounted equipment, and integrates these on site, to achieve an overall fast-track project.

Ole Abildgaard, a Batch Process Automation Specialist at NNE in Denmark will describe the success of these techniques, using contractors spread across five countries, to the Manufacturing Excellence Ireland conference on "Automation and Asset Management in the Pharmaceutical Industry", scheduled for October 22-23 in Cork, Ireland.

His presentation will give experience from completion of the NovoSeven production plant in Hillerod in Denmark, and will describe the NNE approach that meets the challenges of this approach, including the overall consolidation that integrates the modules into a validated production unit.

NNE describes this technology as "Unique Know-How", and is using the approach on several further commercial fast-track plant construction projects.

Ole Abildgaard, a Batch Process Automation Specialist with NNE A/S, is based in Denmark, and has an MS in electrical engineering plus a PhD in advanced control from the Technical University of Denmark.

He has worked for Novo Nordisk Engineering as project engineer on life science and biotech projects since 1997.

Before then he worked on process control and optimisation in the Danish steel industry.

New Sales Manager at Dust Extraction International

2007-02-14T21:42:00.001-08:00

Dust Extraction International has expanded its national sales force with the appointment of Gareth Hine as Sales Manager for the Midlands and South of England regions.

Dust Extraction International has expanded its national sales force with the appointment of Gareth Hine as Sales Manager for the Midlands and South of England regions. Gareth, 31, from Cannock in Staffordshire joins Dust Extraction from a national sales position within the industry and replaces Barry Sayers who retires from the company after 25 years service. Gareth will work from his home in Cannock and will cover a wide geographic area from Mid-Wales, Staffordshire, Nottinghamshire, Derbyshire and Lincolnshire right down to the south coast.

Around 30 per cent of the company turnover is generated from work with clients based in this part of the UK.

Gareth will work to enhance Dust Extraction International business with existing clients as well as to promote its services to new contacts.

Offering a bespoke service to meet the specific needs of each client, Dust Extraction International manufactures, supplies and manages dust control solutions for a range of businesses across many industry sectors.

Recent projects include work for Alstec Systems Technology to supply the Ho Ping Power Station in Taiwan with a complete dust control and centralised vacuum cleaning operation.

Corrosion and wear resistant coatings now viable

2007-02-14T21:41:00.001-08:00

Arc Energy Resources, a specialist in corrosion and wear resistant weld overlay cladding for the oil and gas, petrochemical and process industries, has completed a refit of all their workstations.

Arc Energy Resources, a specialist in corrosion and wear resistant weld overlay cladding for the oil and gas, petrochemical and process industries, is completing a comprehensive refit of the workstations at its Gloucestershire factory. Managing Director Alan Robinson says new state-of-the-art control systems designed to suit the very specialised company requirements, will effectively increase capacity by 25 percent whilst providing the flexibility to handle a wider variety of projects. "The new Arc Energy designed control systems have significantly improved efficiency", he says, adding that "this will help to make weld overlay cladding economically viable for many industries outside the traditional oil and gas sector".

More precise control also allows weld deposits to be laid to much finer tolerances and positioned with greater accuracy.

"The smoother finish limits the amount of alloy used and reduces the post weld machining time - which means a double saving for customers", explains Robinson.

Arc Energy is able to clad components of up to twelve tonnes, even in areas of restricted access such as bores as small as 20mm diameter.

At the other extreme, units as large as four metres in diameter can be handled.

The factory is also equipped with a 15-tonne gantry crane and work is manipulated on positioners and rolls with capacities from 1-12 tonnes.

The Arc Energy weld overlay cladding service provides heavy-duty protection against corrosion and wear for a wide range of process plant and pipeline equipment, and offers significant savings when compared to manufacturing from solid corrosion resistant or wear resistant alloys.

It is specified in many industries to increase the life of new components, and refurbish and extend the life of worn parts.

Optical analysis system shows interfacial stress

2007-02-14T21:40:00.000-08:00

Sensor Products introduces the Topaq Advanced Imaging System, providing a unique perspective of the distribution and actual magnitude of stress between any contacting or impacting surfaces

Sensor Products introduces the Topaq Advanced Imaging System. Used in conjunction with Pressurex stress indicating films, Topaq provides a unique perspective of the distribution and actual magnitude of stress between any contacting or impacting surfaces. In general, any application involving stress between two objects could benefit from Topaq capabilities.

"Measuring pressure distribution and magnitude in components, tools and machines as well as determining effective placement of strain gauges and drawing pressure in dies," said Jeffrey Stark, Senior Technical Manager, "are some of the common applications using Topaq.

Automotive components (such as gaskets), electronics packaging applications, heat sinks and PCBs lend themselves particularly well to interpretation with this unique system".

"Unlike FEA, Topaq is a post-process interpretative system that actually collects stress and force data at the interface surface," Stark commented further.

"In many instances, Topaq can be used to confirm the results of FEA analysis.

Topaq has extremely rapid response time usually requiring no more than five seconds to render an image".

Some of Topaq's features include histograms of pressure levels, enlargement and reduction, pseudo-color and 3-D viewing modes, extensive smoothing, filtering and thresholding enabling integration of total area and magnitude of force.

Surface contact area down to 3 mils as well as multiple and single regions of interest can be compared and analysed.

A line scan function allows the user to assess narrow bands of stress over unusual or intricate shapes.

Another feature called Grid-Maker applies a user designated mesh overlay to an image and quickly assimilates the statistical data for each cell into Excel format.

A bicubic interpolation algorithm allows Topaq to enlarge an image without the usual increase in graininess that normally accompanies such function.

Each image and its accompanying statistics can be saved, printed and exported for analysis in other software packages.

Parts cleaning options with tight budgets in mind

2007-02-08T21:06:00.001-08:00

With new Solvent Regulations coming into force soon, Layton Technologies has developed a range of fixed-price budget cleaning options to fit virtually every parts cleaning and degreasing application.

With new Solvent Regulations coming into force later this year, UK-based component cleaning equipment manufacturer, Layton Technologies has developed a range of fixed-price budget cleaning options to fit virtually every parts cleaning and degreasing application. Many companies using trichloroethylene and similar solvents will be looking to invest in compliant enclosed technology. Layton can offer a high capacity system that includes an hermetically sealed chamber, on-board solvent reprocessing and vacuum drying for a fixed cost of GBP40k.

This system can safely use tric, perc or a range of hydrocarbon solvents in a near-zero emissions and environmentally compliant system.

For some specialised solvent applications such as Npb, which may not be fully suited to the distillation process in fully sealed systems, Layton has developed its enclosed Bluestone solvent system which incorporates internal handling for a budget cost of GBP35k.

Where companies can move to aqueous cleaning, Layton say that they can provide objective advice on the best process to consider and offer a multi-stage clean, rinse and drying system, complete with ultrasonics and an automated integral handling system for a budget price of GBP30k.

If aqueous cleaning is required for complex parts that need high performance drying, for GBP35k Layton has a compact aqueous system that offers ultrasonic, spray and immersion cleaning with highly efficient warm air and vacuum drying.

Layton Sales Manager Chris O'Rourke explained that they had brought together this budget range of component cleaning systems in response to the need for companies to up-date their parts cleaning processes to comply with impending regulations.

'We are trying to simplify things for customers who need to find a viable and affordable replacement system before SER becomes a requirement in October.

We also offer a range of affordable purchase options including lease-purchase'.

For companies who want to out-source their component cleaning, Layton have also opened a contract cleaning service offering an efficient alternative to in-house parts cleaning.

Developing a Trike replacement strategy

2007-02-08T21:05:00.000-08:00

We all need to look forward not backwards - SED Compliance legislation is here and will apply very soon. How you respond could be critical for your company future: here Guyson review some alternatives.

There has certainly been plenty written recently about 'Solvent Emissions Directive (SED) Compliance' and rumours are rife that we are all going to be prosecuted for cleaning virtually anything, even down to our tea cups! Is it really going to be as bad as that? Of course not, but what many of the articles have failed to mention is the existence of alternatives. Everyone is keen to tell you what you can't do anymore - now Guyson would like to suggest to you a few of these alternatives.

Let's make it plain right from the start: there may have to be compromise and there certainly will be change.

However unpalatable, costly or time consuming the exercise, a line has been drawn in the sand and, with very few exceptions, from 31st October 2007 we will have to change to safer alternatives.

So why not go with it and draw as many positives out of this change as you can?

Such as safer working environments for your employees, less or no harmful emissions, cost savings through reduction of disposal costs, good PR for your company - replacing harmful solvents can be promoted as demonstrating 'best practice' manufacturing.

The solvents affected by the new EC Regulation are Trichloroethylene, Methylene Chloride, Perchloroethylene, n-Propyl Bromide and HCFC (hydrochlorofluorocarbon) solvents such as HCFC 141b.

And everyone has to have complied by the above date, the few temporary exceptions being for the precision cleaning of electrical and other components in aerospace, aeronautics and certain other military applications, for which the ban enters force on 31st December 2008.

CHANGE WORKING PRACTICE TO MINIMISE CLEANING.

There is no going back only forwards so we will start with a simple question: do your parts need to be cleaned?

Is there nothing upstream in the process that can be altered to prevent the parts from being contaminated or reduce that contamination?

Or downstream; can you reduce the number of inter-stage cleaning processes?

Either clean your products less or even clean just once, at the end of the manufacturing process?.

DO YOU HAVE TO USE SOLVENTS TO CLEAN?.

Have you looked at every alternative?

To start with, do your parts actually need to be cleaned with solvents?

If so, there are now SED-compliant cost-effective solvent processes, which we will come to later.

But the answer in some cases is no; you may have simply always done it that way or you may prefer the perceived quality of cleaning - but without actually needing to use solvents.

It is often the case that companies who have a 'trike' tank get into the habit of putting everything through it.

Let's look at the options.

AQUEOUS SPRAY WASH.

There are many safe aqueous alternatives that are perfectly suitable for cleaning a wide range of components.

So why not ring a reputable equipment supplier like Guyson, book some components in for free cleaning trials and take it from there?

You will then know for certain what cleanliness standard can be achieved, and it may surprise you.

The detergent and equipment manufacturers have been working together for many years to produce today's excellent ranges of cleaning products.

Through these cleaning trials, you will hopefully identify that there is at least one alternative technology you can adopt and pursue this further with specific equipment trials to ascertain what type of spray washer you need.

Below, the Allkajet is just one type of aqueous cleaning machine supplied by Guyson.

Model selection will only come about with a full audit of your cleaning requirements, cleanliness specification, throughput volume, total running costs, factory space, budget etc.

Allkajet.

The Guyson Allkajet 600 Rotary Washer delivers high quality cleaning and drying for a wide range of components and is typically used to great effect in batch manufacturing applications in the automotive, aerospace, and medical and defence sectors.

The washing process combines periods of both partial and total submersion with high volume spraying of special low temperature water based solution - pumped at a rate of up to 350 litres per minute at 15 bar pressure - through 14 high-pressure spray jets.

The deluge and turbulence produced completely saturates all component surfaces and penetrates deeply into all awkward recesses and areas normally difficult to reach.

The submerged phase of the operation provides the opportunity to use optional ultrasonic agitation when it is needed to achieve the highest cleaning standards.

At the end of the wash cycle, the cleaning chamber is emptied and flushed out to remove all traces of wash solution.

Rinsing is a repeat of the wash process using a heated rinse solution drawn from its own separate 450-litre tank.

Cycle time is usually shorter for the rinse.

After draining, heated air and blown compressed air are used to dry the components before the component holding baskets are manually removed from the chamber using the integral loading and unloading carriage.

This assists handling outside the machine via the flat folding door, en route to a roller conveyor.

The three-stage cleaning sequence of the Allkajet is PLC controlled and provides wash, rinse and dry options in any combination.

To agitate the components there is a choice between a left and right tilting movement or a continuously revolving tumble-basket at speeds between 0.7 and 1.5 rpm.

Where cleaning volumes are greater, multi module systems are available and a larger model, Allkajet 1200, can accommodate baskets up to 1200mm long in loads of up to 150kg.

Of course aqueous cleaning is not the answer for every component.

Some, such as electronics, PCBs, precision optics, medical and aerospace components may need engineered fluids to provide the high level of cleanliness associated with solvent cleaning.

SOLVENT CLEANING USING HFC OR 3M NOVEC HFE.

Not to be confused with HCFCs (general use of which was banned from 2002), HFC (hydrofluorocarbon) and 3M Novec HFE (hydrofluoroether) do not contain chlorine and do not deplete the ozone layer.

Microsolve ultrasonic cleaning systems.

The Guyson Kerry Microsolve ultrasonic cleaning systems attain the highest cleaning standards yet, crucially, keep running costs low.

Solvent retention features unique to the latest Microsolve machines, including triple coil reflux cooling, vapour break, 150% freeboard, auto top-up and solvent monitoring, ensure the systems are safe and comply fully with environmental and safety legislation.

And as so little solvent is lost, the equipment is extremely cost-effective in use.

Guyson Kerry Microsolve Co-Solvent systems generally provide two cleaning stages, both with ultrasonics and filtration, followed by vapour rinsing and freeboard dry.

In the first cleaning tank a mixture of 3M Novec HFE (Hydrofluoroether) and a hydrocarbon solvating agent, agitated by ultrasonics and the boiling action, removes gross contamination from the components.

Large quantities of soluble contamination can be taken up by the solvating agent, and this makes the process particularly suitable for heavy duty cleaning applications - heavy weight oils, greases, waxes, fluxes etc.

In the second stage, pure HFE distillate, also ultrasonically assisted, removes from the components any residues carried over from the primary cleaning tank.

Cleaning is followed by a rinse in the vapour zone above the tanks and then a dwell in the freeboard zone to dry the components.

Autotrans work transfer systems ensure consistent, repeatable quality whilst increasing throughput, and also contribute to cost reductions by controlling the speed of basket movement through the vapour zone, thus reducing solvent drag-out caused by disturbance of the vapour blanket.

All Autotrans transporters can integrate with feed and exit conveyors or load and unload tables for fully automatic operation.

An optional Primewave generator allows selection of 38, 70, 128 or 194 kHz in both ultrasonic stages, the higher frequency being preferred for certain sensitive component such as electronic components, optical lenses and computer disk drive components to provide effective submicron particle removal.

ULTRASONICS.

Guyson International manufactures a broad range of Kerry branded ultrasonic baths and tanks that cover applications from laboratory bench top to large industrial multi-tank installations.

KS and UCR ultrasonic cleaning tanks.

Typical applications for this range of tanks include production cleaning of machined, extruded, pressed and stamped parts, refurbishment of office equipment, aerospace and automotive engine and gearbox components and maintenance of mould tools, dies, printing components, electronics assembly system parts, food processing machines.

High-end quality cleaning includes printed circuit boards, surgical instruments, and laboratory, medical and dental applications.

These latest KS and UCR (ultrasonic clean and rinse) systems have been designed to achieve optimum cleaning results.

Ultrasonic transducers bonded to the tank base provide high performance and reliability together with uniform distribution of the ultrasonic energy.

The frequency is tuned to the individual tank/transducer combination and then optimised under normal usage conditions with frequency sweep and fully automatic tuning.

Pulsatron KS and UCR tanks allow the user to pre-set exact cleaning times and temperatures, ensuring consistent levels of cleanliness from batch to batch and providing an affordable way to improve cleaning quality.

All functions are controlled by a simple four-button membrane keypad.

An LCD panel displays the temperature and time set by the user, the time elapsed since the start of the cleaning process, and the status of the power supply, heater and ultrasonics.

Each unit works within operating temperatures from 20 to 80 degrees Centigrade which can be set in 1-degree increments, allowing the optimum temperature to be selected for a particular combination of component material, cleaning solution and contaminant.

Sonics time may be set in the range 0.1 up to 99.9 minutes in 0.1 min increments, or to constant when sonics may be switched on and off manually.

Automatic safety devices include non-operation of sonics if solution temperature is more than 10 degrees Centigrade above set temperature, and low-level protection to prevent heater burn-out if solution level drops.

IN CONCLUSION.

We all need to look forward not backwards - the legislation is here and will apply very soon.

How you respond could be critical for your company future.

Guyson has a range of solutions to suit your budgetary and production needs.

As a starting point, apply now for your jargon busting four page PDF leaflet on 'Achieving Compliance with the Solvent Emissions Directive' produced in conjunction with 3M.

New Director for customer equipment modernisation

2007-02-08T21:04:00.002-08:00

Increased business volumes and surging demand have led Wheelabrator Group to create a new senior role in its specialist after-market team.

Increased business volumes have led Wheelabrator Group to create a new senior role in its specialist after-market team. The world market leader in manufacturing and supplying surface preparation and finishing machinery has appointed Lawson Pryke director, equipment modernisation programmes (EMP) within its Wheelabrator Plus service. Mr Pryke has been with the group for over 30 years and served as technical director for the last seven years: so was selected as the ideal candidate for this position.

Wheelabrator Group EMP activities have grown considerably over the last few years as customers continue to recognise the benefits of incorporating the latest technology into their exisiting equipment via EMP rather than spending on new: therefore they have gained considerable savings in time and money.

The EMP team begin the programme by inspecting customers' current equipment and assessing present and future needs before making the appropriate recommendations.

In his new role, Mr Pryke will lead the entire EMP initiative.

Mr Pryke said: 'Our group experience and technology is considerable, the EMP campaign has been hugely successful and become an increasingly important part of our business, which has led to this full time position.

I'm delighted to have been asked to take on this challenge and am very much looking forward to further developing our EMP opportunities'.

The EMPs are part of the wider Wheelabrator Plus offering, which comprises an extensive range of equipment support services.

These include training, maintenance, service and parts, consumables, polyurethane fixtures and masking, plus media supplies for blasting, vibratory equipment and washing.

Staffordshire-born Mr Pryke joined Wheelabrator Group in 1974, after attending North Cheshire Engineering College (now South Trafford College) in 1969, where he gained the full technical certificate of the Mechanical Institute of Technical Engineers.

He went on to hold technical and commercial posts, allied to project engineering and management, which included research and development responsibilities.

He also became an active member of the European Committee for CE Standards on Blast Equipment.

As technical director, Mr Pryke was responsible for the UK (Tilghman Wheelabrator) wheel and special airblast machine design.

He oversaw the development of UK-based EMP services and more recently focused on domestic wheelblast equipment sales, as part of the European heavy duty equipment specialist team.

Welcoming Mr Pryke to his new role, Clifford Parr, Wheelabrator Plus managing director in Europe, to whom he will report, said: 'Anyone who knows Lawson will be familiar with his wealth of knowledge about, and passion for, our technology.

They will also realise he is completely dedicated to our business.

Lobo Systems safe and secure platform product

2007-02-08T21:04:00.001-08:00

Miller Brewing do not have to rely on outsourced scaffolding companies, their own maintenance personnel can assemble the Lobo System, quickly producing a safe working environment.

The Problem: Scaffolding services to the Miller brewery are provided by an outsource company which costs the plant management around USD10k + per year. The managers at Miller realize that these costs have to be reduced to ensure the overall plant efficiency. Safety cannot be compromised at any price.

The Solution: the Lobo Systems safe and secure platform product.

The unique and patented clamp allows the system to be quickly assembled without the use of tools into any size or shape.

Maintenance engineers can assemble, perform the task and dismantle the Lobo System before traditional scaffolding can be erected.

Miller have opted to spend approximately USD6500 from their maintenance budget and now own their own Lobo System.

The Benefits: Miller Brewery managers expect to save significant costs by using the innovative Lobo product.

This is because they do not have to rely on outsourced scaffolding companies, since their own maintenance personnel can assemble the Lobo System.

The unique versatility of the Lobo System brings labour cost reduction, enhanced efficiency and performance.

The Lobo System creates a safe working environment, which increases productivity and maximizes the return on investment.

Wheelabrator spares and repair service blasts out

2007-02-08T21:03:00.001-08:00

Wheelabrator Group, world-leading designer and manufacturer of surface preparation equipment, has launched a blast cleaning supplies, spares and replacement parts supply service.

Wheelabrator Group, world-leading designer and manufacturer of surface preparation equipment, has launched a blast cleaning supplies, spares and replacement parts supply service. Details of this comprehensive, rapid reaction service are contained in the new open blast cleaning systems and replacement parts brochure, which covers the needs of factory based and onsite blast cleaning users, offering a wide range of parts, protective clothing and blast media. The service is supported by the Wheelabrator in-house technical team, which can provide advice and training, on areas such as media selection, correct parts usage and operator safety clothing.

Peter Longstaff, UK national sales manager at Wheelabrator, said: 'This service has been conceived in response to customer demand.

Businesses using open blast technology need quick and convenient access to an extensive range of support materials, to help maintain the performance and productivity of their equipment.

We have more than 100 years shot blasting experience, gained across a wide variety of sectors, in more than 20 countries worldwide.

This makes us ideally positioned to provide advice, and we can help engineers keep abreast of the latest technology available to them'.

The new service can provide equipment ranging from metering valves, nozzles, hoses and helmets, right up to complete blast rooms with automatic recovery systems.

There is also a range of multi-fit valves and guns designed for use in Wheelabrator Group machinery, as well as in other manufacturers' equipment.

Wheelabrator Group owns, designs, manufactures and provides wheelblast, airblast and vibratory mass finishing equipment for surface preparation and cleaning, and serves a variety of sectors, including the aerospace and automotive industries.

For product enquiries or to arrange a visit to the Wheelabrator Group Surface Technology Centre, please contact: Brian Rodgers, sales manager, Wheelabrator Group.

New silos supplied for polypropylene storage

2007-01-30T21:31:00.003-08:00

Braby, the UK's leading manufacturer of aluminium and stainless steel silos and storage tanks, have supplied a silo system for polypropylene, with load-cell contents weighing, to Craemer in Telford.

Bristol-based Braby, the UK's leading manufacturer of aluminium and stainless steel silos and storage tanks, have successfully completed a contract to supply the Craemer Group of Germany with a silo system for the storage of polypropylene. The Craemer Group recently announced that it was to start manufacturing injection moulded waste bins at its brand new factory in Telford this autumn. The company, which produces the Kliko range of two-wheeled and four-wheeled bins, called on Braby to install four new silos which have also been equipped with a specially designed load cell system for accurate weighing.

Dr Paul Corscadden of Craemer commented, 'This is the first time that we have used load cell technology in our factories and we are extremely impressed with the results.

The technology provides us with accurate figures that we feel we can rely on.

Braby supplied Craemer with four new 4.5 x 22m silos for storing polypropylene.

The silos all feature the Braby new style plastic skirt doors which are ABS moulded and 100 per cent weather-proof.

The doors also have twin hinges and twin locks making them much less susceptible to damage or being stolen than the more traditional metallic doors.

Paul Mayer, Sales and Marketing Director at Braby said, 'The move into injection moulding at its Telford facility is a significant development for the Craemer Group.

We were delighted to be awarded the contract and be able to use our expertise to assist the company expansion'.

Refinery and petrochemicals complex FEED in India

2007-01-30T21:31:00.001-08:00

Indian Oil Corporation (IOCL) has awarded Foster Wheeler services contracts for the Paradip Refinery Project, expected to be one of the largest integrated refinery petrochemicals complexes in India.

Foster Wheeler Energy and Foster Wheeler India have been awarded services contracts by the Indian Oil Corporation (IOCL) for the Paradip Refinery Project, which is expected to be one of the largest integrated refinery petrochemicals complexes in India. This world-scale facility, comprising a new export refinery and petrochemicals complex, will be built in Orissa State.The Foster Wheeler scope includes the front-end engineering design (FEED), preparation of cost estimates and the overall project strategy, and supervision of early works on site up to financial investment decision for the refinery, which is expected in mid-2008. The planned new refinery, with a crude processing capacity of 15 million tonnes per annum (TPA), will include a fluidised catalytic cracking unit, an aromatics complex and a polypropylene unit.

The new complex will ultimately produce 700,000 TPA of polypropylene, 1.2 million TPA of paraxylene, 600,000 TPA of styrene monomer, along with 10.5 million TPA of refined petroleum products.

This award also includes a detailed feasibility study for Phase 2 of the development, the Paradip Naphtha Cracker Project.

'Foster Wheeler is very pleased to be awarded this strategically important project,' said Steve Davies, chairman and chief executive officer, Foster Wheeler Energy: 'This award reflects our in-depth expertise in refining and petrochemicals and in the successful integration of refining and petrochemicals production.

We have been active in the Indian market for over seventy years and it remains a very important market for Foster Wheeler.

We look forward to working with IOCL to deliver a high quality FEED which meets or exceeds our client's expectations'.

EPC Contract for Refinery Project in Malaysia

2007-01-25T03:49:00.002-08:00

Foster Wheeler has been awarded the basic design engineering package (BDEP) and the EPC contract for a debottlenecking/revamp project at the MRC PSR-2 Melaka Refinery in Malaysia.

Foster Wheeler has been awarded a contract by Malaysian Refining Company (MRC), a joint venture between Petronas and ConocoPhillips, for the basic design engineering package (BDEP) and the engineering, procurement and construction management (EPC) for a debottlenecking/revamp project at the MRC PSR-2 Melaka Refinery in Malaysia. 'This award reflects our in-depth technical expertise in refining, our revamp experience, and our reputation as one of the leading EPC contractors in the industry,' said Aziz Ali, director, Foster Wheeler E+C (Malaysia): 'In addition, we have an extensive knowledge of this refinery, having been the MRC front-end engineering design contractor and project management consultant for the original PSR-2 facility, which was completed in 1999. We look forward to building upon our close working relationship with MRC and are committed to delivering a successful project which fully satisfies our client's business objectives'.

The debottlenecking and revamp project is expected to permit MRC to increase the overall refinery throughput from 130,000 to 175,000 barrels per day.

This project includes the revamp of the hydrocracker unit, significant modifications to the internals of the vacuum distillation and crude distillation units, the installation of additional heat exchangers, and modifications to other process units and associated offsites and utilities.

Arc Energy is able to weld clad the elbows

2007-01-25T03:49:00.001-08:00

A contract at one of the UK's leading fabricators involved weld overlay cladding four very large elbows: cladding specialist Arc Energy Resources was one of only a few UK companies able to handle this.

Part of a contract awarded to one of the UK's leading fabricators, involved cladding four very large elbows. Weld overlay cladding specialist Arc Energy Resources was one of only a few companies able to handle the project. Salford-based Langfields is one of the UK's leading fabricators of components in nickel alloy, titanium and reactive metals.

Its welding teams, which are qualified to international standards, specialise in the production of pressure vessels, heat exchangers, pipelines and other equipment that is required to resist corrosion and/or elevated temperatures.

Customers include blue-chip companies in the chemical, pharmaceutical, offshore, marine, defence and nuclear industries.

When Langfields won a major contract from the Shell Stanlow Refinery, part of the project required overlaying four 36'' carbon steel elbows with stainless steel'.

As the company's senior welding engineer Wayne Griffiths explains, 'Finding a weld overlay cladding specialist that could meet the specification and delivery time wasn't easy.

The technical skills and knowledge of welding procedures required were so demanding that not many companies can, or even want to, handle this type of work.

Fortunately I had dealt previously with Arc Energy Resources and remembered that they had a lot of experience in the oil and gas industry, so we were able to ship the elbows to their factory in Gloucestershire for weld overlay cladding'.

Commenting for Arc Energy, sales director Alan Brown says: 'Elbows are always difficult to handle but to accommodate the unusually large diameters for this project we also needed to design and build two special jigs'.

To meet the tight delivery schedule both workstations operated 24 hours a day for the duration of the contract.

'In addition, Arc Energy was responsible for proving the quality of its cladding prior to delivery, by 100% non-destructive testing'.

Summing up for Langfields, Wayne Griffiths added: 'Arc Energy made an important contribution to the contract, meeting our quality and delivery expectations on a very difficult project'.

Arc Energy is able to weld clad the elbows

2007-01-21T21:51:00.001-08:00

New methanol project licensed

2007-01-21T21:50:00.001-08:00

A new methanol project at Qinghai Zhonghao Natural Gas Chemical Co will use Johnson Matthey Catalysts and Davy Process Technology to supply methanol technology, basic engineering design and catalysts.

Johnson Matthey Catalysts (JM) and Davy Process Technology (DPT) are pleased to announce they have entered into contracts for a methanol technology licence, basic engineering design and catalysts with Qinghai Zhonghao Natural Gas Chemical Co, for their new methanol project. The project will use JM/DPT advanced steam reforming technology, methanol synthesis technology and catalysts for the production of 2000 tons per day of methanol from natural gas. The methanol plant will be built at a new production facility at Geermu City in Qinghai Province, China.

The basic engineering of the plant is currently being performed by DPT and the detailed engineering of the plant will be performed by Chengda Engineering Corporation of China.

The methanol technology has been chosen from an extensive portfolio of syngas and methanol synthesis processes developed and marketed by JM and DPT for use in gas and coal to chemicals plants.

As a supplier of both precious and base metal catalysts, Johnson Matthey Catalysts offers products for a diverse range of industries: from fuel cells and environmental catalysts to petrochemicals, edible oils and specialist oil and gas purification.

In addition JM also supplies a full range of catalysts for synthesis gas (syngas) and methanol and is able to custom manufacture Fischer Tropsch catalysts.

Stabilising plinth addresses health and safety

2007-01-13T21:19:00.000-08:00

Rittal have addressed an important health and safety issue with the launch of a new accessory for server enclosures.

Rittal have addressed an important health and safety issue with the launch of a new accessory for server enclosures. The pull-out stabiliser plinth is quickly and easily retrofitted to the base of TS8 and flexRack server enclosures and only extended when servers or other heavy equipment is withdrawn for access. When not in use, the unit is fully retractable to avoid a tripping hazard.

It is absolutely crucial to use such stabilisers when withdrawing heavy equipment on slide rails to prevent the enclosure tipping forward and endangering the operators safety.

The stabilising plinth can support up to a maximum of 150kg.

Conservation and preservation on a concrete bridge

2007-01-13T21:18:00.000-08:00

A multi-faceted concrete reinstatement system, able to satisfy structural protection demands as well as local environmental requirements, has been employed on the Dolwen Bridge over the River Severn.

A multi-faceted concrete reinstatement system, able to satisfy structural protection demands as well as local environmental requirements, has been employed to reinstate and repair deteriorated concrete on the Dolwen Bridge, which traverses the River Severn in Wales. At certain times of the year this particular section of the Severn experiences significantly fluctuating water levels and is prone to severe flash flooding with water levels often reaching as high as the bridge arches. This unique circumstance, plus the fact that the soffits of the structure were suffering from low cover over the steel reinforcement, meant that over time the concrete had simply worn away.

As if to exacerbate the problem, the river is also a waterway for migrating salmon and because of this the adoption of an environmentally sensitive repair system was essential.

Powys County Council therefore considered it important that the reinstatement system comprised of materials that would provide the necessary long-term protection to the concrete, whilst at the same time being sympathetic to the river's environmental requirements.

The full concrete repair and reinstatement system, from Tamworth based Instarmac Group, provided the answer.

In addition to providing a finish comparable to additional concrete cover, the system's water based 'Cemcoat ACE' - an elastomeric, anti-carbonation coating, was specified entirely because of its environmentally-sympathetic properties, thus minimising the risk to the waterway's marine life and protected Salmon population.

Specialist repair contractor Concrete Repairs (CRL) carried out the project and found Instarmac materials both easy to mix and apply.

After breaking out the damaged concrete, the cleaned reinforcement was primed with Instarmac zinc rich 'Cemprime ZN' and the surrounding prepared concrete surface primed with a 'Cemprime SP' slurry, before localised patch repairs were completed with 'Cembuild GPR'.

This polymer modified, shrinkage compensated, high build cementitious mortar is specifically formulated for applications of up to 50mm on vertical surfaces and up to 20mm on soffit areas.

The soffits on the Dolwen Bridge received 50mm, applied in several passes.

The mortar gains strength very quickly, provides low permeability to water and long-term durability.

Larger repair sections were reinstated with 'Cemflow MC' - winner of the recent 'Smart Award for Innovation'.

The material's hydration control system significantly reduces the possibility of shrinkage cracks in its plastic and hardened state.

The micro concrete complies with the DoT BD27/86 - materials for repair of concrete highway structures, conforms to clause 1704.6 control of alkali silica reaction, is compatible with cathodic protection techniques and will not segregate or bleed.

After curing with 'Cemcure AR', the application of Instarmac 'Cembuild FC' created a fair-faced surface ready to accept 'Cemcoat ACE', the water based, weather-resisting elastomeric anti-carbonation coating.

Forged vessels designed for strength and longevity

2007-01-12T21:18:00.001-08:00

EPSI (Engineered Pressure Systems), a world leader in custom-engineered high-pressure solutions, offers its Monobloc-Forged Vessel for both strength and longevity.

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EPSI (Engineered Pressure Systems), a world leader in custom-engineered high-pressure solutions, offers its Monobloc-Forged Vessel (forged from a single ingot). This EPSI Forged Vessel features a simple elegant design, based on years of experience, which can be inspected on all surfaces (inside, outside and ends), to establish that no cracks are developing anywhere. Many other vessels have not only exceeded their "service life" but also their "theoretical life", and are still in service, some after more than one million cycles of operation.

The ability to inspect all areas of a vessel, during and after its predicted life, assures that the vessel is not putting life and limb at risk.

It is well known that a vessel containing high-pressure gas is a potential hazard.

Gas is compressible and the vessel may explode like a bomb releasing the energy that was stored in the compressed gas.

What is not so well appreciated, is that a vessel containing high-pressure water also contains considerable stored energy.

A vessel with an inside diameter of 20 inches and a void length of 80 inches operating at 30,000 psi will contain water that has been compressed by about 7%, and which contains the same energy as 1.5 lbs of TNT explosive.

Clearly then, any high-pressure vessel must be designed and operated in such a manner that the vessel does not fail catastrophically and release this energy.

The design of EPSI high-pressure vessels has two major aspects: Design for strength - In the simplest terms this is the ability of the vessel to contain the presence of the pressure, without failing.

It turns out that this is a relatively easy task, controlled by well-established calculation procedures.

In any event, the correctness of this part of the design is confirmed when the vessel is pressure tested at the end of manufacturing.

Design for longevity - This is the ability of the vessel to continue operating under repeated cyclical loading conditions without failing.

This is a difficult design problem, which comes down to predicting the fatigue behaviour of the material.

Because of the inherent statistical nature of fatigue data, and the fact that the environment of the vessel may change (corrosion, scratches, temperature etc) large "Safety Factors" are applied to the fatigue life predictions (typically 20 on the number of cycles) for use in service, and regular inspection is essential to confirm that the vessel is behaving as expected.

New chemically resistant power transmission chain

2007-01-12T21:17:00.001-08:00

SSS Super Stainless Steel chain is suitable for use in the most demanding applications, exhibiting resistance to water, acids, alkalis, chemicals, high humidity and extremes of temperature.

SSS Super Stainless Steel chain from UK power transmission manufacturer Cross+Morse, is suitable for use in the most demanding applications, exhibiting resistance to water, acids, alkalis, chemicals, high humidity and extremes of temperature. Stainless Steel transmission chain is especially suitable for operation in application encountering harsh media, where corrosion occurs, with the resultant weakening of the chain and rapid wear. Specifically, within food and pharmaceutical processing, regimes for the maintenance of hygiene frequently involve wash-down utilising very harsh chemicals, potentially destructive to ordinary chain.

Cross+Morse SSS chain completely overcomes corrosion and wear problems remaining impervious from attack by even the most severe chemicals and offering life-time high performance.

The new chain series, a joint venture by Sugiyama, Japan, and Cross+Morse, UK, offers exceptional performance, with load bearing capability to 14.7 Mpa and, due to advanced techniques in surface treatment, higher corrosion resistance than other chain of its type.

(test results available) SSS chain, conforming to BS228, 150 606 and ASME29 standards, is available in both simplex and duplex formats, in a wide range of sizes and with Cross+Morse standard or customised attachments, to suit specific applications.

Optional protective coatings available include Nickel-coated and Aqua-proof.

The new brochure on the SSS stainless steel chain includes test results, and is available from Cross+Morse.

Coated Magnesium passes 2000 hour corrosion test

2007-01-11T21:17:00.000-08:00

A sample of magnesium coated with Apticote Keronite 3250 SG, a new Apticote composite, has completed a 2000-hour salt spray test with virtually no signs of corrosion.

A sample of magnesium coated with Apticote Keronite 3250 SG, a new Apticote composite, has completed a 2000-hour salt spray test with virtually no signs of corrosion. Put into context, the performance of the specialised coating from surface coating specialist Poeton Industries, compares with 150 hours resistance for uncoated magnesium. The result means that magnesium, which is chemically very reactive and therefore highly corrosive, can now be used in the most demanding environments.

The coating process uses electrolytic oxidisation to transform the surface of magnesium into a hard, dense ceramic oxide that is twice as wear resistant and seven times as scratch resistant as anodised surfaces, and is capable of protecting even the most complex shapes without cracking or chipping.

On a standard AZ9ID alloy it can also have hardness of 400-600 HV.

Besides its obvious applications on magnesium, these properties make Magnesium coated with Apticote Keronite 3250 SG an ideal substitute for steel, cast iron, sintered ceramic, even plastic.

Recent applications have included automotive components (cam covers, gearbox housings, roof rails, etc), consumer electronics (computers, cameras, mobile phones), erosion-resistant surfaces for textile machinery, frames for mountain bikes, fashion glasses and a wide range of engineering components.

Monitor ensures welds are clean

2007-01-11T21:15:00.000-08:00

Orbimatic have introduced the ORB1000 Oxygen Analyser into their range of equipment, for monitoring oxygen levels in welding purge gases.

Orbimatic have introduced the ORB1000 Oxygen Analyser into their range of equipment. The ORB1000 is supplied in a robust ABS case, which houses the main unit and all accessories. The unit interfaces directly into the Orbimat C range of orbital welding power supplies with no additional interfacing required.

This can be used to ensure the internal purge of a tube is pure before welding can commence.

The ORB1000 uses a long life heated zirconium sensor which a life expectancy of at least five years.

The easy to use menu driven software makes operation of this unit a welder's dream.

An audible alarm is also included to alert the welder should the oxygen level of the internal purge rise during the welding cycle.

The unit will measure down to 1ppm and is calibrated down to 10ppm and starts measuring at around 0.1%.

The sensor reacts instantly to change in oxygen level and displays shows changing level instantaneously.

As well as being used with the Orbimat C orbital welding power supplies the unit can be used as a stand-alone unit for connection to welding systems or enclosures.

Tanker offloading facility successfully installed

2007-01-10T21:16:00.000-08:00

Forbes have recently installed a 36% concentration Hydrochloric acid tanker offloading and storage facility for Acrow Galvanising, a major galvanising company in Essex.

With ever increasing public concern and more rigorous legislation, the need to contain potentially dangerous and noxious fumes produced during chemical storage is becoming more and more important. When storing chemicals such as Hydrochloric acid the normal method of scrubbing outlet fumes is to use a caustic solution to efficiently remove the acid fumes. This can however cause further problems in that it produces a chemical waste stream which must then be disposed of safely.

Forbes have recently installed a 36% concentration Hydrochloric acid tanker offloading and storage facility for Acrow Galvanising, a major galvanising company in Essex.

A Minibulk bunded storage tank with a capacity of 25 tonnes, an offloading TUF pump and scrubber system were part of the package.

The tank is vented through a compact scrubber system which has been designed to use water as the scrubbing liquor.

This environmentally friendly approach means that the system produces no waste stream.

The scrubber produces an acid solution which is utilised in the customer's process.

The scrubber design means that all fumes produced even during tank filling is captured and reduced to a safe level.

With access to the unit being difficult due to restricted space, part of the design criteria for the system was to reduce the need for frequent operator input to the system.

This innovative design is controlled via a control panel to give automatic packing wetting during static storage and an overflow vapour seal pot which is automatically refreshed to prevent fuming.

The waste acidic scrubbing liquor is pumped over into the process just prior to it giving off acidic vapour.

Big contract for odour control project

2007-01-10T21:15:00.000-08:00

Forbes has recently been awarded a major subcontract for the mechanical design, manufacture and installation of odour control scrubbers and chemical storage tanks.

Forbes has recently been awarded the major subcontract by Birse and Alderley Birse Alliance Limited for the mechanical design, manufacture and installation of the odour control scrubbers and chemical storage tanks for the massive odour control project for United Utilities (North West Water) at their Davy Hulme Waste Treatment Plant close to Manchester. The initial phase includes six large scrubbing columns fabricated in thermoplastic/GRP. With three at 4.7 metres diameter and three at 2.7 metres with heights p to 13 metres Forbes are able to manufacture these items alongside each other in their specialised fabrication facilities in Kelso in the Scottish Borders.

Coupled with these scrubbing columns are 8 thermoplastic/GRP tanks with capacities up to 95,000 litres.

These are designed for a range of chemicals including sodium hypochlorite, caustic soda and sulphuric acid.

The overall contract is classed as "fast track" with some of the equipment due on site only 14 weeks after receipt of the official contract.

Melvyn Jupp, Director of Forbes, states "It is thanks to a dedicated team that we are able to turn round this project so quickly.

The entire project, worth £650,000, equates to approximately 7 weeks of our manufacturing capacity spread over 3 months, therefore we are able to maintain the normal fast track deliveries to our existing customers".

Forbes has a single source framework agreement for tanks and vessels with United Utilities.

This ensures that United Utilities receive highly competitive prices for correctly designed and manufactured tanks for the safe storage of hazardous chemicals on their numerous water and waste treatment plants.

New Atex Turbolite Airlamp range

2007-01-09T21:14:00.000-08:00

Wolf Safety has launched the new generation of Turbolite high power compressed-air driven safety lamps, CE marked to the ATEX 94/9/EC Directive for use in Zones 1 and 2 Hazardous Areas.

With revolutionary lightweight Aluminium construction for use in Group II industrial applications, the A-TL44A Baylight provides a high level of all round general illumination, while the A-TL45A Floodlight with matt reflector gives a powerful wide-angle beam. They are also dual marked with US Factory Mutual Approval. Alternatively, the A-TL44B and A-TL45B models incorporate traditional brass housings approved for use in Group I mining applications as well as Group II.

Other major improvements over the existing models include sealed bearings, a refined regulator, greater use of stainless steel components, a bulb-life enhancing device and a silencer, incorporating a particle trap.

Used extensively in the petrochemical, oil and marine industries, Wolf Airlamps provide illumination in many applications, including shot blasting, cleaning and coating of storage tanks and vessels, and for pipeline and structural engineering activities.

They offer a safer alternative to mains and low voltage lighting, where explosive atmospheres present a serious risk to the workforce.

A full range of accessories is available, including anti-static hose, filters, filter stands, tripods and setting and testing devices.

EPSI provides ASME coded high pressure vessels

2007-01-08T21:14:00.000-08:00

EPSI (Engineered Pressure Systems), a world leader in custom-engineered high pressure solutions, provide high pressure vessels that are TUV or ASME coded.

The current code for pressure vessels maintains safety for the public and is a requirement in most countries. ASME Section VIII of the code sets standards for responsibilities, material requirements, design requirements, fabrication, non-destructive examination and testing. EPSI ensures the vessels we supply meet all requirements under the ASME code.

User Design Specifications and a Manufacturer's Design Report are certified by an on-staff registered professional engineer with over 25 years experience in pressure-vessel design.

The ASME coded forged vessel is an essential building block of most of EPSI high pressure products.

EPSI is a leading manufacturer of hot, cold and warm isostatic press systems.

With its unique application-specific approach to R and D, manufacturing, and testing, EPSI has built a tradition of excellence in high-pressure engineering and technology worldwide.

Coating prevents mould corrosion and adhesion

2007-01-08T21:13:00.000-08:00

A specialised Apticote coating from Poeton Industries has 're-covered' a set of rusty filter moulds, recovering their performance and saving Sogefi Filtration over GBP25,000.

The South Wales based Coopers Division of Sogefi Filtration manufactures air, oil and fuel filters for cars and heavy goods vehicles. To produce an after-market air filter for a leading car range the company was using 150 sets of ferritic stainless steel moulds supplied by a sister company. Prior to production the moulds were coated with a PVC chemical, incorporating a release agent, which then had to be oven cured.

Despite the coating, the presence of carbon in the stainless steel caused the moulds to corrode, making it impossible to remove filters without ripping their seals.

A zinc coating applied by a local company also failed to prevent sticking; and even getting coatings to stick to the moulds was proving to be a problem.

It was at this point - with the company facing a GBP25,000 bill to replace the moulds - that the engineering department called in Poeton.

Says Gwyn Thomas of Sogefi: "By this time the moulds were in poor state and very badly rusted; and the profile meant they would be difficult to clean or polish".

He says: "In spite of their condition Poeton was able to apply a number of its Apticote coatings for us to test for compatibility".

Apticote 460G, one of a family of nickel polymer coatings developed for rubber and polymer moulding applications, produced the best result.

Its combination of permanent lubricity and high hardness enabled filters to be easily released and significantly extended the life of the moulds.

Gwyn reports that eighteen months later with an estimated 60,000 filters produced, there are no signs of wear or deterioration in the coating, even though a metal gauze inside the filters rubs against its surface during the process.

New website for high-pressure engineers

2007-01-07T21:13:00.000-08:00

EPSI (Engineered Pressure Systems), a world leader in custom-engineered high-pressure solutions, offers its newly updated website as a resource to the high-pressure engineering industry.

An in-depth view of various hot, cold and warm isostatic press systems, custom applications, and accessories is available via the website. The updated EPSI website features English or Chinese language options, and contains a "What's new" section, highlighting projects in Belgium and the USA. Additionally, the section includes a list of the upcoming EPSI tradeshows.

The new site enables visitors to learn more about a variety of systems best suited to fit their specific application needs.

By simply clicking on the menu bar, users can quickly and easily obtain the features and benefits of the large EPSI selection of systems, including simulators, quartz growth equipment, and high-pressure engineering technology.

In addition, visitors can find an updated contact page and a library of new product photos.

Process plant integrity monitoring

2007-01-07T21:11:00.000-08:00

New technology for monitoring and assessing process plant structural integrity is introduced by IDEAS Ltd, the Glasgow based specialist engineering services consultancy.

Ideas Ltd has developed this revolutionary technology which is being described as the world's first truly automated fitness for service and real time integrity monitoring system. The technology, based on a combination of complex assessment linked to live measuring devices, gives a real-time, quantified assessment of mechanical integrity. This is being offered to clients for issues regarding Corrosion, Erosion, Leakage, Fluid Flow Transients, Acoustic Pulsation, Vibration, Defects, Support Loads, Settlement, High Temperature, Liquid Sloshing, Vehicle, Ship or FPSO Motion, Fracture and Fatigue, or General Integrity Problems.

An up-to-the-minute and detailed understanding of the integrity status of process plant and structures will be a key factor in improving safety and avoiding expensive, unplanned shutdowns and failures, in applications across a wide range of industries, from oil and gas, petrochemical and power generation, to unloaders, ship hulls and wind turbines.

The new technology will reduce operational costs by optimising inspection and maintenance procedures, and at the same time reduce risk by using quantified integrity data in the development of inspection plans.

Safety incidents such as plant failures, explosions, and ship fracturing will be reduced.

The methodology is a quantum leap forward beyond that used by existing monitoring systems, which are mainly dependant on identifying changes in trends and patterns, and from which integrity is not immediately quantifiable.

For the first time, clients will have quantified integrity information available in real time, avoiding reliance on guesses, statistics, trends, estimates and databases.

The technology will be used either as a problem solving tool, or as a method of providing regular health checks.

It will also be web-enabled as a remote monitoring system, with particular applications in offshore facilities, power stations and chemical plant, where access to the plant is difficult or dangerous.

Hygienic stainless steel manways

2007-01-06T21:04:00.000-08:00

Axium Process has a range of stainless steel Manways for atmospheric and medium-pressure liquid, powder and grain applications in the food and pharmaceutical industries.

Axium Process Ltd is a new supplier of hygienic stainless steel components to the chemical, pharmaceutical, food, cosmetics and toiletries industries. The Manways, manufactured from 316 stainless steel, are available in rectangular, oval and circular form, with apertures ranging in size from 100mm to 1200mm. Hinged, multi-clamp and swivel-lever-arm designs are available, with domed lids and a glueless seal to minimise any potential bacterial contamination.

Material options available include 304 stainless steel and a variety of alloys, including Hastelloy and SMO254.

Full material certification to BS EN 10204 3.1.B is available for the glueless seal, domed lid options.

All manways are supplied with mirror polished lids and skirts finished to customer specification.

EPDM seals are standard on all manways, allowing operating temperatures between -25C and +150C.

A range of alternative seal material is available, which includes silicone, Viton and nitrile rubber.

Providing access to tanks, storage vessels and ducting systems, Axium Process hygienic manways are complemented by a range of ancillary items featuring level gauges, sight glasses and sprayballs.

The company also offers a comprehensive range of hygienic stainless steel components and pipe fittings which can be fabricated to customer specification by Axium Process coded welders (ASME IX).

Innovative stainless tank construction

2007-01-06T21:03:00.000-08:00

Prep-Tec Systems recently supplyied 3 shop built and 2 site built stainless steel water tanks for Pulrose Power Station in the Isle Of Man: site tanks were constructed using a unique jacking system.

Prep-Tec Systems, a Bury, Lancashire based company have recently been involved in supplying 3 shop built and 2 site built water tanks for Pulrose Power Station in Douglas, Isle Of Man. The contract was part of a multi million pound development to transfer the existing oil fired power station to natural gas. The gas will be supplied direct from the Irish Sea.

The order to Prep-Tec Systems was awarded direct from the Isle of Man government who purposely formed a company PGT Ltd (Pulrose Gas Turbines) to oversee the development.

The tanks range from a 15 cubic metre horizontal cylindrical main cooling water system head tank, a 5 cubic metre cylindrical raw water break tank, and a 3 cubic metre vertical closed loop cooling water system head tank.

Each of the tanks was supplied in carbon steel with 15-year life paint finish to the internal and external surfaces.

The site built de-mineralised water tanks, each 225 cubic metre and 11.5 metres high, were manufactured in 316 quality stainless steel and erected one metre apart from each other.

The North tank was built with a spiral access stairway and the South tank with a hooped access ladder.

A bridge was fitted between each tank to join them together.

The components were shop formed and shipped to the Isle of Man on 3 articulated 12 metre trailers.

Due to the limited access the tanks were built using a unique jacking system where each of the top sections were erected and fully welded complete with lids, handrails etc and jacked up to allow the next course to be positioned under.

The tanks were progressively jacked up this way until all the sections were attached.

The staircase and ladders were also progressively attached this way.

The benefit of this method of construction is that all the work, welding etc can be completed at ground level, which eliminates the need for expensive crane hire and scaffolding.

Also the inside of the tanks are always closed off to the elements and the outside can be easily covered with a simple tent arrangement to allow welding to progress in any weather conditions.

Apticote delivers rally championship performance

2007-01-05T21:03:00.001-08:00

Poeton Industries has been awarded a contract to apply Apticote 100 hard chromium plating to high-performance damper tubes for the suspension of the Mitsubishi Ralliart World Rally Championship cars.

The hard chromium application is described as an "extremely delicate job" by James Glover of SPA Design, the company that manufactures the damper tubes and other components for Ralliart. "It really is the most difficult surface treatment job we've been involved with" James commented: "and Poeton, with its combination of coating and motorsport experience, is the only company we've found that can meet the high standard we require". He adds that the damper tubes also have to be handled very carefully to minimise surface scuffing and avoid any contact with objects that might damage them.

Explaining the difficulties, he says: "The specification from Ralliart called for a hard wearing, low-friction coating for the damper tubes, which have very thin walls that need to be hard chrome coated inside and out to extremely tight bore tolerances.

The outside diameter also comes into contact with a fragile seal so the surface has to be free of any defects that might damage them".

The Poeton Apticote 100 hard chromium coating is one of a dozen processes that the damper tubes go through before they are delivered to Ralliart at a cost that runs into four figures for each one! Commenting for Poeton Motorsport Division, Neill Ricketts says: "We were delighted to accept the challenge from SPA Design, and happy that we could provide both the quality and the overnight service they needed.

It is also another example of how Apticote is helping motorsport companies win in the most demanding of environments".

New surface coating technology centre

2007-01-05T21:02:00.001-08:00

The new Poeton coating technology centre boasts an array of wear and friction test equipment, and three environmental corrosion chambers, allowing Poeton to solve customer coating problems.

Poeton Industries Limited, a world leader in surface coating technology, has completed a 120,000 sterling investment in its Gloucester Technology Centre, creating a focal point of surface coating excellence within the Poeton Group, which also has production facilities in Cardiff, Southampton and the USA. The Centre was officially opened on Friday 15th January by Dr Keith Dennis, President of the Institute of Metal Finishing. Other VIP guests included John Kirkpatrick of the Motorsport Industry Association and Professor Frank Walsh, Professor in Electro-Chemical Engineering at the University of Bath.

Among the analytical and test equipment now in place are PC-driven microscopes capable of resolving surfaces and micro-sections down to sub-micron levels, with attachments that allow entry into bores only 2mm in diameter.

This investigative capability is supported by state-of-the-art chemical analysis, including Atomic Absorption.

Group R and D Director Keith Stevens says this level of sophistication underpins the Poeton position as one of the leading European surface engineering companies.

He also emphasises that much of the work carried out at the centre is of direct benefit to customers, explaining that his team has already been able to fast-track the successful resolution of problems such as in-service component failure by providing analysis that has saved customers from potentially expensive litigation.

The technology allows Poeton to solve customer coating problems, often via direct electronic transfer of images and reports.

Importantly, the new centre boasts an array of wear and friction test equipment, and three environmental corrosion chambers, allowing Poeton to pioneer ground-breaking developments in such diverse applications as F1 engines, plastic moulding and stylish beach wear.

Bespoke fittings manufacture

2007-01-04T21:02:00.000-08:00

Axium Process have strengthened their position in the manufacture of high purity stainless steel fittings for the process industry with the introduction of an Orbimatic Orbital Welding System.

Axium Process are now in a position to offer custom fittings of systems from 0.5 inch to 6 inch outside diameter using this system, the procedure can then be stored in the machines internal memory using a smart media card, which allows jobs to be very quickly re-produced at a later date. They can also use a range of other automated equipment to produce components up to 300mm in diameter. The Orbimatic system can produce true data log files, which will include exact deviations for each welded joint on the fitting, giving the customer confidence in the quality of the product supplied.

Managing Director, Dave Houldsworth, sums up the Axium Process company philosophy: "We provide a rapid, reliable and highly qualified supply and manufacturing service, focussed on the hygienic process industries.

Our aim is to exceed customers' expectations in terms of quality, delivery and service".

The introduction of the Orbimatic system helps Axium Process continue this with this philosophy and further increase the quality of the finished component.

New sample changer from Metrohm

2007-01-04T21:01:00.000-08:00

The Metrohm 824 Easy Sample Changer is one that every Titration or Karl Fischer Plant Laboratory can afford, and is simple and easy to operate.

The Metrohm 824 Easy Sample Changer: one that every Titration or Karl Fischer Plant Laboratory can afford. This new instrument from Metrohm is extremely easy to operate thanks to a simple key-pad layout linked to pre-programmed methods. The 824 is available in two versions.

The Macro version for Titration where large volumes, up to 250 ml, are involved: here 12 samples are processed sequentially.

Plus the Micro version, which will handle 24 samples of up to 75ml.

This version can also be converted into a Karl Fischer sample changer by means of the accessory kit 6.5610.020 KFT.

Both versions are supplied with comprehensive accessories, which include a sample rack, glass or polypropylene beakers, stirrer and titration head, plus all cables to connect the sample changer to the Metrohm Titrando or Titrino ranges of Titrators and Karl Fischer moisture analysis systems.

All laboratories can now take advantage of the Metrohm Sample Changer to achieve: easy automation at affordable prices; Save money when processing large numbers of samples; Enhance the reproducibility of their manual techniques; Contact with toxic chemicals is reduced to a minimum; Operational personnel need no special knowledge; Operational personnel are freed to do other work; The laboratory can operate 7 days per week, 24hrs /day.

Manage multiple projects with Mathcad

2007-01-03T21:01:00.000-08:00

With a 100-year history, customers depend on Johnson Screens to create effective and cost-conscious solutions to problems across a range of industries, including water intake, treatment and monitoring.

With its 100-year history, customers depend on Johnson Screens to create effective and cost-conscious solutions for problems across a range of industries, including architectural, food processing, general industrial, petrochemical processing, and water intake, treatment and monitoring. The company designs and manufactures industrial and commercial screens for more applications in more markets than any other organisation in the world. Applications Engineer Michael Ekholm manages projects ranging from keeping drinking water clear of contaminants to filtering sugar and purifying oil and gas supplies.

Ekholm uses Mathcad on a daily basis to design, test and document new projects, collaborate with teams and create applications used around the globe.

Part of Mike's job is to work with public water supplies to create applications for keeping debris and aquatic life out of drinking water.

To do this effectively, Johnson Screens pioneered a 'passive' intake screen system that eliminated moving parts and represented a breakthrough in surface water withdrawal.

This unique approach removes common problems such as heavy debris plugging an open system or the destruction of fish related to using the traditional complex, moving screens.

By reforming the water intake mechanisms, Johnson Screens creates highly efficient intake systems and fish diversion screens without the potential for mechanical failure.

Presenting official calculations that have been certified as accurate with the stamp of a professional engineer is a requirement for the water process industry, and in most of Johnson's other markets as well.

The accuracy and presentation quality of the technical information that a calculation tool provides can define a company's success.

Ekholm uses Mathsoft's Mathcad as his 'daily desktop destination,' leveraging its range of integrated tools to tackle anything from everyday calculations to the tracking of major projects with colleagues.

Mathcad enables Ekholm to maintain control of a single project without having to move between many applications, ensuring a high quality of data that cannot be compromised with conversions.

Mathcad's intuitive 'live whiteboard' style of mathematical notation and calculation means Ekholm can compute solutions as fast as he can type in equations.

This is critical to Ekholm because it saves him time.

With Mathcad, he is able to quickly map out a design and test its abilities, making adjustments along the way that seamlessly re-calculate the design applications.

'We receive many requests for projects-large and small-every day,' said Ekholm.

'It's rare that I get to work on only one design at a time, making it essential that I have a tool that provides the flexibility and intelligence to track my calculations and share my work with my colleagues'.

Team collaboration is extremely important to Ekholm, who often manages multiple projects with his peers.

Mathcad lets him document, track and share his work, ensuring consistency during a project and the freedom for him and his colleagues to work at their own pace.

'I depend on Mathcad to be my tool for everything I do during the design process, from planning and executing our technical calculations to reporting'.

By using Mathcad, Ekholm is able to simplify the design process to create, test and publish his projects.

Ekholm appreciates the Mathcad capability to interface and integrate his calculations with his other desktop tools, such as TK Solver, to gain the advantage of timesaving and a seamless design process.

Ekholm uses Mathcad reporting features to hide proprietary work and calculations when sharing documents outside of the office and making professional presentations to his clients.

'We conduct all team calculation work and reporting with Mathcad,' Ekholm said.

'It makes the process so streamlined that I can't imagine work without it'.

Mathcad is supplied and supported in the UK and Ireland by Adept Scientific plc.

New pump enables affordable water recycling

2007-01-03T21:00:00.000-08:00

The Filterpump has a 250 micron fixed intake screen, continually backwashed by internal rotating jets powered by a dedicated impeller, keeping the screen clear even in highly contaminated fluids.

The Rotorflush Filterpump is a revolutionery new product, a submersible pump with an integral self cleaning intake filter. The pump has a 250 micron fixed intake screen, which is continually backwashed by two internal rotating jets powered by a dedicated impeller, keeping the screen clear even in highly contaminated fluids. With no external moving parts, even fluids containing string, plastic bags or sanitary products cannot cause blockage.

In addition the pump produces a filtered output, which will not block nozzles and valves in upstream equipment.

Huber Technology UK Ltd are a major supplier of inlet screens for sewage treatment works.

They wished to use the in-flowing sewage as a source of wash water for their screens.

Previously potable water had been used.

The Rotorflush Filterpump provided the ideal solution, an easy to install, submersible pump and self cleaning filter in one unit.

Not only was the unit able to work directly in sewage without blocking, an essential requirement on unmanned sewage treatment works, it also provided a filtered supply that would not block the nozzles and solenoids on their screening equipment.

A number of units have been supplied to Huber over the last 9 months with great success.

Cross filter improves sewage treatment efficiency

2007-01-02T01:23:00.001-08:00

A fully automatic Cross filter has been installed at the Thames Water Deephams STW in North London to enable treated final effluent to be used to clean recently upgraded works inlet screens.

A fully automatic Cross filter has been installed at the Thames Water Deephams sewage treatment Works in North London to enable treated final effluent to be used to clean recently upgraded inlet screens at the head of the works. Using final effluent for this task saves the considerable expense of using fresh town water, but it is essential to ensure that it doesn't contain any suspended solids that are large enough to block up the spray nozzles. At Deephams this is achieved by using a Cross Phoenix filter, rated at 400 microns.

Sewage treatment at Deephams has been upgraded to meet strict new Environment Agency consent targets.

Treatment entails screening and grit removal, primary sedimentation, aeration and final sedimentation at a designed daily capacity of up to 460,000 tonnes (cubic metres).

A proportion of the final effluent has always been used as the source of cooling water in the site's powerhouse, where electricity is generated from methane gas produced during the treatment processes.

The same water supply is now also used for inlet screen cleaning, passing through the Cross filter on its way from the powerhouse to the head of the works.

Despite its compact size, the Cross Phoenix filter is capable of filtering at a flow rate of up to 85,000 litres per hour, without interruption, even during automatic backwashing.

Filtering is performed by patented Cross 'zero gravity' coils, six of which are fitted in the Phoenix.

Backwashing is triggered by an adjustable pressure differential signal, supported by a time lapse back up.

Each coil is individually backwashed in a sequential programme, which reverses the flow, enabling the coil to open slightly along its entire length, ensuring that the debris build-up is completely flushed away.

Since only one coil is backwashed at a time, five coils always remain on-line, maintaining an uninterrupted flow through the system at all times.

The complete backwashing cycle takes less than a minute and uses a minimal amount of water.

Piano wire screens in tune with productivity

2007-01-02T01:22:00.001-08:00

Harpscreen piano wire screens, a proven choice for all makes and models of screening equipment, now offer an alternative to traditional steel crossbands: plastic crossbands can now be fitted!

Harpscreen piano wire screens, a proven choice for all makes and models of screening equipment, now offer an alternative to traditional steel crossbands. Both round and square plastic crossbands can now be fitted to suit an even wider variety of applications and needs. All crossbands on Harpscreen piano wire screens are easy to install and fully moveable for ease of positioning.

The screens are individually tested at the point of manufacture and can be supplied in an extensive range of sizes, with next day delivery available from stock for standard products.

To ensure that all applications are catered for and maximum productivity and efficiency are achieved, the screen wire apertures range from 1mm up to 50mm.

Only the highest quality high tensile piano wire or stainless steel wire is used to give extended trouble-free operation.

The wires range in size from 0.65 up to 5mm diameter and can be provided in four duty ratings from heavy up to XXH.

Piano wire cassette and conversion kits are also available.

They are individually manufactured to suit specific screen-boxes and employ a high quality tensioning system that readily houses a variety of screens including flexi-harp and square mesh.

Another recent addition to the range of accessories for Harpscreen piano wire screens is the Harpscreen Multiframe.

Using the company's modular Multimat piano wire screen, the main benefit is that there is never a need to replace a full size screen as each worn piano wire section can be replaced individually without removing the frame.

Reliability on Beverley sludge at the WwTW

2007-01-01T01:21:00.000-08:00

Yorkshire Water reports that 8 Mono Industrial E Range pumps fitted on the autodesludge process at Beverley WwTW have completed 18 months of trouble-free operation following their installation.

Yorkshire Water reports that eight Mono Industrial E Range pumps fitted on the auto desludge process at Beverley WWTW have just completed eighteen months of trouble-free operation following their installation. The pumps replaced competitive products, which had to be removed after they had suffered constant blockages and unreliable service. Two Mono CE071SJR4 progressive cavity pumps are fitted to each of the four primary settlement tanks at Beverley WwTW as part of the framework agreement with Yorkshire Water, and were specified with minimum maintenance requirements and low whole of life costs uppermost in mind.

The competitor pumps had only been in operation for approx 1 year before Yorkshire Water had to resort back to manual desludging of the tanks because of constant blockages and this was proving to be cost prohibitive.

The pumps draw sludge from the bottom of the sludge hopper under the head of water in the primary tanks and transfer it to the sludge wet well.

The previous equipment was situated in a confined place below ground, which proved inconvenient given the levels of maintenance subsequently required.

The Mono pumps are situated above ground to improve access if required, although in the event they have not suffered a single blockage in the first year and a half of operation.

The primary sludge has a dry solids concentration of 3 - 8% and all the eight pumps have a transfer rate of 15m3/h.

Powered by 3kW motors, the pumps internal fluid velocities are designed to be kept within operating limits to guarantee a long and relatively trouble free life - an assumption which has been borne out by experience.

Other characteristics which demonstrate the far sighted Yorkshire Water approach to lowering fixed costs and controlling long term budgets is the decision to have the pumps fitted with mechanical seals, rather than packed glands and to be equipped with overpressure and dry run protection systems.

Commenting on the Yorkshire Water experience of the E Range pumps at Beverley WwTW, Area Operations Supervisor David Sutton said, 'The Mono equipment is trouble-free in operation and has significantly reduced the levels of maintenance required.

On this basis it entirely justifies the decision to purchase equipment with a higher specification because it gives us a lower cost of ownership'.

Mono Pumps are designed to give least whole life costs through component life, reliability of operation and ease of maintainability.

Rotor and stator materials are selected and coated according to the end users industry to ensure that the type of wear likely to take place is accounted for and the best combination of materials is supplied.

Differential pressure per rotor stage is kept to a minimum.

This reduces the load at the rotor/stator seal line and consequently reduces wear.

Pump speed is selected according to the end product and is kept to the optimum and as the E Range pumps are fitted with the Mono Flexishaft coupling, wearing parts are minimised and lubrication is unnecessary, eliminating product contamination in the unlikely event of joint failure.

Dewatering decanter range completed

2007-01-01T01:18:00.000-08:00

Westfalia Separator announces the launch of the new UCD 345 dewatering decanter, aimed primarily at the municipal waste water treatment plants or for use in larger industrial waste water facilities.

Westfalia Separator announces the launch of the new UCD 345 dewatering decanter. With a bowl diameter of 340mm and a dewatering capacity up to 15M3/hr it is larger than the popular 'Crocodile' UCD 305. It is aimed primarily at the municipal waste water treatment plants or for use in larger industrial waste water facilities.

The UCD 345 is the fifth member of the new CD Force family and its performance approaches the large 400mm dia machines while being very compact.

As with all the range the new UCD 345 has been designed with customer benefits in mind including improved price/performance ratio, greater ease of access for maintenance and cleaning, user friendly operation and lower energy consumption.

The entire CD family features the 'Twin Shell' concept, which means that the product discharge catchers and housings are not connected to each other but form self contained units: this translates to lower noise levels and less air circulation.

As with other CD Force units, the UCD 345 has the main motor located beneath the housing while the secondary motor is mounted on the frame.

The V belt drives operate without an intermediate clutch.

The compact design facilitates fast replacement of bowl, scroll and bowl bearings, either individually or as complete assemblies.

Exchanging a regulating plate only takes a few minutes.

The new CD345 has been designed for minimum downtime and ease of service and with a significant reduction in the number of parts.

These state of the art decanters offer trouble free operation in municipal and industrial waste water treatment.

Feed forward control of chemical dosing

2006-12-31T01:16:00.000-08:00

The removal of phosphate from the effluent of a sewage works is an essential part of the urban waste water directive: Partech has trialled closed loop feed forward control of an inlet dosing system.

The removal of phosphate from the effluent of a sewage works is an essential part of the urban waste water directive. Many treatment works have phosphorous discharge consent, but with the increasing use of detergents containing phosphate, the problem of staying within consent is growing. Phosphate removal is carried out by dosing chemicals, normally iron salts or occasionally aluminium salts, at a rate determined by a preset diurnal profile derived by analysing a series of samples over a period of time.

Over the past 18 months, Partech Instruments has trialled closed loop feed forward control of an inlet dosing system for the removal of phosphate at three sites.

The results of the trials demonstrate that this approach is reliable and cost-effective, and can assist in making considerable savings in chemicals.

The natural removal both of nitrate and phosphate where applicable is the method of choice.

However, in most cases it is not possible and it becomes necessary for the works operator to resort to chemicals, with Ferric Chloride and Ferrous Sulphate being the most commonly used.

Where the efficiency of iron is much reduced, aluminium salts has been applied successfully, and works normally in conjunction with an iron salt.

In all cases, the amount of chemical used is critical for the performance of the works, cost control and meeting the metal discharge consent.

Dosing iron salts at the front end of a works requires a level of control to ensure that the pH of the influent is not made too acidic as this has a detrimental effect on the nitrifying process.

Historically, the iron dosing rate was calculated by taking a series of samples throughout the day and having them analysed to derive a diurnal profile.

This profile is entered into the dosing system such that a specific volume of iron is dosed at the time intervals used and this is then employed to 'control' the dose.

The Partech MicroMac sampling system is based around analysing ortho-phosphate, as opposed to total phosphorous.

This is because the ortho-phosphate chemistry is simple and fast, unlike the total phosphorous chemistry, which is complex and can be very slow.

Iron reacts directly with the soluble phosphate, which is almost totally in the ortho-phosphate form and the total phosphorous is largely in the bound form with the solids and is therefore flocculated by the iron with the solids.

It is also to be noted that in order to analyse for total phosphorous, it would be necessary to analyse an unfiltered sample, which on the inlet would be impossible.

The ortho-phosphate chemistry used is the standard ascorbic acid method, with the analyser calibrated using a 10mg/l as P standard and capable of detecting up to 25mg/l as P.

The analytical cycle time for this analysis is approximately five minutes.

Throughout the 18-month trials period, Partech gave great attention to designing a sampling system that would be low maintenance and ensure reliable crude sewage sampling.

The sampling system is a critical part of the control system and requires an optically clear sample to determine accurately the ortho-phosphate level.

The finished design copes with low flow and low sample levels, grit, ragging and turbulent flow.

In addition to low maintenance, the simple design helps with operator confidence and keeps the cost to a minimum.

The advantage of determining the phosphate level on the inlet is that the dose rate of the iron or aluminium salt can be calculated and the dosing system controlled using the combined flow and phosphate concentration.

The combined output generated allows the operator to adjust the dose for site-specific conditions that allow the 'P to Fe' ratio to be adjusted until it is optimised.

This optimisation requires the monitoring of the final effluent to ensure that the phosphate levels are within the Environment Agency consent; once the optimisation has been done there is no need to monitor the final effluent.

By using feed forward control the dose responds to actual changes in phosphate levels and provides an active dosing regime whereas the commonly used 'diurnal profile' cannot respond to changes in the inlet and can be either over dosing or under dosing both of which have financial consequences.

Three water companies provided sites for the Partech evaluation programme, these being Thames Water, Southern Water and Anglian Water.

The Thames Water site, with a Population Equivalent (PE) of 39,000, had a pumped inlet and a Gee and Co system dosing ferric sulphate controlled by a predetermined diurnal pattern.

The inward flow varied between 40 and 200 litres per second and upstream of the measuring point was a weir below which were two 'sandbanks' which release significant amounts of grit during high flow.

The trial unit was positioned above the inlet channel some 20m upstream of the dosing point and the sample pump was located directly below the trial unit.

The flow signal was obtained from the existing Warren Jones flow meter.

After four months the system was reliably analysing crude sewage for ortho-phosphate and when combined with the inlet flow, was successfully controlling the dosing system.

During the initial stages, Partech was able to demonstrate a saving of some 25% of the iron dosed when compared against the diurnal dosing regime.

This was later improved by a further 8% by adjusting the 'P to Fe' ratio.

The second trial, with Southern Water, took place at a site with a PE of 100,000 and a standard inlet channel equipped with well performing screens and de-gritting.

The flow rate ranged from 100 litres per second to 300 litres per second at storm flow and the existing dosing system operated using a predetermined and optimised diurnal pattern was a Chemfeed unit with full dosing control computer.

The works also had tanker waste delivered at irregular intervals, which had some effect on the incoming phosphate levels.

The trials unit was installed above the inlet channel about 10 metres upstream of the dosing point.

After just a few weeks the Partech system had provided several daily profiles and was shown to agree with the laboratory results.

The positive results of this trial was the confirmation of the results and with a redesigned filter coping well with the sample, the maintenance interval was increased to greater than 8 weeks.

The third trial was at an Anglian Water site with a PE of 45,000 and contained a balance tank on the pumped flow inlet.

The dosing system on site was a Gee and Co unit with a Chemtrol computer unit for the dosing control and the unit was set up to run on a dosing profile.

The flow into the works was highly variable between 20 - 180 litres per second with a common discharge channel to 3 PSTs.

The dosing point was in a chamber prior to the channel to the PSTs and the trials unit was mounted above the common channel prior to the ferric sulphate dosing point.

This site had not been optimised prior to the trial starting and the profile being dosed was a flat dosing rate with little variation.

After an initial period of running baselines to look at the diurnal pattern, the Partech analyser system was attached to the dosing system and a controlled trial was carried out.

During this trial the amount of iron dosed was reduced by some 47% against the flat dose rate that was initially controlling the system.

The sampling system worked very well and it was found that the filter did not require cleaning for a period of three months.

With the cost of the control system being in the region of GBP12k - 17k, depending on site conditions, a saving of 18% per annum at a site with a dosing rate of approximately 400 litres per day and at a cost of GBP50 per ton, the payback period is less than 12 months.

The use of an 'active' control system at the inlet to a works can have the following effect.

* Tighter and more effective control of the chemical dosing, with response to routine and non-routine events.

* Saving of dosed chemical expected to be in the range 10 to 40% depending on the status of the works as far as optimisation is concerned.

* Less likelihood of consent failure for both residual chemical - iron or aluminium - and phosphate.

* Reduced sludge production.

* Reduced potential for corrosion of the works due to over dosing of iron.

* The control system will have a payback period relative to the size of the works and volume of iron being used and is not expected to be viable on a small works.

* A reliable, robust dosing control system now exists.

Eight year success for non-stop submersible mixers

2006-12-31T01:14:00.000-08:00

Submersible mixers made by Landia have successfully completed eight years of untroubled operation at one of the largest wastewater treatment plants in Germany.

Submersible mixers made by Landia have successfully completed eight years of untroubled operation at one of the largest wastewater treatment plants in Germany. At the Bremen-Seehausen WWTW, which handles approx 62.8 million m3 of wastewater every year, Landia mixers have been working non-stop, 24-hours per day, seven days per week for a full eight years. One of the benefits that the 26 submersible Landia POP-I mixers bring to the plant is the highly efficient mixing of wastewater with activated sludge, which has to meet stringent environmental requirements laid down by German law.

'The mixers have operated satisfactorily through the years and so far we have had no problems', says Mr Sven Wedderman, Head of Process Technology at the Bremen-Seehausen WWTW (hanseWasser Seehausen WWTP).

The utility value of the biological process and the quality of the treated wastewater at Bremen-Seehausen depend very much on the reliability of the Landia mixers, which apart from routine servicing, have proved virtually trouble-free.

Landia POP-1 mixers continue to ensure that all bacteria and organic matters in Bremen-Seehausen are equally suspended throughout the whole tank volume, creating optimum homogenised wastewater for a biological process that has a cleaning performance of 91% for COD, 92% for phosphorous and 79% for nitrogen.

The slow-speed Landia POP-I 1.5 kW-150 rpm flowmakers are also very energy efficient, designed to to provide a gentle treatment of the medium with thorough, efficient mixing, achieved by a low number of propeller revolutions.

This greatly improves flocculation and ensures the biological balance.

The low number of revolutions also creates less turbulence on the surface and thus prevents oxidation in the anoxic tank.

Balancing act at Aillwee Cave by Landia aerator

2006-12-31T01:13:00.000-08:00

A submersible, free-standing Landia Air Jet has significantly helped the owners of a popular tourist attraction in Ireland with the management of the site effluent treatment plant.

At one of Ireland's most ancient and stunning caves, a submersible, free-standing Landia Air Jet has significantly helped the owners of the popular tourist attraction with the management of the site effluent treatment plant. Aillwee Cave, which is situated in the Burren in County Clare, attracts 180,000 to 200,000 visitors every year - but as with many tourist attractions, visitor numbers can be unpredictable, causing irregularities for their effluent plant balance tank, as Nick Johnson, managing director, explains: 'When the plant was running at typical levels it worked quite efficiently', he said, 'but when it wasn't being fed continuously with the right amount of liquor, we had problems'. He added: 'The Landia Air Jet has successfully kept the balance tank aerated and homogenised, giving us much better management of our effluent treatment plant, as well as removing any unpleasant odours.

It is fair to say that without the Landia aeration equipment, which is proving very reliable, we may have been forced to change the effluent plant completely'.

The Landia DG-I Air Jet (3.0 kW), which was supplied through Fergon Enterprises, is a highly effective non-blocking system that is very easy to install in aeration or storm water retention tanks, and requires no ancillary equipment.

One of the key attractions on the inspiring, almost moonscape Burren, which is a paradise for geologists, botanists, ornithologists, speleologists and archaeologists, Aillwee Cave treats visitors to a guided, informative walk through 1.3 km of passageways, where they can see animal remains, waterfalls and numerous spectacular cave formations.

Pulsar Sludge Finder is a blanket success

2006-12-30T01:17:00.000-08:00

The Pulsar Sludge Finder is a new ultrasonic device designed to reliably and accurately detect and measure the interface between water and sludge in a variety of water industry clarifier applications.

Pulsar Process Measurement of Worcester has launched Sludge Finder, a new ultrasonic device designed to reliably and accurately overcome the tricky problem of detecting and measuring the interface between water and sludge in a variety of clarifier applications. A reliable sludge level measurement allows the correct dosing of chemicals to the process, reduces the amount of sludge pumping and can eliminate the need for manual measurements. Furthermore, by providing a reliable signal, advance warning of process upset can be generated so that remedial action can be taken.

Sludge Finder is an ultrasonic device, consisting of a control box and transducer, which is immersed in the liquid and fires a sound pulse down towards the sludge blanket.

This creates an echo returning to the transducer face, which is analysed in the control unit.

By using sophisticated echo processing algorithms, the change in density between the water and sludge is identified and signalled via an analogue output.

The transducer also features an automatic wiper that keeps the transducer face clean and makes the whole unit very low maintenance.

Up to four transducers can be connected to a single Sludge Finder control unit, at a distance of up to 500m.

Water extracted from raw sewage to clean screens

2006-12-29T03:46:00.003-08:00

The unique Rotorflush Filterpump, a submersible pump with a self cleaning intake screen, is used for extracting water from raw sewage and final effluent to provide washwater for inlet screens.

The unique Rotorflush Filterpump, a submersible pump with a self cleaning intake screen, is used for extracting water from raw sewage and final effluent to provide washwater for inlet screens at sewage works across the UK. The self cleaning intake filter on the Rotorflush Filterpump enables it to be used in sewage and final effluent without danger of the pump or upstream valves and nozzles becoming blocked. With outputs up to 2 litres/sec at 4 bar it's ideal for providing washwater for inlet screens.

The pump enables cost savings both in installation and running costs.

Being a multi stage submersible there is no need for weather or frost protection, it is self priming and only requires a minimum water level of 300mm to operate.

It can be installed into channels after the inlet screen, very close to where the washwater is required.

Running costs are reduced in two ways, the first and perhaps biggest saving is the re-use of sewage water, because the cost of using potable water for sewage screens is considerable and a wasteful use of this increasingly precious resource.

The second is the reduction in losses from having long pipe runs in conventional systems, which cause pipe friction losses and hence increased electricity consumption of the pressure sets.

There are 8 models to choose from both single and 3 phase with outputs from 80-120 litres/min and pressures from 2.5 bar to 8.4 bar.

The single phase versions are available with integral float switches.

The standard screen apertures on the self cleaning intake strainer are 315 micron which is more than enough filtration to prevent most nozzles and solenoid valves from blockage.

However where finer filtration is required screens can be specified with apertures down to 50 microns.

The self cleaning filter mechanism, which is the key feature of the Rotorflush Filterpump is extremely simple.

An additional impeller inside the filter continuously backwashes the filter screen, removing any debris that might be sucked onto the screen every half a second.

Without this feature the high pressure multistage pump would be blocked in a few hours when used in sewage.

The pump is finding many other uses, for example the provision of a filtered supply of water to online analysers, irrigation of effluent from dairy and pig farms, and supply of water to membrane systems.

Innovative cover design for inlet tanks

2006-12-29T03:46:00.001-08:00

Meeting the very specific and technically challenging requirements for new tank access covers at the Tonbridge Wastewater Treatment site - all in a day's work for GRP cover designers AMi Designs.

Meeting the very specific and technically challenging requirements for new tank access covers at the Tonbridge Wastewater Treatment site (WwTw), is another example of the engineering skills of Bristol based specialist GRP cover designers AMi Designs. Following the addition of the new Tonbridge inlet works AMi Designs were chosen to design, manufacture and install GRP covers for the inlet tanks and Magnaflow chamber. Tonbridge WWTW required the tank to be visually accessible by a series of hatches strategically placed across the length and breadth of the tank cover, without sacrificing aesthetics, strength or durability.

They also required the covers to be easily removable to allow full, uninterrupted access to the tank by their on-site staff, without the need for an additional installation team.

AMi proposed flush fitting hatches with the same herringbone design texture relief pattern (similar to a durbar pattern) to ensure a match with the existing tank cover.

To ensure a lightweight, yet strong and durable solution the safety hatches incorporated a stainless steel grill beneath the hatch lid.

This meant that the required structural support, loading (5.0kN/m2) and deflection criteria (1/200 of beam span), were all met, whilst enabling the removable part of the cover to be easy and light to handle.

To allow the large GRP cover to be fully removable, AMi Designs adopted a technique which did not necessitate the traditional overlapping panel design to be implemented.

This was achieved by placing the locating sockets in the secured supporting beams, making the interlocking flanges on the panels self-aligning and with the aid of simple handles, each panel remained vertically accessible and removable.

The cover panels are secured by steel quarter turn locks that fix onto locking clamps mounted on the inside wall of the tank at either end of each panel.

The complete hatch assembly is fitted with stainless steel hatch stays and a flush finger lift and pad lock security system.

AMi Director and qualified engineer Darren Bishop who lead the 3 man team for the Tonbridge project commented, 'This project was successfully completed thanks to our specialist design skills in GRP cover design, as illustrated by our innovative design solution which met the strength, durability and aesthetic requirements of the existing tanks'.

AMi Designs was established by Directors Kevin Daykin and Darren Bishop, who are both qualified structural engineers.

Thanks to a range of successfully completed projects, AMi is enhancing its reputation in the design, manufacture and installation of innovative GRP cover designs.

Automatic filtration ensures clean intake screens

2006-12-28T03:45:00.000-08:00

Southern Water wastewater treatment sites use automatic Boll filtration systems to ensure the primary screen washwater filtration, enabling compliance with stringent industry regulations.

Set deep in the heart of rolling Sussex countryside, the Southern Water Vine Cross wastewater treatment plant had a particular issue with build up of solids in the washwater system. Loss of the washwater system resulted in the crude sewage inlet screens becoming fouled. Final effluent from the humus tanks, which is used to keep the inlet screens clean as well as for general washwater, requires filtration to protect the high pressure multi-stage washwater pump from becoming blocked with particulates, such as algae and sludge particles.

However, the manual strainers, which required daily cleaning, were causing blockages in the system.

A similar problem had been solved at East Worthing WTW by the installation of an automatic Boll filtration system and, after liaising with the Southern Water process scientists, Morrison Utility Services recommended investing in a similar system at Vines Cross WTW.

The Bollfilter system is a low pressure installation comprising a Boll 6.18 automatic self-cleaning filter with independent backflush pump fitted on the water inlet to the waste water pump.

The unit, which operates at pressures of between 0.5 and 1 bar, is set up to automatically clean once an hour.

Ideal for remote water sites, Boll systems feature unique backflushing technology to ensure reliable, efficient filtration with minimal maintenance and without the need for regular cleaning.

Jon Moss, part of Morrison Utility Services, is pleased with the performance of the new system.

He commented: 'Compliance issues are always urgent and Bollfilter was able to provide a suitable system without delay.

The two operators based at Vines Cross, who are also responsible for a number of other sites, no longer have to take time every day to clean the manual strainers.'

GRP tank covers installed in a single day

2006-12-28T03:44:00.000-08:00

Speed of installation and minimal disruption were the important benefits appreciated by Water Services of Ireland in a recent project by specialist GRP cover designers AMi Designs.

Speed of installation and minimal disruption were among the important benefits appreciated by Water Services of Ireland following the completion of a recent project by specialist GRP cover designers AMi Designs. Bristol based AMi Designs have installed both GRP covers and baffle walls at the WS water and waste treatment site situated in Strabane, Northern Ireland. This most recent project, completed in conjunction with the contractor EarthTech (Ireland), required the design and installation of a single GRP cover for an existing tank with an inside diameter of 8.5 metres.

The cover was for odour control purposes and was designed and installed with all connections and vents to suit the existing tank.

AMi successfully completed the project, and had the cover assembled, placed and bolted into position in a single day.

Established by Directors Kevin Daykin and Darren Bishop, AMi Designs are building a reputation for innovative GRP cover designs combined with outstanding success in fast and efficient installations across a wide range of engineering projects.

Structural monitoring system for scraper blades

2006-12-27T01:52:00.001-08:00

AV Technology has successfully completed a six week exercise to monitor and record in-service loadings on scraper blades operating in primary settlement tanks, a Zone 1 hazardous area.

The Structural Monitoring Division of Stockport based AV Technology (AVT) has successfully completed a six week exercise to monitor and record in-service loadings on scraper blades operating in the Primary Settlement Tanks at Davyhulme sewage treatment Works in South Manchester. Based on a six channel, hazardous area, strain gauge monitoring system, the work has been carried out for Birse Water as part of a wider odour control project at the works for United Utilities. Although Birse were able to use their in-house finite element (FE) capability to understand the stress distribution on the structure, no data existed which could quantify the actual in-service loadings on the scraper blades resulting from the different depths of settled sludge for the two operating regimes.

As a result, AVT were contracted to measure and record the actual bending forces acting on the scraper frames as they move up and down the tanks.

The project presented several practical challenges for AVT, as their special projects manager Neil Parkinson explains: 'Firstly, in order to measure the maximum bending moment forces on the frame legs the strain gauges had to operate permanently underwater at a depth of around 1.5 metres.

Secondly, because the scraper frame runs up and down rails either side of the 70 metre long tank, the monitoring system needed to be able to operate remotely under its own power.

The task of measuring the forces was further complicated by the fact that the three primary settling tanks have recently been fully enclosed to provide effective odour control for the surrounding residential area.

Due to the potential risk of explosive gases entering the sewage network, and subsequently the settling tanks, the environment inside the tanks is classified as a Zone 1 hazardous area.

To meet the ATEX requirements, we created a micro safe area around our equipment fitted on top of the scraper bridge.

This consisted of a novel dual Exd-Exi environment using two explosion proof enclosures (EExd IIC T6), one to house the Campbell Scientific CR10X Data logger, multi-plexer and zener barrier systems, the second the 7Ah battery pack.

This novel solution is virtually identical to a strain monitoring system we have installed on an offshore oil tanker to monitor the integrity of the mooring chains'.

To measure the maximum bending forces on the six vertical legs, pairs of waterproof single element gauges were spot-welded at the mid point on the front and back of each leg.

These were then wired back to the Exd enclosure using the integral leads.

To ensure gauge integrity in this particularly harsh environment, the gauges were protected with a further 3-stages of environmental coating.

Precision 120 ohm resistors were used to complete a full Wheatsone Bridge configuration in the enclosure for each leg and the input and outputs were wired through zener barriers to the data logger.

In order to comply with the ATEX requirements for simple apparatus, an insulation test was carried out on each strain gauge to ensure that the insulation between the gauge circuit and the metal supporting substrate was capable of withstanding an AC rms test voltage of 500 V.

The output strain signals from the gauges have been calibrated into bending moments (Nm) based on a site calibration procedure using a reference load cell.

This was achieved by attaching a winch to the end wall of the tank and applying a force to each leg in turn, using the reference load cell to measure the load applied.

The project was split into two three week tests.

Initially measurements were taken with the scraper carrying out a scrape approximately every eight hours.

To optimise storage capabilities the data logger was timed to log data during these three 'time windows'.

It was programmed to measure strains every 1 second and to store running maximum values per channel every 10 seconds.

With a scrape time of approximately 40 minutes, this gave the unit the capacity to store data for up to 37 days with the data from each three week test fitting on a single Excel spreadsheet.

The measurements were then taken for the second three week period with the scraper only carrying out one cycle during a 24 hour period.

The data were manually collected by AVT on a weekly basis.

As the system is self-contained within the hazardous environment a mandatory gas test was carried out to ensure a safe working environment before opening the explosion proof enclosure and downloading the data to a laptop.

Collecting data is only a small part of the work AVT carry out and as Neil Parkinson continues: 'The key to successful fatigue analysis is being able to analyse and interpret large amounts of information and then present it to the client in the optimum format.

All round good communication and the ability to work closely with other interested parties are also vital ingredients.

In projects such as this one at Davyhulme, the working environment is far from perfect and a far cry from conditions found in the laboratory.

However, we are used to working in difficult and often remote areas with limited facilities and have developed a high level of ingenuity to ensure that our equipment can operate without problems.' The Chief Mechanical Engineer at Birse Water, Ken Craven, is pleased with the overall results and as he concludes: 'We needed to establish the nature of the loading on the scrapers under the two operational regimes attributable to varying sludge depth, to assess the long term reliability implications.

We recognised that gathering real time data in such an awkward environment was not going to be very straightforward.

However from the outset AVT applied a professional and pragmatic approach to the problem and their expertise has allowed us to obtain some very useful information.

We have combined the results of their trial with data we also collected regarding the build-up of sludge within the tanks under the two operational regimes and we are now working with our client to determine the best way forward.'

Pulsar Sludge Finder is a blanket success

2006-12-27T01:51:00.000-08:00

The Pulsar Sludge Finder is a new ultrasonic device designed to reliably and accurately detect and measure the interface level between water and sludge blanket in a variety of clarifier applications.

Pulsar Process Measurement of Worcester has launched Sludge Finder, a new ultrasonic device designed to reliably and accurately overcome the tricky problem of detecting and measuring the interface level between water and sludge in a variety of clarifier applications. A reliable sludge level measurement allows the correct dosing of chemicals to the process, reduces the amount of sludge pumping and can eliminate manual measurement. Furthermore, by providing a reliable signal, advance warning of any process upset can be generated so that remedial action can be taken.

Sludge Finder is an ultrasonic device, consisting of a control box and transducer, which is immersed in the liquid and fires a sound pulse down towards the sludge blanket.

This creates an echo returning to the transducer face, which is analysed in the control unit.

By using sophisticated echo processing algorithms, the change in density between the water and sludge is identified and signalled via an analogue output.

The transducer also features an automatic wiper that keeps the transducer face clean and makes the whole unit very low maintenance.

VSD units improve sewage plant efficiency

2006-12-26T22:11:00.000-08:00

Emotron variable speed drives and softstarters control pumps, blowers and mixers, and Emotron shaft power monitors protect other equipment on a new sewage works at Svenljunga.

When the sewage treatment plant in Svenljunga, a community of 10,000 inhabitants, was renovated in the summer of 2005, investments were made in order to increase operational efficiency and reliability. One measure taken was to install Emotron variable speed drives and softstarters to control pumps, blowers and mixers, and Emotron shaft power monitors to protect equipment. The result has been more reliable control, lower energy consumption and reduced wear.

The whole plant is now managed by one operator, instead of the two or three that used to be required for daily control and supervision.

The increased efficiency means, among other things, that time has been freed up for preventive measures and maintenance.

'We used to regulate most of the equipment manually, but today everything is controlled by Emotron products,' says electrician Johan Arvidsson.

In a sewage treatment plant, the objective is to keep a constant flow despite the large variation in load during the day and night.

In Svenljunga, Emotron products ensure efficient operation continuously adjusted to demand.

Variable speed drives and softstarters regulate pumps, blowers and mixers, and shaft power monitors protect screw conveyors.

'One advantage of Emotron products is that they can withstand harsh environments and be located within the plant,' says Johan Arvidsson: 'No costly cabling or cabinets are required.

We also minimise the risk of damage and downtime, since we are warned in good time of process disturbances'.

The Emotron products react immediately to deviations and send a warning or stop the process if operation is not optimal, for example if a pipe is blocked or a valve is not fully opened.

The operator can take action quickly in order to prevent damage and downtime.

Common and costly problems such as cavitation and dry-running can be avoided.

The stop sequence is a critical moment in pump operation, often causing stress on pipes, valves and other equipment.

The Emotron solution offers soft stops by gradually reducing the pump speed, thereby avoiding water hammer and other potential damage.

A total of 17 Emotron FDU variable speed drives are installed in the plant.

They control, among other things, three inlet pumps that pump in untreated sewage.

Two of the pumps are normally used to handle storm overflow water, i.e water that is allowed to pass the plant after only limited treatment, for example in the case of heavy rainfall.

The flow must not exceed 220 m3/hour in order for the particles that are to be removed to have time to settle to the bottom and not run out with the water.

If the flow is too high, the system regulates this by starting the third pump to pump water past so that the particles can settle.

The operation of the blowers supplying oxygen to the sewage water was also made more efficient by installing Emotron FDU variable speed drives.

'Until now the blowers were either running at maximum speed or standing still,' says Johan Arvidsson: 'That was wasting energy.

The Emotron FDU now continuously adjusts to demand, ensuring that the water maintains the correct oxygen content.

In this way we minimise our energy consumption and equipment wear'.

The sludge scrapers in the sedimentation basins are monitored by Emotron M20 shaft power monitors.

The monitors send a warning or stop the process if operation is not optimal, for example if a scraper is blocked, a blade is worn or a chain is broken.

Equipment wear and downtime are minimised.

The monitors are connected to the motor cable.

No sensors are required.

Emotron FDU variable speed drives control the sludge pumps that pump out surplus sludge from the basins.

The FDU units are located in cabinets outside near the basins.

An eccentric screw pump that pumps sludge to a thickener is also controlled by an Emotron FDU.

An Emotron M20 shaft power monitor on the screw conveyor sends a warning or stops the process if a blockage occurs.

Mixers placed down in the basins are regulated by Emotron FDUs, as are the sludge pumps that pump sludge to centrifuges where it is dewatered.

Seven Emotron MSF softstarters control the screw conveyors for the centrifuges.

The sludge is used as fertiliser or sent for final disposal.

As Svenljunga sewage treatment plant was being renovated, the largest local industry, Elmo Leather, built their own treatment plant next to the municipal plant.

The sewage water from the tannery had been putting high demands on its capacity.

'Now our plant is rated at 3000 pe, compared to the 100,000 pe required to treat the sewage from Elmo Leather,' says Johan Arvidsson.

The new Elmo Leather wastewater treatment plant is the first of its kind.

A fully biological process is used that has never been tested before on an operation that uses such large quantities of chemicals.

The EU environmental fund contributed to the financing and the good results mean that the company will show the way for other tanneries in Europe.

The new technique reduces nitrogen emissions by 80%, compared to 30% in the old plant.

Emotron variable speed drives control, amongst other things, the blowers that oxygenate the waste water.

Balancing act at Aillwee Cave by Landia aerator

2006-12-26T22:10:00.000-08:00

6th 'Sewers For Adoption Guide' for Mayday

2006-12-25T01:15:00.001-08:00

1st May 2006 is the date when new guidelines govern all new applications for the adoption of sewers and their accompanying contracts and pumping stations.

Mayday 2006 is the date when new guidelines come in to govern all new applications for the adoption of sewers and their accompanying contracts concerned with the planning, designing and construction of sewers and pumping stations. Water and environment consultants WRc has launched the sixth edition of its 'Sewers For Adoption' guide to alleviate problems and issues as well as making it easier for developers to complete adoptions faster and more economically. This latest edition covers changes in the law from the Water Act 2003, new developments in technology as well as details and opportunities for lateral drain adoption.

The guide also encompasses changes to the adoption process allowing an earlier release of the bond - 1 year earlier than previously, and includes information on which SUD systems could be adopted.

'This is a definitive guide giving the latest information to all those involved in sewer adoption.

Using this new edition, developers will be able to complete adoptions faster, easier and get their money (bond) back faster, ' confirms Dr Iain Naismith, Head of WRc Standards, Testing and Approvals.

Measuring level with non-contacting ultrasonics

2006-12-25T01:15:00.000-08:00

The latest Siemens range of ultrasonic transducers for level measurement is delivering accurate and reliable measurement to the water industry.

The latest Siemens range of ultrasonic transducers for level measurement is delivering accurate and reliable measurement to the water industry. For most level measurement applications in the environmental industries, ultrasonic technology is a highly desirable solution. Ultrasonic sensors (transducers) emit acoustic pulses and receive an echo from the material being measured.

The sensor is connected to a transceiver that calculates level by processing the time between the original signal and its echo.

Siemens Echomax transducers are built to provide accurate, reliable measurement even in harsh and hazardous environments.

They're impervious to dust, moisture, corrosion, vibration, flooding and temperature extremes.

Siemens ultrasonic transceivers feature Advanced Sonic Intelligence echo-processing capabilities to ensure reliable data even in conditions with obstructions, turbulence and foam.

The transducers also have an integral temperature sensor to compensate for sound velocity variations caused by changes in air temperature.

Siemens transducers are easy to install, and the non-contacting design makes them low maintenance by avoiding the corrosion, material build-up, and general wear and tear associated with contacting devices.

Higher maintenance costs and repairs associated with contacting devices can easily exceed any initial savings.

The Echomax device has become the preferred choice in a wide range of applications including wet wells, weirs and flumes, storage tanks, penstock and sluice gate control, and rake screens.

Sewage flow metering in ductile iron pipes

2006-12-24T01:13:00.000-08:00

Ductile iron pipes are relatively inexpensive and long lasting, so they are quite common in waste water installations, but they are not a problem for Fluxus clamp-on ultrasonic meters.

Ductile iron pipes are quite common in waste water installations: they are relatively inexpensive and last a long time. For ultrasonic flow measurement, such pipes can present quite a problem. Clamp-on ultrasonic flow meters are the ideal solution in cases where the flow disruption is impossible, or very expensive.

Unfortunately, ductile iron tends to attenuate sonic energy, and it can be a problem for clamp-on ultrasonic flowmeters..

If such pipes are furthermore lined with cement, the attenuation becomes even stronger, thus presenting a considerable problem.

Recently, a dual channel Fluxus ADM 7407 was successfully installed in a waste water treatment plant in New Jersey, where the facility operator needed to measure the influent and effluent of the primary treatment portion of the plant.

Thanks to its high output voltage and power, Fluxus succeeded where all other tested ultrasonic clamp-on meters had failed.

After a series of tests, Fluxus meters were permanently installed on both wastewater lines.

The installation went flawlessly - with no flow interruptions, because the unit was installed onto fully operational pipework.

'Poma' submersible pump suited to narrow sumps

2006-12-24T01:12:00.000-08:00

The new Tsurumi 'Poma' submersible pump produces an exceptionally large flow from its highly efficient 150W motor, making it ideal for continuous running and many other industrial applications.

The new Tsurumi 'Poma' submersible pump produces an exceptionally large flow from its 150W motor, making it ideal for many industrial applications. It is especially suited for pumping needs within narrow sumps where a traditional pendant type float switch could be fouled. Constructed from reinforced plastic and stainless steel, 'Poma' pumps are highly resistant to corrosion and rust and will pump water to a maximum head of 5.5m.

Outlet size is 50mm with a maximum flow rate of 250 litres per minute.

The optional integral tube float switch provides start and stop levels of 285mm and 175mm respectively and the vortex impeller gives generous 35mm suspended solids handling.

Other features include a 403 stainless steel shaft fitted with an ultra hardwearing silicon carbide double mechanical seal installed in an oil chamber to give efficient, long-life sealing; automatic motor protection and an air release valve to prevent air locks; a common occurrence with other competitive pumps in its class.

The 'Poma' can be offered with or without float switch in 110 and 230V versions and comes with a generous 1-metre cable in HO7 rubber for indoor or outdoor use.

Overall dimensions (mm) are 225L x 183W x 354H.

Low power consumption from the highly efficient 150W (output) motor makes it ideal for continuous running applications.

Tsurumi submersible pumps are available from UK agents, Obart Pumps and their MD, Matthew Hill states: 'A large part of our business has resulted from the ability of Tsurumi pumps to operate reliably in the most arduous of conditions.

I am convinced that the introduction of the new 'Poma' will strengthen that position and, for those especially needing to pump within restricted space, we will offer this particular pump with confidence'.

The 'Poma' can be seen on the Obart website, or further information can be had from the Obart Pumps sales office in the UK.

Fabrication contract for sewerage equipment

2006-12-23T01:14:00.001-08:00

As the principal fabricator for Hydro International, fabrication specialist Arc Energy Resources has secured a further contract to manufacture their Hydro Vortex Drop-Shaft systems.

As principal fabricator of Hydro-Brake Flow Controls for Hydro International, fabrication specialist Arc Energy Resources has secured a further contract to manufacture their Hydro Vortex Drop-Shaft systems. The Hydro Vortex Drop-Shaft is a specialised unit used to quietly and safely drop water/sewage from heights. Its principle function is to dissipate the energy generated when water/sewage falls to the lower levels, preventing any noise, vibration or damage to the network infrastructure.

Commenting for Arc Energy, project manager Neil Cook says that with all stainless steel fabrication great care must be taken to avoid distortion and maintain the integrity of the material.

He explains that this is why the company used one of its new dedicated fabrication units for this contract, and staff that are skilled in working with the specialised materials.

Hydro Vortex Drop-Shafts are self-activating with no moving parts and Arc Energy is fabricating four lengths - one 25m, one 15m and two 3.5m - in stainless steel, complete with mounting brackets and special switch pipes designed to control the intake of air.

They will be installed in major sewer upgrade projects in Oldham and Bonnyrigg in Scotland.

Wayne Jones, an engineer for Hydro International says: 'Delivery was an important factor on this contract and Arc Energy was able to meet our tight deadlines.

The company's extensive experience of fabricating other tubular components as well as our Hydro-Brake Flow Control units meant that lead times for the Hydro Vortex Drop-Shafts could be significantly reduced.'

Single relay option available with MultiRanger 100

2006-12-23T01:13:00.000-08:00

Siemens announced today that a new option is available for the MultiRanger 100 ultrasonic controller for liquid level measurement, a single relay version with analogue and communications outputs.

Siemens announced today that a new option is available for the MultiRanger 100 ultrasonic controller for liquid level measurement. Customers now have a choice to order a single relay version, and enjoy the savings that Siemens is passing along. Many users simply use an analogue 4-20 mA output or digital communication output from the MultiRanger and do not use all the alarm relays that have been a standard feature of the MultiRanger 100 up until now.

This means that users now pay only for the features they need.

MultiRanger is ideal for short- to medium-range applications up to 15 meters (50 ft).

MultiRanger 100 offers cost-effective level monitoring, while MultiRanger 200 provides high performance measurement of level, flow, differential level, and volume conversion.

The flexibility to choose between models makes MultiRanger a cost-effective solution.

It is configurable at time of order, allowing you to select just the features you want for your application.

It is available in either wall or panel mount versions and includes options such as the number of relays, single or dual point functionality, and application specific software functions.

MultiRanger can be programmed with the Siemens Simatic Process Device Manager (PDM), the ideal software tool for configuration, parameter setting, record keeping and diagnostics, including trending and echo profiles.

Digital communications capability is provided by built-in Modbus.

Other communications protocols, including Profibus DP, are available through plug-in modules.

Inlet works pumps offer self cleaning sumps

2006-12-22T01:12:00.000-08:00

Hidrostal and their pumps have played a significant role in the improvements made to the inlet at the Sewage Treatment Works situated in and serving Esher in Surrey.

Hidrostal and their pumps have played a significant role in the improvements made to the inlet at the sewage treatment Works [STW] situated in and serving Esher in Surrey. The Thames Water project to replace the existing pumps and pipework has been a joint venture between Black and Veatch and Costain who have overall responsibility. Hidrostal were awarded the contract to supply replacement pumps, and fifteen Hidrostal pumps were also used during the over-pumping project.

The refurbishment started with a major over pumping project to keep the sewage flowing to the STW; both the Esher and Hersham pumping stations had to be by-passed ensuring no adverse effect on the residents.

This massive over-pumping project was delivered, installed and commissioned in less than three weeks.

It involved the installation of 10 Hidrostal pumps at the Esher pumping station (maximum flows of 900 l/s), 5 Hidrostal submersible pumps at the Hersham pumping station (maximum flow 410 l/s) and over 370m of pipe was installed (70m at 700mm diameter and 300m at 500mm).

The whole installation was controlled by a telemetry system allowing for remote monitoring.

Once the over- pumping solution was in place the two new Hidrostal pumps could be installed.

As the old pumps suffered from blockages, Hidrostal immersible pumps incorporating the Hidrostal Prerostal self-cleaning sump system were selected.

Each pump operates at 990 rpm and will pump at approximately 480 l/sec.

The screw centrifugal impellers offer high pump efficiency and, due to the impeller geometry and the large free passage, have a very low risk of blocking.

The Prerostal system is unique to Hidrostal.

It has been specifically designed to prevent the build up of solid material floating on the surface and forming a floating raft in the pumping chamber which is often the cause for pumps to block.

It is especially effective on wet wells handling unscreened raw sewage and waste water with oils, fats and greases on the surface.

The Prerostal system comes into operation at low sump levels when a high degree of liquid rotation occurs; the specific geometry of the basin and bellmouth ensures all floating material is entrained by the liquid and pumped out of the wet well.

The system automatically directs all materials which tend to settle or float at every pump cycle to the screw centrifugal pump with its proven track record for solids handling and, as a consequence, provides trouble-free pumping.

Commenting on the total project Dean Clayton, Hidrostal Area Sales Engineer, said: ''This has been an impressive project and a credit to all involved.

The superior rag handling ability of Hidrostal pumps combined with our Prerostal self cleaning sump, has played a key part in ensuring a much improved pumping operation.''

Pulsar ultrasonics go deep and narrow

2006-12-22T01:11:00.000-08:00

Pulsar have worked with United Utilities to solve waste water level control problems in two separate applications in Cumbria, in both cases using long range non-contacting ultrasonic equipment.

Pulsar have worked with United Utilities to solve waste water level measurement and control problems in two separate applications in North West Cumbria, in both cases using long range non-contacting ultrasonic equipment featuring the latest digital echo processing to accurately locate the liquid level. At Seascale WwTW, a 15m deep tank includes a shelved base leading down to a small sump housing two submersible pumps, a mere 2m square in section and 2.5m deep. In order to control the tank properly, it is important to measure the level down between the pumps.

This creates a very difficult application, requiring the level measurement unit to discriminate between many conflicting echoes while retaining the location of a relatively small target.

Previous efforts to monitor the level in the small sump had been unsuccessful.

Pulsar supplied a high-power, narrow beam dB25 ultrasonic transducer, which was mounted at the top of the tank.

The DATEM software built into the full range of Pulsar's 'Ultra' level controllers identified the correct level, and maintained contact with the level even down into the furthest reaches of the sump.

This solved a difficult measurement application for United Utilities and allowed the process to operate at maximum efficiency.

In another North Western application, Pulsar equipment was again chosen to provide reliable measurement in a very large, deep, sump at the John Pier pumping station in Workington.

This tank collects waste water from the town and pumps it on to the main treatment works, about 2 miles up the coast.

The depth of the tank is around 25m and the water surface is often turbulent and foamy.

Pulsar used their new dB40 ultrasonic transducer, offering a range of up to 40m with fantastic acoustic power.

Two separate Pulsar systems were installed, again following previous unsuccessful efforts to monitor the level reliably.

Each comprises an Ultra 3 controller with a db40 transducer, and these have provided extremely reliable level measurement in these arduous conditions.

Since the success of these applications within the Cumbria area, Pulsar have been awarded a single-source framework agreement by United Utilities for ultrasonic level measurement and open-channel flow measurement, for the AMP4 period.

Level control for 250 Beijing subway wetwells

2006-12-21T01:10:00.000-08:00

Hycontrol announce a prestigious contract to supply over 250 of their Miniflex-LR ultrasonic level control units for control and monitoring water levels at stations across the Beijing subway network.

Leading level specialists Hycontrol have been awarded a prestigious contract to supply over 250 of their Miniflex-LR ultrasonic level control units for controlling and monitoring water levels at stations across the Beijing subway network. The first units have already been commissioned, with further units being installed over the next eighteen months in time for the start of the Olympic Games in 2008. The opening of the XXIX Olympiad in Beijing will be the culmination of the most ambitious and expensive investment by any host nation to date.

During this mammoth construction project, the transport infrastructure has been a key area for improvement to cater for the anticipated influx of millions of visitors.

Until recently the Beijing subway system has been barely adequate to handle the daily passenger requirements and, as a result, main contractors BCECCL have been tasked with refurbishing 70 existing stations and with the construction of four new subways in time for the Games.

By 2008, the total length of the Beijing subway system will reach almost 200 km with a capacity of 1.74 billion passengers per year.

The 'Olympic Subway' linking the Olympic Green to South Beijing will be capable of carrying 40,000 to 60,000 passengers per hour.

The Miniflex-LR units, which are configured to operate in a conventional dual pump mode, are being installed at all the stations to control the water levels in wet wells.

All underground networks stand the risk of being flooded during heavy rain storms and because the wells handle both waste and storm water, accurate and reliable control is vital.

If any of the pumping systems fail, the stark reality is that stations could become flooded with sewage.

It is clear that the Chinese authorities need to be confident that no such mishaps can occur, especially when the eyes of the world are on them during the Olympics.

Hycontrol export manager Maurice Mahoney is justifiably proud of the Hycontrol achievement in gaining the order and as he explains: 'The contract was won against very stiff international competition and involved extensive site trials over three years.

Throughout this time our Beijing based engineers have worked very closely with the authorities and main contractors.

The Hycontrol unit was the only instrument to meet all the customer's stringent requirements and consequently the Miniflex-LR is now written into the Beijing Subway Design Institute main specification'.

At each installation the relay outputs from the Miniflex are fed locally to the PLC controlling the pumps.

There is also a high level alarm and analogue output.

Details of alarm status and level information from each installation are transmitted via a telemetry system to a central control hub.

The pump control mode offers seven different operating configurations depending on the requirement for specific applications.

In addition to the standard Duty standby and assist mode, options include alternating duty to even out pump wear, pump exerciser to test idle pumps periodically and pump monitoring to record pump usage.

The development of the Miniflex has come from hard won experience in the design and application of ultrasonic level control equipment over the past 30 years.

This cost effective instrument, which has an impressive 10 metre measuring range, boasts a range of features normally associated with units costing over twice as much.

In fact the Miniflex-LR offers four instruments in one: in addition to pump control, it can be configured for standard level measuring, open channel flow measurement and differential control.

Design focus has been on reliability, versatility and ease of use.

The simple, security-coded five button programming guides the operator rapidly through the set up and calibration procedure.

This is further facilitated by the bright multi-line 16 digit per line backlit display, which gives excellent parameter clarity under varying light conditions.

The front panel LEDs give a clear status indication of the ultrasonic echo and the three multi-function SPDT relays.

Transducer design is crucial to effective level control and the extensive Hycontrol experience is embedded in their range of transducers, which includes flanged and standard mounting versions with GR epoxy or PVDF face materials.

At the heart of the Miniflex-LR is the Hycontrol proprietary Proven Ultrasonic Level Signal Extraction technology (PULSE).

PULSE has been specifically developed to overcome traditional level control problems associated with unwanted or spurious echoes.

Utilising a unique window technology, the Miniflex recognises and then ignores signals from obstacles such as stirrers, cross beams, fill pipes or ladders.

Can cured-in-place linings reduce infiltration?

2006-12-21T01:09:00.000-08:00

As part of the Portfolio Collaborative Research Programme, WRc has taken on the management of the sewer lining infiltration test procedure that Thames Water started to develop in 2004

Can cured-in-place linings reduce infiltration into sewers? As part of it's Portfolio Collaborative Research Programme, WRc plc has taken on the management of the sewer lining infiltration test procedure that Thames Water started to develop in 2004 with input from Industry end users and Practitioners. As part of the project (CP308 'Infiltration Reduction Capabilities of Cured-In-Place Linings'), WRc is able to offer manufacturers free witnessing of such tests, though these opportunities are limited to a first come, first served basis.

The test quantifies the amount of groundwater that can infiltrate after lining with cured-in-place pipe (CIPP) systems.

Such infiltration can occur either by water peculating through defects within the lining material or by water tracking between the lining and host pipe, and exiting either at the ends of the lining into a manhole or into the sewer at lateral connections.

The test requires a full length CIPP lining to be installed within an assembly (comprising five clayware pipe sections including a 45degree tee) against water infiltrating at 3m water pressure.

Valves at each of the collar joints allow water pressure to be applied to the lining.

After resin cure, the water pressure is increased to 5m head and any infiltration is collected and measured at the ends of the lined section.

The pass/fail infiltration rate has been set the same as for a new sewer.

To date 14 CIPP systems have been tested and 6 have passed.

The WRc Portfolio project CP308 is being sponsored by 4 water and sewerage companies.

As part of the work programme WRc will witness infiltration tests and provide a test letter certificate to those system/installers which are successful.

There is no fee to the installer for WRc witnessing the infiltration test during the project, but the number of witnessing visits is limited.

There are 8 visits remaining on a first to be tested, first to be served basis.

The number of tests witnessed for a particular CIPP system and supplier is limited to a maximum of two.

After the remaining 8 visits have been undertaken witnessing by a suitably qualified experienced independent company is likely to incur a charge.

Further information on the infiltration test procedure, CP308 project details and test letters for the CIPP systems who have passed to date can be found on the project web site.

To register for a witnessing slot contact Andy Russell.

Project CP308 is part of the WRc GBP1.5M programme of collaborative research called Portfolio.

The Portfolio research programme addresses topical problems in the water industry through promoting innovation, sharing research costs and leveraging budgets/experience.

Third UK membrane bio-reactor filtration project

2006-12-20T23:23:00.000-08:00

Biwater Treatment has secured its third major contract incorporating membrane bio-reactor filtration - for the Northern Ireland Water Service's Ballyclare wastewater treatment works in County Antrim.
Biwater Treatment has secured its third major contract incorporating membrane bio-reactor filtration - for the Northern Ireland Water Service's new Ballyclare wastewater treatment works in County Antrim. The GBP9.1m project is being carried out by the Biwater Graham Joint Venture, following on from the previous Biwater MBR schemes at Campbeltown for Scottish Water, and at Severn Trent's newly completed Buxton WwTW. All three plants are for a population equivalent of around 29,000 and use Zenon environmental membranes.
Designed to cater for projected population growth and development needs over the next 25 years, the new Ballyclare works is scheduled for completion in July 2005.
It will replace the overloaded existing facility, which was built in two phases in the 1950s and 1970s, and two smaller works at Ballynure and Straid.
The MBR plant will ensure that the final effluent is of a quality suitable for discharge to the Six Mile Water, a sensitive salmon and trout river.

Package wastewater treatment plant in Scotland

2006-12-20T23:22:00.000-08:00

ABVEast (AMEC and Black and Veatch) has supplied a new 250 PE package wastewater treatment plant, designed and built at Stenton WWTW in East Lothian for Scottish Water Solutions.
As part of the works undertaken by ABVEast (a joint venture of AMEC Capital Projects with Black and Veatch), a new 250 PE package wastewater treatment plant has been designed and built at Stenton WWTW in East Lothian as part of a multi-million design and build framework within Scottish Water Solutions. The new works, which has to meet the Urban Wastewater Regulations (Scotland), sees the replacement of two former septic tanks and provides a final effluent quality of 20 mg/l BOD, 30 mg/l suspended solids. Design, environmental reporting and landscape design was carried out by Black and Veatch, including a significant amount of work carried out in the siting of the works.
Lengthy consultation was required with the local community to provide a design that blended into the existing environment of the conservation village.
Construction of the works by ABVEast saw new interceptor sewers to divert flows to the new works and the new package plant comprising inlet screens, flume, combined primary settlement tank and rotating biological contactor (RBC), final settlement tank and control building.

Poultry plant uses Mono Muncher to reduce waste

2006-12-19T23:21:00.001-08:00

To meet environmental legislation and avoid the penalties which could result from non-compliance, the 2 Sisters Food Group has installed a Mono Series 'A' Muncher at its poultry processing plant.
The need to meet increasingly stringent environmental legislation and avoid the penalties which could result from non-compliance has led the 2 Sisters Food Group to install a Mono Series 'A' Muncher at its UK poultry processing plant. 2 Sisters Food Group is one of the UK's largest poultry processing companies and its plant supplies chicken produce for a wide variety of food uses. In order to meet the relevant legislation from the Department for Environment, Food and Rural Affairs, covering the disposal of animal by-products via land injection, 2 Sisters needed to ensure that the waste from its processes is reliably and consistently reduced to a particle size of no more than 4mm.
Waste material from the processing operations is passed over a run-down screen from where all the screenings - mainly chicken offal and feathers with 10% dry solids - are fed via an existing Mono Merlin progressing cavity pump into a waste holding tank.
From the holding tank all solids pass through the newly installed Mono Muncher which grinds the product until the required particle size is reached.
Another Mono pump then transfers the reduced waste to road tankers for land injection, where it is used to provide an agricultural fertiliser.
The Mono Series 'A' Muncher offers a reliable and economical solution to the problem of reducing food waste.
It is a twin-shaft, low speed, high torque grinder which, while allowing liquids to pass through it, traps any entrained solids.
These are then fed through a series of cutters, which revolve at differential speeds to pull apart, crop and shear any solids such as bones or feathers down to a small particle size.
The integral gearbox in the Muncher converts its relatively low motor power into high output torque to make it extremely powerful but also energy efficient.
The low revolving speed of the cutter shafts creates low cutter tip speeds, and this dramatically reduces wear rates and noise levels compared to high speed macerators.
The Mono customer, TAPS of Huddersfield, originally installed the Mono Muncher on a trial basis to ensure that it was able to fulfil all 2 Sisters' requirements.
The unit features a 2.2kW electric motor and processes the waste at a 5m3 per hour.
Since successfully completing the trial, the Muncher has gone on to complete its first six months of continuous, problem-free, operation without incurring any maintenance costs.

Wastewater plant control for Robin Hood Airport

2006-12-19T23:21:00.000-08:00

Controlstar Systems has just commissioned the control system for the wastewater plant at the recently opened International Robin Hood Airport, (previously known as Finningley) near Doncaster.
Controlstar Systems has just commissioned the control system for the wastewater plant at the recently opened International Robin Hood Airport, (previously known as Finningley) near Doncaster. This 'fast track' project included a full SCADA and programmable system that controls the high efficiency wastewater plant that not only processes the wastewater from the facilities but also handles substantial volumes of run off from the runways. The dosing requirements imposed on the runway wastewater can create special problems if not processed correctly.
The Controlstar unit which provides both the control and telemetry interface is linked by mobile phone technology back to the main support centre near Brooklands in Kent.
A full display and record of the plant activity is available to the support organisation, both controls and plant optimisation can be carried out remotely.
Controlstar Systems won the contract by demonstrating the ease and speed of implementing the control algorithms using it's unique 'Fusion' visual programming tool; this allowed the project team to meet their 'fast track' and cost deadlines.

Meter makes the most of low-pressure flows

2006-12-18T23:20:00.001-08:00

Influx Measurements has solved the design problem of achieving economical flow measurement for low-pressure gases, typically met on methane or sour gas monitoring from digesters.
The Influx product is a stainless-steel Flotrak VA meter, fitted with a PTFE float. Supplied recently to FM Environmental of Newry, a 2 inch flanged Flotrak meter was calibrated over a range of 5-70cubic metres per hour, for an available pressure of only 6mbar in the process gas monitored. Encapsulated within a PTFE float, a lightweight 'supermagnet' signals the float position to a microprocessor based sensor module.
The 4-20mA output from this ATEX approved intrinsically safe sensor transmits the digester gas flow information to the process control system.
FM Environmental is a specialist in waste treatment, and this unit was supplied for a novel dissolved air flotation and anaerobic digester system used to treat a high BOD effluent from a brewery maltings factory.
The digester gas flow measurement provided by the Influx Flotrak is one of the many parameters monitored by the FM Environmental SCADA system, assessing the digester status and controlling the effluent feed.
Mark Towner, Managing Director of Influx Measurements, commented: 'Previous designs of variable area flowmeter have not been able to achieve flow transmission output at such low operational pressures.
The unique design features of the Influx Flotrak now allow the lower cost VA (variable area) flowmeter technology to be applied to biogas and digester gas flow applications'.

Verderflex in thick sludge at Scottish Water

2006-12-18T23:19:00.000-08:00

For Brechin Waste Water Treatment Works in Tayside, Verder proposed two Verderflex VF65 peristaltic pumps for discharging from the settling tanks, to replace a Sewpas air system.
In June 2001, MacLeod Consulting in Dundee asked Verder to put forward an alternative pumping solution at Brechin Waste Water Treatment Works in Tayside. Verder visited the site and discovered that the existing pumping system used a Sewpas air system. The application required a 2m suction lift, discharging primary sewage sludge into settling tanks 10m away to feed a filter press.
Discussions with site personnel and the consultants indicated that this system was very old and was unreliable when pumping sludge that contained more than 5% solid content.
As a solution, Verder proposed a design that incorporated two Verderflex VF65 peristaltic pumps, one for each of the settling tanks, with each pump able to act as a standby for the other.
These units were chosen because they can handle up to 80% solid content and can self-prime to a depth of 9.5m.
Verder specified inverter drives for the pumps and hose burst detection sensors to shut the system down in the event of a hose rupture.
Following discussions with the client, Verder were also asked to include a turbidity detection system, to monitor the sludge density between 1% and 12%.
A Dr Lange Solitax turbidity control was chosen and programmed to shut the pumps down when the sludge density read 1.5% or less.
Following approval of the design, the new system was installed in August 2001.
The pumps are specified to discharge 8.2 cubic metres/h, but this can be adjusted by the inverters to suit the current sludge density.
The system is linked to a control panel that includes a series of timers, enabling the pumps to start, run and rest for predetermined times dependent on application conditions.
Since installation, the new system has operated trouble-free and provides Scottish Water with a far more reliable and flexible pumping solution.

Chemical recycling plant for industrial wastes

2006-12-17T02:35:00.001-08:00

The Ecotron chemical recycling plant for industrial wastes developed in Belarus has no counterparts in the world.

The Ecotron recycling plant for industrial wastes developed in Belarus has no counterparts in the world. According to Alexander Matvejchuk, chief of the R and D laboratory of the Amir-C Ecological-Power Company, Ecotron was developed in co-operation with the Lykov Heat- and Mass-Transfer Institute of the Byelorussian Academy of Science. A number of Byelorussian and Russian patents prove the plant's uniqueness.

The plant is designed to recover ecological and power resources from various industrial wastes.

The principle of the plant operation is the chemical reprocessing of industrial wastes transforming them into energy carriers and other industrial feedstock.

According to Matvejchuk, the plant can fully recycle any hazardous chemical waste.

As a result, various products can be manufactured: gas fuel, which is an analogue of the natural one, high quality mazut, petrol, fuel for ships, diesel fuel, and a number of technical products such as carbon black, steel wire, etc The tentative appraisal puts the profits of an enterprise using Ecotron at USD 158/hour and the repay term at no more than half-year.

Breakthrough in hydrocarbon removal

2006-12-17T02:35:00.000-08:00

The innovative and patented ECO electro-catalytic oxidation system has proven to be a large success in oily wastewater treatment, reaching previously unobtainable levels of hydrocarbon remediation.

The innovative and patented ECO electro-catalytic oxidation system from Aquatic Technologies has proven to be a large success in oily wastewater treatment, reaching previously unobtainable levels of hydrocarbon remediation. A recent testing programme at the Scottish produced water treatment plant, serving the North Sea oil fields, showed the ECO pilot plant has successfully super-coagulated oils and reduced total hydrocarbon levels in produced water to below EU 2009 consent levels. Produced water is oily wastewater entrained in drilling muds during exploratory oil well production.

The ECO super-coagulation and oxidation treatment process is applicable to barge ballast water, oil and gas pipeline dewatering, oily process water, washdown water, commercial steam-cleaning stations, also for reducing industrial chemical waste such as residual pesticides, herbicides and chemical dyes in spent process waters, and for increasing biological activity of farm manure handling lagoons, reducing smell to negligable levels.

In the water treatment field, ECO is now in commercial use for recirculating aquaculture, in military use for pre-RO filtration by inactivation of potential biological warfare contamination, and in USDA testing for suppression of moulds/fungus in irrigation water.

ECO has unique unmatchable capabilities to any other treatment system.

ECO operates quietly, runs 24/7, needs minimal maintenance and has no moving parts, only a routine changeout of electrodes on a predictable basis.

Aquatic Technologies has development partners operating the ECO systems around the world.

CERTIFIED TEST RESULTS.

Chemical Name Formula Percentage Reductions Noted in * Tests Results 1: carried out on a batch treatment of NGL condensate resulted in the following percentage reductions in final outflow: Benzene 94%; Ethyl Benzene 100%; Toluene 95%; Xylene 75%; Aromatic Hydrocarbons 90%.

* Test Results 2: carried out on batch treatment of stormwater run-off from an NG transfer station, in South Dakota: HEM Total Hexane reduced by 100% Extractable Material.

* Test Results 3: carried out on batch treatment of oil-barge washout water, resulted in the following reductions in concentration in the supernatant: Total Hydrocarbons 99.96%; Aromatic Hydrocarbons 99.98%.

Scottish Island says No to Sludge Exports

2006-12-16T02:34:00.002-08:00

Following the pioneering installation of an Aero-Fac treatment system at Errol five years ago, Scottish Water Solutions has ordered a similar 2,500 pe plant for Tobermory on the Isle of Mull.

Following the pioneering installation of an Aero-Fac treatment system at Errol five years ago, Scottish Water Solutions has reaffirmed its faith in the process by ordering a similar 2,500 pe plant to be constructed at Tobermory on the Isle of Mull. The Aero-Fac process is a low energy, low maintenance wastewater treatment system that removes the requirement for sludge handling and disposal. A recent report (Ref1), independently produced by the University of Leeds, and shortly to be published in the CIWEM journal, confirmed that, over a 12 month monitoring period at Errol, 99.99% of the solids entering the system were successfully destroyed by the process.

At Errol, not one sludge tanker has passed through the gates of the plant in the 5 years since its construction, nor is it anticipated one will be needed over the remaining lifetime of the plant.

At Tobermory, Scottish Water Solutions are taking further advantage of this feature to process not just sewage from the local communities, but also septic tank sludge collected from outlying areas.

Up until now, a tanker has had to make frequent trips by ferry to collect septic tank sludge for export back to the mainland, highlighting the unsustainable nature of this means of disposal.

Once the Aero-Fac plant is commissioned, septic tank sludge will be deposited at a collection centre incorporated into the new facility, from where it will be steadily pulsed into the primary treatment cell.

Here the sludge will be digested in an odour-free manner; just as will any solids entering the plant via the main sewer.

Many Water Companies estimate that sludge disposal now accounts for up to 50% of the operating cost of a WwTP, so remove this requirement and add the savings to those of low energy consumption through the use of wind power, couple that with minimal operational complexity and it's not difficult to see why theAero-Fac process is attracting increasing attention.

Mobile Centriquip dewatering unit in Ireland

2006-12-16T02:34:00.001-08:00

The Centriquip agent in southern Ireland, Roto Spiral, has equipped a 20-foot flatbed lorry with a CQ5000 centrifuge to provide mobile dewatering services for a wide range of applications. The mobile unit is fully self-contained and has its own on-board generator to supply power to the centrifuge in any location. The company, based in Knocktopher, Count Kilkenny, operates the mobile service through its subsidiary Terra watch and offers a range of services for the treatment of wastewater and other environmental processes such as effluent clarification.

The mobile unit, which is available for both long and short-term hire, can be ready for use within one hour of arriving at the site.

The Centriquip system is operated by fully trained staff who take full responsibility for the entire process.

'These days dumping sludge or untreated effluent into a river or the sea is not an option, so if someone's equipment breaks down it's a serious problem,' says Terra watch director Larry Doyle.

'Our mobile unit can often get someone out of a tricky situation until the machine can be repaired.

We can service and repair any make of centrifuge in much the same way as Centriquip does in the UK and having the mobile CQ5000 gives us the opportunity to show customers just what the latest technology can do,' Larry continued.

The Roto Spiral investment in the mobile unit has already paid dividends and bookings for the hire service are very healthy.

Having the ability to demonstrate a Centriquip decanter to a prospective customer on site is expected to win sales of new equipment in the buoyant Irish market.

Castrol cuts cutting fluid disposal by 80%

2006-12-15T02:33:00.000-08:00

A cutting fluid reprocessing facility, installed and managed by Castrol, has cut waste fluid disposal by more than 80% at the Perkins Engine plant in Peterborough.

A cutting fluid reprocessing facility installed and managed by Castrol, has cut waste fluid disposal by more than 80% at the Perkins Engine plant in Peterborough. Perkins Engines, part of the engines division of Caterpillar, is a major supplier of diesel engines for the industrial, agricultural and power generation markets, with UK manufacturing plants in Peterborough and Stafford and a manufacturing location in Curitiba, Brazil. The two transfer systems at the Peterborough plant have an annual output of 20,000 cylinder heads and cylinder blocks.

A cylinder head machining line supplied by Renault produces 80,000 units.

And a bearing cap machining facility produces 150,000 sets for a variety of different engines.

Perkins has been a Castrol customer for more than ten years and currently uses Alusol XTH soluble cutting fluid to machine cylinder heads and cylinder blocks at the Peterborough site: Castrol supplies metalworking fluids and services to other Caterpillar sites in the UK.

Four years ago the company adopted Six Sigma methodology and applied the system to evaluate the potential for outsourcing fluid management.

Following the review, which included proposals from the existing cutting fluid suppliers, the company concluded that a total fluid management programme would not benefit the business.

However, some of the specific proposals put forward in the Castrol proposal were of interest, and the company decided to progress them in a separate working partnership.

Initially the partnership focused on a specific project, and Castrol was awarded a contract to install and manage coolant reprocessing and laundering equipment in the main metal cutting facility responsible for producing cylinder blocks and cylinder heads.

The performance of the 3-year contract exceeded expectations by generating a substantial cost saving and, more importantly, a significant reduction in the amount of waste cutting fluid that needed disposal.

Commenting on the project, Perkins manufacturing manager Chris Baty-Symes explains that the waste fluid volume was actually reduced from 466,000 litres to 45,000 litres, a reduction of over 90%, adding that whilst cost savings are important, meeting the demanding target of zero emissions to landfill by 2010, set by the Caterpillar environmental policy, was an even greater incentive.

'We expected the environmental benefits to be at least 'cost neutral',' he says, 'but this was a major environmental improvement that was 'cost beneficial' and meant that the equipment paid for itself within the three year contract period'.

He added that the waste reduction improvements achieved in the first twelve months of the partnership with Castrol, not only met the Perkins 2003 target, they also enabled the company to meet its 2006 targets two years ahead of schedule! Needless to say, Castrol retains its contract and continues to manage the reprocessing and laundering system for Perkins.

And, having demonstrated the effectiveness of the products and the technology that it brought to the partnership, Castrol is now working with Perkins to investigate other opportunities to improve the way its fluids are managed.

Castrol contract manager Adam Cavanagh explains that the gains are mutual.

'We are not selling product, we are selling solutions.

The contract we have with Perkins enables us to generate revenue even though we are supplying less cutting fluid.

And it helps us to meet our environmental obligations as part of the BP Group'.

Summing up the relationship Chris Baty-Symes says it is very professionally handled by Castrol, who are extremely focused on the activities they are supporting.

'They have delivered tangible results that are not just financial.

Thanks to the close working partnership we are now disposing of less than 10% of the fluid that previously left the Peterborough site as waste, and that is a huge environmental benefit'.

Elga water treatment solves washing waste problems

2006-12-15T02:32:00.000-08:00

By installing Elga C1000 water treatment cylinders, Superior Seals has eliminated the need to store, handle and ultimately dispose of the potentially harmful chemicals required by the previous plant.

By installing C1000 water treatment cylinders from Elga Process Water, Superior Seals, an internationally recognised UK based manufacturer of precision O rings, seals and mouldings has, at a stroke, eliminated the need to store, handle and ultimately dispose of the potentially harmful chemicals required by the old plant. The new cylinders also take up far less space, than the ageing ion-exchange water conditioning equipment, and maintenance is reduced to simply ordering and connecting a replacement cylinder when the one in use has reached its maximum treatment capacity. In addition, the use of cylinders offers significant cost savings compared with installing and operating a new ion-exchange system.

'This is an excellent solution for us,' said David Payne, Quality Systems Manager at Superior Seals.

'Not only is it very cost effective, the space savings it offers are also invaluable, as we are constantly expanding our manufacturing capacity, and space is always at a premium.

The environmental issues, or rather the lack of them, are another a big plus,' he continued.

'We are a very environmentally conscious company, so the opportunity to eliminate the need to use strong acids and alkalis in our water treatment system was particularly attractive'.

The cylinders are used to purify water supplied to the machines which Superior Seals uses to wash its products prior to packing and despatch.

Three washing machines are currently in use, and a fourth will be installed shortly to handle the rapidly growing demand for the company's products.

Each machine is provided with two Elga C1000 cylinders, one in service, the other on standby.

Flow is switched to the second cylinder when water conductivity checks show that the first is nearing exhaustion, allowing replacement cylinders to be fitted with no interruption to the supply of treated water.

The cylinders are fed directly from the mains water supply, with no pre-treatment.

Elga Process Water offers cylinders with a wide choice of resins, allowing their performance to be accurately matched to user requirements.

For Superior Seals, a standard weak de-ionisation resin is used, which produces treated water with a conductivity 10microSiemens at a flow rate up to 2,835 l/hr.

While this is considerably in excess of the flow currently required, Superior Seals chose C1000 cylinders rather than their smaller counterparts to allow for future expansion, and also to maximise the interval between cylinder replacements.

While some applications undoubtedly need more sophisticated water treatment equipment, the experience of Superior Seals clearly demonstrates that, where the requirements are straightforward, Elga cylinders have a lot to offer in terms of economy, convenience and environmental friendliness.

Petrochemical plant oil-contaminated waste treated

2006-12-14T02:32:00.000-08:00

Surface Active Solutions secures an 18 year deal to treat refinery and petrochemical oil contaminated wastes at Grangemouth using a range of micro-emulsion cleaning product and support services.

Surface Active Solutions (SAS) the pioneering micro-emulsion technology specialists have announced an unprecedented 18 year exclusive supply contract to a market estimated to be worth over GBP50 million across Europe. SAS is to provide Ondeo Industrial Solutions with a range of micro-emulsion cleaning product and support services for the INEOS (formerly BP and Innovene) petrochemical complex in Grangemouth, Scotland. The 18 year contract, covers the use of micro-emulsion technology and the method of application developed and patented by SAS for the treatment and remediation of refinery crude oil slop wastes and other hydrocarbon contaminated wastes from petrochemical processes and installations.

This technology in combination with the latest engineering and expertise available in waste processing from Ondeo Industrial Solutions will bring to the market a wholly new method of waste treatment and minimisation.

It is hoped that the new strategic partnership will be able to greatly reduce the volume of hydrocarbon wastes produced from industry operations, recover the oil for recycling and clean water for disposal along with a small fraction of non-hazardous solid materials.

Laurence Bower, Corporate Vice President and UK Managing Director of Ondeo, stated; 'This is a very exciting partnership as it enables us to offer a complete turnkey service to our customers by funding the installation of equipment, managing the movement and treatment of waste and getting best value from disposal routes.

The combination of the latest separation and mixing technology together with the SAS chemistry delivers significant savings on current disposal routes and offers a sustainable environmental solution.

We are currently processing significant volumes of oily waste and will be rolling out the package across UK and Europe in the coming months'.

John Harrison, Development Director of SAS commented, 'This process demonstrates a huge leap forward in terms of technological achievement in this area of waste treatment which has long been a major challenge for a number of industries.

The technology clearly has the potential to provide a complete and economic solution to many applications in this industrial area in line with ever tightening EU environmental legislation'.

Mark Zwinderman, the Operations Director of SAS added, 'We hope and expect that the formation of this strategic alliance with Ondeo will enable us to diversify the use of our technology into other key areas of application within the industry.

So far our focus has been on the upstream side of the oil industry.

Working with Ondeo will allow SAS to penetrate the downstream application areas.

In addition the process developed by Ondeo and SAS is applicable to many types of oil contaminated wastes and both partners are committed to expanding the process and applied technology to other areas of the oil and gas and other industry sectors.' SAS has been supplying micro-emulsion cleaning products to the global oil and gas industry, primarily in the UK sector of the North Sea, for over 3 years.

The technology has been used in a number of key application areas including WBCU displacements, mud pit cleaning, rigwash applications and in onshore slops treatment.

Thus far the technology has set new industry standards in levels of cleaning efficiency and in environmental performance capabilities, efficiency and in environmental performance capabilities typically reducing the volume of oil contaminated hazardous wastes produced in these cleaning applications by 70 - 100%.

Significant time, HSandE advantages and related cost savings to operators accompany the benefits of implementing the technology on the site of waste production.

Upgrading local NI wastewater treatment works

2006-12-14T02:31:00.000-08:00

Black and Veatch and Dawson WAM are making good progress at a number of rural sites in Northern Ireland for the Water Service Northern Region Integrated Wastewater Treatment Framework.

Black and Veatch, a leading global engineering, consulting and construction company, and its joint venture partner Dawson WAM are making good progress at a number of rural sites in Northern Ireland for the Water Service Northern Region Integrated Wastewater Treatment Framework. Enabling Water Service to reduce the number of small works by redirecting flows to suitably upgraded Wastewater Treatment Works, Loughguile is a fitting example of the type of small-to-medium wastewater projects being undertaken by Black and Veatch, which includes the entire civil, mechanical, electrical and process design - as well as off-site pumping stations, hydraulics and sewerage infrastructure. The decision to contract local companies for completing the projects has provided Water Service with enhanced value, competitive costs and on-time project completions.

In addition, the upgraded systems at Loughguile will employ membrane bioreactor (MBR) technology providing substantially better final effluent quality than conventional secondary treatment.

'Black and Veatch prides itself on our ability to draw upon the best resources to support our clients' needs,' said Niall Rogers, Black and Veatch Project Manager for the Loughguile project.

'The Loughguile project is an excellent example of our ability to bring together some of the best contractors within Northern Ireland to complete this challenging work.' A WWTW serving 30 dwellings at nearby Ballyknock is being decommissioned and replaced by a new pumping station that will direct flows through a new 1,700m pipeline to Loughguile, which serves a 2006 PE of 869 and 2030 enhanced PE of 1,353.

Rogers said what makes the project challenging is the requirement to minimise the visual impact of the new works, so the MBR structures have been built substantially below ground.

In addition, construction must remain within the boundaries of the existing site while the current WwTW stay online and within compliance throughout the construction period.

With space at such a premium on the site, Black and Veatch has been renting part of a farmer's land, which sits adjacent to the treatment plant - an arrangement that has proved mutually beneficial and an example of the importance of working with the community.

'Our success to date is a direct result of good communication among the many project teams and contractors,' Rogers said.

'In addition, open dialogue helps support the local communities at every level.

Working with local businesses and contractors means that residents understand and can discuss the project with team members as opposed to having a faceless workforce on the other side of the fence'.

At the Loughguile wastewater treatment works, control panels and electrical installation have been supplied locally by TES (NI) of Cookstown, whilst mechanical plant installation has been carried out by Shaw Automation Company of Ballymena.

Generators have been brought in from A1 Power Systems of Cookstown, whilst lifting equipment is from Heyn Engineering of Belfast and MBR Installation by Copa Wastewater Controls.

In addition, all fixings and fittings are supplied locally and 'off the shelf,' helping Black and Veatch keep costs competitive and deliver on time.

Elga Process Water cuts costs for Anglian Windows

2006-12-13T23:24:00.000-08:00

A Rapide Strata counter-current short-cycle deioniser is the ideal solution for the Anglian Windows requirements for improved water quality in a new glass soft-coating process.

A Rapide Strata counter-current short-cycle deioniser from Elga Process Water has proved to be the ideal solution to the Anglian Windows requirements for increased volumes and improved water quality resulting from their introduction of a new soft-coating process for the glass used in many products. The new Elga water treatment system is also providing other important benefits, including reduced regeneration time, smaller effluent volumes and substantially reduced running costs. Soft-coated glass has a much better energy performance than ordinary glass but, before the soft coating process can be carried out, the glass must be cleaned to a very high standard.

This requires demineralised water with conductivity of 20micro-S or less.

The existing installation at Anglian Windows - also originally supplied by Elga - had given reliable service over many years but was only designed to achieve 40micro-S.

In addition, its throughput was too low to meet the demands of the new process.

Replacing the existing system with a Rapide Strata 18 deioniser, which has a capacity of 18m3/hr and which produces treated water with an average conductivity of 2micro-S, provided a complete solution.

The new installation has a regeneration time of just 35 minutes, minimising the need for water storage to avoid process interruptions.

In addition, the Rapide Strata installation has a requirement for chemical regenerants which is up to 60% lower, per cubic metre of water treated, than the older system.

This means substantial reductions in expenditure on chemicals, and that less space is needed for chemical storage on site.

The efficiency of the new water treatment installation at Anglian Windows also means that effluent volume has been reduced by around 45% and that the effluent stream is close to neutral pH.

Only a minimum of treatment is, therefore, needed before the effluent is discharged.

These factors result in further cost savings.

'Installing the Rapide Strata system was straightforward,' said David Duncan, General Services Manager of Anglian Windows, 'as the equipment is supplied fully assembled and pre-tested on a skid.

Some modifications were, of course, needed to our existing pipework but, overall, the new plant was up and running very quickly.

From the outset, the results in terms of water quality, reliability and performance have been excellent, and we are naturally delighted to have more treated water of better quality while still being able to reduce costs.

Elga were very sensitive to our needs throughout this project and, without doubt, the company has provided us with a solution that addresses those needs very effectively'.

Elga Rapide Strata systems of the type used by Anglian Windows are available in versions with flow rates of 4, 10 and 18m3/hr.

All sizes feature high-efficiency short-cycle regeneration, and all can be optionally supplied with an integrated polishing device to produce water with much higher quality for very little extra expenditure, if it is required.

New market manager for Veolia Water Solutions

2006-12-13T23:23:00.000-08:00

Veolia Water Solutions and Technologies (VWS) a subsidiary of Veolia Water, has recently appointed Johann Bonnet as the new market manager of its Global Pharmaceutical Group.

Veolia Water Solutions and Technologies (VWS) a subsidiary of Veolia Water, has recently appointed Johann Bonnet as the new market manager of its Global Pharmaceutical Group. Johann will be responsible for promoting VWS products and services to a global pharmaceutical audience and ensuring its business units are kept up-to-date with the latest market information and key company messages. Johann joined VWS in 2001 as a sales engineer and spent five years designing water treatment plants and promoting the pharmaceutical side of the business in Western France.

During this time, he continuously achieved significant turn-over and market share growth goals for the division, almost tripling its turnover during one two year period.

David Dolphin, General Manager of the Global Pharmaceutical Group in Marlow, said: 'I'm delighted to welcome someone of Johann's experience to the Group and I'm looking forward to us working together to promote VWS in the pharmaceutical marketplace.

His background in process water treatment and pharmaceutical process engineering combined with a strong track record of driving business initiatives make him ideally suited to the position of Market Manager'.

'I'm very happy to be to joining the Global Pharmaceutical Group and have the opportunity to work with David and the team,' said Johann.

'It's a privilege to be part of a company that is at the forefront of design and engineering in the water treatment industry and which has established an enviable global reputation in the pharmaceutical sector.

I'm looking forward to helping our global pharmaceutical clients address their key business challenges and ensure our future products and services are developed to fit their needs'.

VWS is a world leader in the design of technological solutions and the construction of turnkey facilities and water treatment plants for municipal and industrial clients.

VWS pure water for pharmaceuticals

2006-12-12T23:23:00.000-08:00

A new brochure from Veolia Water provides a concise discussion of water purification in the pharmaceutical industry, with solutions to meet, reliably and cost effectively, the demanding requirements.

A new brochure from Veolia Water Solutions and Technologies (VWS) provides a concise discussion of water purification in the pharmaceutical industry, and introduces a range of solutions which are specifically designed to meet, reliably and cost effectively, that industry's uniquely demanding requirements. A useful aid to all who specify water treatment equipment for pharmaceutical applications, the eight-page brochure provides a range of key information in a compact and readily accessible format. Illustrated throughout with photographs and diagrams, the brochure discusses the production of purified water, highly purified water, pyrogen free water and WFI as critical processes, and lists the key standards with which water treatment plant for use in the pharmaceutical industry must comply.

It also explains how VWS addresses compliance and validation to ensure problem-free implementation in even the most demanding of applications, and gives details of the company commitment to service: which means that, wherever in the world the plant is installed, performance-critical maintenance, spare parts and consumables, are always readily available.

An illustrated overview of five packaged water solutions for pharmaceutical applications is provided, along with guidance on important selection criteria.

A three-dimensional chart illustrates the relationships between capital investment, life-cycle cost and levels of application risk for each of the solutions, and gives examples of how the chart can be used as an aid to the selection of the most appropriate solution for specific applications.

For a copy of the VWS new brochure describing Pharmaceutical Water Solutions please use the brochure enquiry service.

Veolia Water Solutions and Technologies (VWS) is a subsidiary of Veolia Water.

VWS is one of the major world designers of technological solutions for, and constructor of facilities for water treatment.

With over 6,500 employees, the company has operations in more than 50 countries.

VWS recorded a revenue of Euro1.6 billion in 2005.

Veolia Water, a division of Veolia Environment, is the world leader in providing out-sourced water and wastewater services for municipal authorities, as well as industrial and service companies.

Nitrifying filter helps gain discharge consent

2006-12-12T23:22:00.000-08:00

Vexamus Water has helped Wessex Water meet rigorous new discharge consent for final effluent quality, by using an innovative, continuous filter package, which has a proven track record in Europe.

At Merriott WWTW, process specialist Vexamus Water has helped Wessex Water meet rigorous new discharge consent for final effluent quality. Working in close conjunction with leading civil engineering contractor Morgan Est, Vexamus Water has installed an innovative, continuous filter package, which has a proven track record in Europe. In giving Wessex Water the opportunity to cost-effectively enhance an existing treatment plant, the DynaOXY nitrifying tertiary sand filter has significantly reduced washwater requirements, eliminating the need for storage and collection.

This tried and tested sand filter, which is available in the UK exclusively from Vexamus Water, also benefits from a much smaller footprint than most conventional systems, making it ideal for any site where space is at a premium.

In addition to reducing capital and civils costs, DynaOXY has low head loss, is low on energy consumption, low on maintenance and requires only minimal operator supervision.

Waste water samplers available in Ireland

2006-12-11T23:22:00.000-08:00

Leading international environmental company Bord Na Msna is introducing a growing number of Aquamatic wastewater samplers into Ireland.

Leading international environmental company Bord Na Msna is introducing a growing number of Aquamatic wastewater samplers into Ireland. Compliant with the UK Environment Agency's E32 automatic sampling equipment specification for the Urban Waste Water Treatment Directive, Aquamatic's kiosk-based S2-RK32 samplers are contained within robust and secure glass-reinforced polyester units. Used by Bord Na Msna Environmental, which is the market leader in Ireland, Aquamatic's samplers are a key example of the superior quality technologies and services it has to offer clients in order to help them adhere to increasingly tough legislative requirements.

Designed with sample refrigeration, which is particularly important for biologically active wastewater, Aquamatic's S2-RK32 is suitable for water companies or any industrial user wishing to monitor its effluent for environmental, financial or productivity purposes.

Within a refrigerated, lockable housing, sample collection vessels are stored between 0 and 5C, in order to minimise degradation during the storage period between the taking of the sample and its analysis.

As part of Aquamatic's acclaimed capability for supplying two complete sampler ranges with one sampler module, the stationary S2-RK32 sampler complements the company's portable Aquacell P2-Coolbox (also E32 compliant), which is very convenient for use at remote sites or where no power is available.

New Ledbury WwTW will remove phosphorus

2006-12-11T23:21:00.000-08:00

Biological phosphorus removal to meet UWWTD tightening discharge consent is central to the Biwater Treatment contract at the Severn Trent Water Ledbury wastewater treatment works in Herefordshire.

Biological phosphorus removal to meet UWWTD tightening discharge consent is central to the Biwater Treatment contract at the Severn Trent Water Ledbury wastewater treatment works in Herefordshire. The GBP6.1m project also includes storm water CSO screening at the main feed pumping station and provision for a future tertiary treatment stage. Completion is scheduled for March 2005.

Designed for a population equivalent of 13,930, the new plant will treat a process flow of 132 L/s to a final effluent standard of BOD 10: suspended solids 20: ammonia 3 (summer) and 5 (winter) mg/l.

The process incorporates 6mm screening, grit removal, crude sewage and RAS conditioning, two diffused air oxidation ditches for biological phosphorus removal, final settlement, odour control to the inlet works, RAS/SAS pumping, SAS thickening and new MCC/power distribution.

Helping water companies meet MCERTS Certification

2006-12-10T23:21:00.000-08:00

Bestobell Service, the service arm of Solartron Mobrey, has a new MCERTS package to help water companies meet the Environment Agency's new legislation regarding the self-monitoring of effluent flow.

Bestobell Service, which operates as the service arm of measurement and control sensors manufacturer Solartron Mobrey, has launched a new MCERTS package to help water companies meet the Environment Agency's new legislation regarding the self-monitoring of effluent flow. To assist compliance with The Water Resources Act 1991, the legislation 'MCERTS: Self-monitoring of effluent flow' came into effect on 1 January 2004, requiring water companies to install and maintain reliable flow measurement equipment that accurately measures (to an uncertainty of +/- 8%) all daily discharges from waste water treatment sites of more than 50m3. Having been consultants to the water industry for the past eight years, Bestobell has now created its MCERTS package to help water companies ensure their facilities are compliant.

They will provide independent, product-neutral, un-biased advice on the equipment, installation, data gathering and transmission, and quality procedures.

Paul Cherry, Flow Specialist at Bestobell is the first MCERTS inspector to be appointed: 'Water companies will be assessed by a third party, the MCERTS inspector, who will be required to produce a report stating whether the facility has met MCERTS standard or if additional steps need to be taken'.

Reports submitted to the Environment Agency from 1 January 2004 require MCERTS validation.

The Agency hopes that better effluent flow monitoring will result in a more accurate measurement of pollutants released into the environment.

Water companies will also benefit from more detailed information that can improve the treatment process planning - resulting in increased revenue.

Wastewater sampler passes Yorkshire Water test

2006-12-10T23:20:00.000-08:00

Yorkshire Water completed a comprehensive report the evaluation of a portable wastewater sampler: eventually selecting the Aquamatic Aquacell P-2 Coolbox, which meets the stringent requirements of E32.

Yorkshire Water has completed a comprehensive report on how it went about evaluating a portable wastewater sampler: eventually selecting Aquamatic the Aquacell P-2 Coolbox, which meets the stringent requirements of E32 - the Automatic Sampling Equipment Specification for the Urban Wastewater Treatment Directive. During the winter sampling regime, the sampler was run for twenty consecutive twenty-four hour composite sampling periods at a Yorkshire Water sewage treatment works near Sheffield. The plant treats around 175 MLD of domestic and trade sewage, using two activated sludge plants.

Around half of the samples were taken from the influent sewage, after fine screening and grit removal, but prior to primary settlement.

The remainder were taken from the final effluent sampling point.

Throughout the course of this trial, the Aquamatic sampler performed reliably.

No breakdowns occurred.

The P-2 Coolbox was found to perform identically during winter and summer conditions.

This is in keeping with the findings of a lengthy WRc appraisal, which noted that the sampler was able to achieve a temperature of 0-40C over the range of temperatures expected from the British climate.

Consent met by using small-footprint sand filters

2006-12-09T22:57:00.000-08:00

To help Yorkshire Water meet tighter discharge consents at Balby WwTW near Doncaster, Vexamus Water has installed the UK's first tertiary sand filter with a 7m2 filter area.

To help Yorkshire Water meet tighter discharge consents at Balby WWTW near Doncaster, Vexamus Water has installed the UK's first tertiary sand filter with a 7m2 filter area. Offering the same continuous filter process as smaller units, but with a significantly reduced footprint of the filter package, the DS7000 is part of the renowned DynaSand range, which is distributed exclusively in the UK by Vexamus Water. Serving an equivalent population of 20,000, the Balby WwTW consent was reduced from 30 mg/l to 20 mg/l of suspended solids (new consent: 10:20 BOD:SS).

As well as reducing washwater requirements, DynaSand also improves the process output and greatly simplifies the system.

Handling high suspended solids without the need for pre-treatment, this tertiary sand filter benefits from lower capital costs and eliminates the need for washwater storage, collection or backwash pumps.

UV equipment grows with waste reclamation facility

2006-12-09T22:56:00.000-08:00

Three new bersonInLine systems join three existing systems to meet the increased wastewater treatment demands at the Flat Creek Water Reclamation Facility in Georgia USA.

The Flat Creek Water Reclamation Facility (WRF) in Gainesville, Georgia, USA, has chosen Berson UV disinfection equipment to meet the facility's increased wastewater treatment demands. Three new bersonInLine systems join three existing systems to meet the plant's expanded capacity, treating over 1,875 m3/hour of wastewater for discharge into a local lake. The closed pipe, medium pressure systems, installed by the Berson American sister company Aquionics Inc, provide high efficiency disinfection with the added benefits of online transmittance monitoring and advanced controls.

Flat Creek WRF originally installed Berson equipment in 2001, with three bersonInLine systems treating approximately 1,250 m3/hour of wastewater (80% industrial, 20% low level commercial and residential).

With the area's growth the plant's capacity increased, and with increased capacity came more stringent discharge permit limits.

The new permit issued for a 1,875 m3/hour capacity with a faecal coliform limit of 23 colonies per 100 ml sample was a significant change from its previous limit of 200 colonies per 100 ml sample.

The City of Gainesville and Berson engineers determined that additional UV systems arranged in series would achieve the level of disinfection required by the new permit.

A total of six bersonInLine systems now treat effluent at the plant.

Berson closed pipe systems use high output medium pressure UV technology to deliver a high dose of UV disinfection which destroys microorganisms using fewer and smaller lamps than comparable low pressure systems.

The closed chambers are compatible with both gravity fed and pumped applications, providing low maintenance disinfection with minimal headloss.

The closed pipe design was an important feature for the City of Gainesville.

When first selecting UV equipment for the Flat Creek WRF, representatives from the City's Public Utilities Department visited several neighbouring facilities and examined a range of open and closed pipe systems from various manufacturers.

'The excessive man hours required to keep an open channel unit clean was a large factor in choosing the Berson closed pipe system initially,' said the plant manager.

Ease of handling was another feature in Berson's favour.

Rather than handling an entire bank of lamps at a time, the bersonInLine single lamps may be changed quickly and easily by plant personnel.

To further reduce maintenance, the chambers are equipped with an automatic cleaning mechanism to keep lamp sleeves free of organic deposits.

The new systems feature the new Berson UVTronic microprocessor controls and transmittance monitor, providing real time transmittance values that allow for dose pacing of the UV system.

The control unit records up to 12 months operational data for record keeping and analysis and generates fault alarms to aid in the diagnosis of performance problems.

The controller can also be fitted with a modem connection to perform remote diagnostics on the system for fast troubleshooting with minimal service interruption.

Danish sludge dewatering plant chooses Hanovia UV

2006-12-08T22:56:00.000-08:00

For wastewater disinfection before mixing with a polymer for sludge decantation and dewatering, a municipality in Denmark has installed a Hanovia medium pressure UV disinfection system.

To ensure wastewater is effectively disinfected before being mixed with a polymer for subsequent sludge decantation (separation) and dewatering, the Stege Kommune municipality in Denmark has installed a Hanovia medium pressure UV disinfection system. The wastewater/polymer mixture decants the sludge into two phases as part of the dewatering process. The sludge, which is subsequently used for agricultural purposes, is disinfected by heat treatment prior to decantation, so the wastewater/polymer mixture needs to be completely free from bacteria, viruses and other microbial contaminants.

The treated wastewater is also used to clean the sludge decanter at the end of the process.

To ensure optimum performance, the Hanovia UV system is fitted with a hand-operated wiper.

This keeps the quartz sleeve surrounding the UV lamp free from fouling and means UV output is always at its maximum.

The system has a capacity of 10.8m3/hr.

UV is widely used to remove harmful pathogens from drinking water and wastewater.

It is a completely clean technology which does not rely on the use of chemicals and leaves no unwanted residues or by-products.

Recent research suggests medium pressure UV is more effective at permanently destroying micro-organisms than the alternative method - low pressure UV.

In the research, the two methods were compared and micro-organisms were shown to repair themselves after exposure to low pressure UV, but not medium pressure UV.

This research has serious implications for operators of water and wastewater treatment plant and is one of the reasons why more and more of them are switching to medium pressure UV technology.

Many WWTP can experience both low and high wastewater temperatures at various times of the year.

The efficiency of low pressure lamps is known to fall off significantly at these extremes, and can even fall to zero when the incoming wastewater temperature is below 5C.

Medium pressure lamps are unaffected by these temperature ranges - they always start up easily, show no change in UV output and do not age any quicker than lamps used at 'normal' temperatures.

According to the Hanovia Danish distributor, the Stege Kommune is very satisfied with the performance of the Hanovia system, which was chosen for its quality and fast pay-back time.

chemical industry information

FMA completes another project for Coors Brewers

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Imagine your best operator always on the job!

Rittal saves money on power distribution

Electroless Nickel plating stops corrosion

Tube clamp system suitable for many diameters

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NNE has opened an office in Sweden

USD1.5B coal-to-chemicals design contract for AMEC

FEED/PMC contract for new petrochemicals complex

For a sixth time FW scoops the ECITB ACTIVE Cup

New Crane Flow of Fluids Premium software released

Modular system for Fast-track Pharma projects

New Sales Manager at Dust Extraction International

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Optical analysis system shows interfacial stress

Parts cleaning options with tight budgets in mind

Developing a Trike replacement strategy

New Director for customer equipment modernisation

Lobo Systems safe and secure platform product

Wheelabrator spares and repair service blasts out

New silos supplied for polypropylene storage

Refinery and petrochemicals complex FEED in India

EPC Contract for Refinery Project in Malaysia

Arc Energy is able to weld clad the elbows

Arc Energy is able to weld clad the elbows

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Stabilising plinth addresses health and safety

Conservation and preservation on a concrete bridge

Forged vessels designed for strength and longevity

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Coated Magnesium passes 2000 hour corrosion test

Monitor ensures welds are clean

Tanker offloading facility successfully installed

Big contract for odour control project

More stainless cabinet solutions

New Atex Turbolite Airlamp range

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Coating prevents mould corrosion and adhesion

New website for high-pressure engineers

Process plant integrity monitoring

Hygienic stainless steel manways

Innovative stainless tank construction

Apticote delivers rally championship performance

New surface coating technology centre

Bespoke fittings manufacture

New sample changer from Metrohm

Manage multiple projects with Mathcad

New pump enables affordable water recycling

Cross filter improves sewage treatment efficiency

Piano wire screens in tune with productivity

Reliability on Beverley sludge at the WwTW

Dewatering decanter range completed

Feed forward control of chemical dosing

Eight year success for non-stop submersible mixers

Balancing act at Aillwee Cave by Landia aerator

Pulsar Sludge Finder is a blanket success

Water extracted from raw sewage to clean screens

Innovative cover design for inlet tanks

Automatic filtration ensures clean intake screens

GRP tank covers installed in a single day

Structural monitoring system for scraper blades

Pulsar Sludge Finder is a blanket success

VSD units improve sewage plant efficiency

Balancing act at Aillwee Cave by Landia aerator

6th 'Sewers For Adoption Guide' for Mayday

Measuring level with non-contacting ultrasonics

Sewage flow metering in ductile iron pipes

'Poma' submersible pump suited to narrow sumps

Fabrication contract for sewerage equipment

Single relay option available with MultiRanger 100

Inlet works pumps offer self cleaning sumps

Pulsar ultrasonics go deep and narrow

Level control for 250 Beijing subway wetwells

Can cured-in-place linings reduce infiltration?

Third UK membrane bio-reactor filtration project

Package wastewater treatment plant in Scotland

Poultry plant uses Mono Muncher to reduce waste

Wastewater plant control for Robin Hood Airport