Bürkert Academy As process control systems continue to advance and the use of complicated networked solutions develops, is there still a requirement for the simple analogue signal? FREE Solenoid Valve Selection Chart The useful chart includes the core product range with useful information like water vapour pressure table and flow rate. Brenntag Application Story Boost in efficiency for top chemical October 2014 distribution company. 2 Hello, Welcome to the latest edition of INSIGHT We are nearly two thirds of the way through the year already, time never stands still. In the same way business never stands still as there is always something new to take on board, new ways of dealing with business and new developments. One development in recent times has been the trend to internationalise projects where a company in the UK might expand their production facilities. This project may be engineered in another country and the equipment may be made in a third country which brings a challenge when trying to deal with different companies in multiple countries. This is a situation where Bürkert’s strategy of segments comes into its own. As you may know, we are unique in dividing our business by application segments and not product segments. We have hygienic, water, gas and micro segments and we have Global Segment Managers who are application specialists available to help and assist. We also have Segment Managers at almost every Bürkert company around the world. This gives us a fantastic team of dedicated colleagues who can work together across international borders to help us be successful in these types of projects. This has helped us directly in the UK with projects that we have been successful with. In some cases it is up to us to help one of our sister companies in a project, this will lead to them getting a big order rather than us here in the UK. However this is balanced by the help we get in return for the next project. It is all part of making Bürkert as a group more successful internationally. Co-operation between our colleagues internationally helps us grow stronger as a company, passes on experience and knowledge, builds bridges and helps keep us ahead of our competitors in this new global market place. Content 03 Bürkert Steam Training - Back by popular demand! 04 Bürkert Academy Control signals - which option is best? 05 Bürkert Academy continued 06 A Day in the Life of 08 Free solenoid valve selection chart offered by Bürkert 09 Brenntag Application Story 10 Challenge the Process 10 Bürkert Competition 12 Meet the Team Bürkert INSIGHT The Newsletter October 2014 3 Bürkert Steam Training - Back by popular demand! Bürkert offer a free two-day steam training course. The next session of steam training for 2014 is being held on Wednesday 19th & Thursday 20th November 2014. In addition to an outstanding, proven technical seminar, enjoy Bürkert hospitality with delicious lunches and a Bürkert goodie bag. This is a great networking event which attracts consultants and end users associated with steam applications. What to expect The two-day course provides theory based learning, backed up with practical applications, for a hands-on approach. Bürkert uses examples and case study materials throughout the course to highlight typical applications. Subjects covered The course will cover the following topics amongst many other subjects: • • • • • • • • • • • • Steam fundamentals Steam as a heat transfer media Heat exchange applications Steam piping and condensate loop design Best practices for new and legacy systems Saving steam and green initiatives Communications protocols Control valve selection and comparison Steam control loops Steam solutions & safety considerations Steam FAQ & troubleshooting Steam sampling systems; pure or culinary steam Why is it free? One of the reasons we decided not to charge for training is that it removes a barrier to people attending. Delegates’ expectations are more than surpassed after each course. To view a short video about our steam training, please visit www. burkert.co.uk. You will see the steam experts and gain an idea of what to expect from the training. The steam course covers best practice and useful tips All delegates receive a free steam pack to take away. Included are useful items such as the Steam Site Guide. For further information, please contact Helen Christopher, Bürkert UK Marketing Manager: E-mail: [email protected] Bürkert INSIGHT The Newsletter October 2014 4 Bürkert Academy Control signals - which option is best? As process control systems continue to advance and the use of complicated networked solutions develops, is there still a requirement for the simple analogue signal? Chris Hoey of Bürkert, provides an insight into selecting the correct control signals to produce the optimum process control system. It is about twenty years since the industry ‘experts’ stated that 4-20mA would disappear from the market, to be replaced by digital networks or fieldbus solutions. Whilst there is some truth that networked systems have taken a large portion of market share, 4-20mA is still alive and kicking. There are two main reasons for this; firstly that higherpriced intelligent sensors, made for specific networks are not always the most cost effective options, nor are the ‘smart’ features on offer from intelligent field devices always wanted or required. Secondly, the process control industry has changed significantly, with much more automation being installed into smaller plants, like food processing, water treatment, remote monitoring, etc. It could be said that 4-20mA was the last truly universal signal, accepted by every system, every vendor, and every control component. This means that single control loops, small plants and transportable skid-type equipment will always have a need for the simple, lowcost solution that 4-20mA offers. Versatility Let’s not forget just how versatile this ‘simple’ signal is. It uses just two wires to transmit the signal, it can power the field transmitter with its own supply voltage and it can run for long distances on standard cable. Using the live zero Bürkert INSIGHT The Newsletter (4mA instead of 0mA) it senses a cable break or instrument failure, it is not overly susceptible to noise, it is highly accurate and low-cost. The downside is that two wires can only carry one variable or instrument. However, as the number of control loops increases, the costs start to multiply, as you need individual cables, glands, terminals and inputs for every element. As well as the hardware, the space it requires and most importantly, labour to design, install and commission, which makes it uncompetitive versus fieldbus networks in applications with many sensors and feedback devices. It is different for every installation, but there is a point where the change from an analogue to a digital network becomes more cost effective. Fieldbus By using fieldbus networks, you can now have thousands of inputs and outputs on a single cable. This reduces the infrastructure that you would have needed for a traditional system and can save up to 50 percent of project costs, even though the actual hardware becomes more expensive. By using smart field equipment, the entire transmission of the signal is digitally accurate and generally there is configuration and often diagnostic data available. For large plant October 2014 design, especially for heavy industry like petrochemical for example, this methodology is ideal The downside is the number of choices that a process designer has to make when designing these systems; the first being which network, as you cannot easily mix networks on site. Whilst the most popular networks used are not proprietary, they are still not available from all vendors, which starts to limit choices in components, even though they may be better suited to the application. For these reasons, it is rare to see a site that utilises only digital networks, however almost every larger site does use fieldbus technology. This leads us to the most common installation, the hybrid system. Hybrid solutions The hybrid system incorporates both technologies. The 4-20mA is used in the field, which keeps the components generic and lower cost, and then the signal is fed into a field Input/Output (I/O) panel where these signals are clustered and then transmitted to the central control via fieldbus. Without doubt, this system is the lowest cost to implement and simple to understand and maintain. The only downside for a network that is not fully digital is that you most likely won’t get configuration or diagnostic information from the field 5 instrument, but the upside is that the instrument itself will be considerably lower cost. In order to clearly show where each communication option may fit, let’s look at an example Crucial Advice There is no perfect fit for all situations. There are many considerations that weigh into the correct selection of the site signal wiring, with cost being just one. Always seek competent advice and develop a tool that will estimate the total cost of the installation, including hardware, software and labour. Then consider whether it will be easy to commission and maintain, and whether you have the competence on site for fieldbus technology. As explained above, Bürkert has solutions for all options, so we have no bias towards one or the other, just a commitment to delivering the best value and long term reliability. Analogue in practice Imagine a single flow control loop; say it’s the water feed to another process that needs to be maintained at the same rate. We would choose a flow meter based on the application requirements, with 4-20mA output. To control the flow, we’d choose a modulating control valve with 4-20mA input. But to close the loop, we need a Proportional Integral Derivative (PID) controller between these two instruments that can be configured to the application; this will need a 4-20mA input and output - done. Now let’s say there are 15 of these loops, all identical, and the plant manager wants to monitor and record the flows in the system (assume a PLC & SCADA layer). Using 4-20mA, we would now need to send 15 signals to the PLC, plus 15 signals out, needing 6-8 input cards and as many as 90 terminals, 30 glands, cable tray, panel space, power supplies, signal isolation, etc. Now this option starts to become more expensive. The digital option Let’s try fully digital. We will choose a fieldbus protocol, such as Profibus. We will need to install a Profibus master at the PLC (unless it is incorporated) and then choose a flow meter that has Profibus, as well as a control valve that has Profibus. So now we have one slot in the PLC rack, one gland and one cable to all the devices. The PLC can now read the process signal and control the loop as well as log the data, via the 30 fieldbus nodes. even allowing for the I/O cluster hardware. For this example the hybrid design provides the most cost effective solution. Best Practice The really interesting thing is that Bürkert has solutions available for each of the options above. The customer can choose the installation that best suits them. But, what if this customer came to Bürkert with this application at the design stage? We would choose flow meters with 4-20mA output (8035) and feed these directly into our modulating valves (2301) with Profibus enabled positioner and optional inbuilt PID controller (8693). This device would control the flows directly as well as transmit process, output, configuration and even diagnostic data to the PLC, via just 15 fieldbus nodes. This ‘Bürkert’ solution, although being partly hybrid, would give all the functionality of the fully digital system, yet be around 30% lower cost than the cheapest option above; a good example of smart solutions. The only downside is that the field equipment is now more expensive, sometimes considerably, and specific to Profibus, so if the plant changed to Ethernet in two years, the field equipment would have to be discarded or a customized network-network gateway would need to be installed. This design is far more complex and may require highly qualified maintenance engineers. The hybrid solution would be to use the original lower-cost field equipment, but to wire them directly to a local (field) I/O panel that converts them to Profibus and transmits them to the PLC. You get the cost savings of the installation, with lower cost field instrumentation, Bürkert INSIGHT The Newsletter October 2014 A Day in the Life of... Paul Barker Daphne Denley Warehouse Operative at Internal Sales Engineer at Burkert UK & Ireland Burkert UK & Ireland When did you start working at Bürkert and which department to you work in? I joined Bürkert on 3/11/2003, it was my birthday and so one of my first tasks was to buy the ‘birthday cakes’. My job is in the warehouse and logistics as part of the Service and Operations team. I joined Bürkert in 2005. I was taken on as an Internal Sales Engineer to provide Service and Technical Support for customers. I was looking for a fresh new challenge, which would help me to progress my career and offer an exciting and interesting change. What are the major tasks in your job? The main task is to ensure swift movement of goods in and out again to our customers. My main tasks are supporting the Key Account Customers, with their enquiries. Providing detailed quotations and technical support, by specifying products to suit their application requirements. Where necessary, obtaining new part numbers for special variants of products from the factory and from the Engineering Team in the UK for special/bespoke engineered solutions. What do you enjoy most about your work? Going home, but seriously, it is good to finish at the end of the working day knowing that our customers will be happy when they receive their orders on time! I enjoy helping my colleagues, our customers and get huge fulfilment from being able to successfully answer queries and enquiries. It is very satisfying for me, the customer and Bürkert, when we achieve the ultimate end result and win new business. It is great that Bürkert’s range of products are constantly growing, up-dating and adapting to suit the market place and new technologies. What is the biggest challenge? The biggest challenge is juggling all the tasks that need doing at the same time, from booking in shipments to stock location and then picking parts for shop orders for the assembly department and customer’s orders. Keeping a tidy and organised workspace and warehouse is also very important to enable us to respond swiftly to the requests of our colleagues and customers. There are many challenges in this role, but the biggest challenge is keeping up with the enquiries and workload, as it is very demanding and often busy, especially when the telephone is red hot and the e-mails are pouring in. What do you like best about working for Bürkert? All the team here in GB and knowing that there is the support of the Bürkert organisation worldwide behind you all the way. Bürkert INSIGHT The Newsletter October 2014 As well as the job itself and the customer contact, the products themselves are quality and Bürkert are a Global success story in my opinion, for which I am grateful to play my part, hopefully for at least another 9 years to come. The best for your RO-System Intelligent, modular solutions for monitoring and controlling the reverse osmosis process Monitoring of your reverse osmosis process can be so easy! With the multichannel controller you can monitor any parameter needed for the process – such as pressure, flow, pH-value, ORP, conductivity or free chlorine. Furthermore, with the mathematic functions it is possible to calculate important process parameters like TMP (trans membrane pressure), rejection rate or recovery rate. The choice is yours. Sensors for flow monitoring, pressure control and analytical control (pH, ORP, conductivity, chlorine) multiCELL 8619: Multiparamter controller/transmitter with data logging and math functions – wall, pipe or cabinet mounted versions Want to know more? Please call +44 (0)1285 648720 or email [email protected] www.burkert.co.uk 8 Free solenoid valve selection chart offered by Bürkert Solenoid valves play a vital role in controlling a multitude of processes across a wide range of industries, which means that the basic design has to be adaptable to suit a variety of temperatures, pressures and media in order to provide reliable service. Bürkert Fluid Control Systems aims to help maintenance engineers and designers in selecting the correct design for their application with the release of a free reference guide. With solenoid valves designed to work in both liquid and gas control systems, the guide offers conversion tables for water vapour pressure, temperature, pressure and kinematic viscosity as well as details on flow rate calculations and information on the available valve bodies, seal and diaphragm materials. the material used to manufacture the valve body and its seals which dictate its suitability for controlling various media types. The chart also indicates the suitability of each solenoid valve for operation with gases, liquids or both and lists any special features associated with each product. The solenoid reference chart provides details for direct acting and servoassisted valves, giving information on process connections, working pressures and temperatures, as well as The latest range of solenoid valves from Bürkert can be selected from a standard build or specified for a particular application, all variants offer excellent operating characteristics and reliability. 2 mm Direktwirkende Klappankerventile Direktwirkende Kipphebelventile Servogesteuerte Kolbenventile 150 4,8 14,5 20,3 0,2 29,0 0,3 39,2 0,4 52,2 0,5 160 69,6 6,2 0,6 89,8 7,9 0,8 180 190 114,6 Chart_Magn 10,0etventile_ Umschlagse 12,5 15,5 1,0 iten.indd 2 145,0 1,3 181,3 1,6 Servogesteuerte Membranventile 19,1 1,9 277,0 23,2 2,3 230 336,4 28,0 2,8 406,0 - M5,G1/8, NPT1/8,SFB 0...21 0...2,1 -10...+100 M5,G1/8...1/4, PIC,NPT1/8,SFB 1,2...2,4 S - S S S 0...10 0...1 S S N N x - -10...+100 - x 1,2...2,0 - - G1/8...3/8, NPT1/8...3/8,SFB S S S S 0...25 0...2,5 S S N N x - -10...+180 - x 2...6 - S S N S A S S A x - - x - S FFKMnuralsSitzdichtung A S A A x - - x - PTFEnurbisDN2,0;FFKM nurSitzdichtungundDN2,0 0285,2200, z.T.0255 6013 2/2 6014 3/2 - G1/8...1/4, NPT1/8...1/4,SFB 6027 2/2 - G1/4...1/2, NPT1/4...1/2 0...16 0...1,6 -10...+120 1,5...3,0 S S S 0...30(100) 0...3(10) -40...+180 2...12 S S N N A S S N x - o x S S N N N N S N x - x x - Mediengetrennt x x 0124,0332, 0780,0788 Mediengetrennt Mediengetrennt 2610 2/2 - G1/4...1/2, NPT1/4...1/2 0330 2/2 3/2 0...10 0...1 -200...+180 6...10 - G1/4,NPT1/8 0...16 0...1,6 -30...+90 2...4 S S N S SFB 0...16 0...1,6 A S N A x x -30...+90 2...3 S S N N A S N N x x x x 0125,0333, 0780,0788 S x x x x 0789 BisDN8,mediengetrennt 0323,0223 Mediengetrennt 0331 2/2 3/2 0121 2/2 3/2 - G1/4,G3/8 0131 2/2 3/2 0...4 0...0,4 -10...+90 2...8 N - S S G3/8...1/2 N 0...3 0...0,3 A S N -30...+50 10...20 S N S N S S N N x x x A S S N x - o - 6240 2/2 - G1/4...1/2 5404 0...16(25/40) 0...1,6(2,5/4) -40...+180 2/2 6,12 1,0 S S N G1/2...1 N 1...50 0,1...5 -10...+90 12...25 S N N S N A S N x - - x - N N N N N S N x - - x - x - FlanschausführunginGG 0404 2/2 1,0 G1/2...21/2, NPT1/4...2,DINFlansch 0406 0...3 0...0,3 -10...+90 12...50 2/2 1,0 G1/2...1, DINFlansch S 1...12 0,1...1,2 -10...+180 13...25 G1/2...2, DINFlansch S N N N 0...10 0...1 N N S N x - -20...+180 - 13...50 S N N N N N S N x - - x - FlanschausführunginGG 0407 2/2 - 0340 3/2 0,5 G1/4...11/2 0,5...16 0,05...1,6 x 8...40 - 2/2 - (HP00) 0...+90 6213EV G1/4...2, NPT3/8...1 S N N S 0...10 0...1 N N N N FlanschausführunginGG, festgekoppelt x - -30...+120 - x 10...40 0342,0786 S S N S Pilotmediengetrennt S S N N x - - x - Federgekoppelt N N x - - x 0280,5281 6281EV 5282 2/2 2/2 2/2 0,5 0,2 G3/8...2, NPT1/2...1 G1/2...2,NPT1/2...21/2, DINFlansch G1/2...21/2, DINFlansch PIC = Push-in connection | SFB= Specific flange Bürkert / Bürkertspezifisches Flanschbil d universell für Gase + Flüssigkeit en 0,2...16 0,02...1,6 -30...+120 13...50 S S N S 0...16 0...1,6 S S -30...+120 12...50 S S N 0,2...16 0,02...1,6 S S S N N x - -30...+90 - x 13...50 - S S S1 S S S N N FlanschausführunginGG, festgekoppelt x x x x - FlanschausführunginGG, Pilotmediengetrennt S = Standard | A = auf Anfrage | N = nicht verfügbar | 1 = Kunststoff Gas- und/oder Dampfanwendungen 26/09/2014 13:23:43 ausführung: Typ 0142 * nur als Dichtungsmaterial | x = geeignet | o = bedingt geeignet | - = nicht geeignet geeignet für Wasseranwendunge n 577,1 26/09/2014 13:23:43 October 2014 Anwendungsbereich Besonderheiten und Ausführungen Vorgängertyp Neutrale Gase Verschmutzte Flüssigkeiten Aggressive Flüssigkeiten FFKM* Neutrale Flüssigkeiten FKM PTFE* NBR EPDM VA Kunststoff Nennweite [DN in mm] Medientemperatur [in °C] Druckbereich [in bar] [in MPa] Prozessanschluss Erforderlicher ∆p [in bar] Typ 2/2 3/2 0290 240 33,5 3,3 485,8 INSIGHT The Newsletter 250 39,8 4,0 Medien 224,8 210 220 Referenz: Sattdampf Dichtungsmaterial Membranmaterial 6011 psi 0,1 0,1 170 alleSprachenDE-EN-US-ES_Selection Bürkert MPa Gehäusematerial 6012 Druck °C 200 Funktion Art 14|©ChristianBü 2014|Druck03/20 894433|Stand03/ Direktwirkende Hubankerventile bar • Broschüren pfdrucktabelle1,0 100 • Wasserdam hnung • Druckumrec 110 hnung 1,4 umrec eratur Temp • 120 osität 2,0 • KinematischeVisk 130 erte 2,7 • Durchflussw fürGehäuse • Kunststoffe 140 toffe werks3,6 • Dicht-&Membran 101 mm Magnetventile im Überblick e Magnetventile Temperatur 102 mm Messing 4 mm rkertGmbH&Co.KG Wasserdampfdrucktabell . t-Contromatic G.m.b.H Schweiz Bürker Diefenbachgasse1-3 1150Wien Österreich 33 z Tel.:+43(0)1-89413 00 1(0)41-7856666 Fax:+43(0)1-89413 41(0)41-7856633 [email protected] @buerkert.com www.buerkert.at uerkert.ch For a copy of the selection chart or for further product details, contact Helen Christopher, Marketing Manager, either by email helen.christopher@burkert. com or by phone +44 (0) 1285 648720. 103 mm rt Selection Cha -Contromatic AG 1 ünenbergZG With a wide range of materials, electrical connections, coil designs and voltages, the complete product range is designed to meet most application criteria. 9 Success Story Bürkert <> Brenntag: Boost in efficiency for top chemical distribution company When Brenntag, a global market leader in chemical distribution needed to replace its effluent monitoring and batch control systems, it turned to Bürkert for the complete solution. The end of life equipment was in need of replacement and improvement at the same time; a task that required expert knowledge of both design and installation. The result was a more efficient plant which complied with local water authority requirements as well as a recommendation to repeat the design at another facility. The end-of-life equipment at Brenntag was in need of replacement and improvement at the same time. The company is required to provide the local water authority with regular pH and flow readings for its discharge of effluent; however, this had become a time-consuming and inefficient exercise. Brenntag decided that a new system was required that would provide automatic pH readings, pH adjustments and flow readings — all of which could be logged and reported to the local water authority. In addition, possible improvements were identified with the batch control systems for producing sodium hypochlorite, sodium hydroxide and hydrochloric acid. The entire project was awarded to Bürkert. Having made the initial site visit to establish the scope of the project and establish the design criteria, Bürkert designed a complete system that included pH sensors and level sensors in the tanks as well as on/off valves for the chemical dosing equipment and flow sensors on the discharge pipework. This was all controlled by a bespoke, custom-built panel that included a programmable logic controller and a human-machine interface. The control system was specifically designed for Brenntag and the software specially written to meet the client specifications Key benefits of product application Working closely with the site maintenance team, Bürkert was able to install the new equipment without disrupting the production process and also ensuring that all the necessary records for the local water authority were maintained. This did entail some out-of-hours working, but the end result was an updated and improved control system that incorporated the latest design and components to ensure long service life. Once commissioned, the finished control panel continuously monitors the pH readings and records them along with the discharge flow rate. Bürkert If an adjustment to the pH reading is required, the dosing pumps are activated and the calculated amount of chemical added to the tank, based on the tank level and the required pH reading. The overall effect has transformed the effluent plant into a very efficient process that also exceeds the requirements of the local water authority. The system now allows the operator to select the preset volume to allow automatic filling of sodium hypochlorite. The completed installation has improved production efficiency and reliability. INSIGHT The Newsletter October 2014 10 Challenge the Process “Challenge the Process” is a key activity that should involve every employee. By encouraging participation the company will benefit from improved processes and the employees gain satisfaction from seeing the improvements implemented. We can all contribute by putting imagination and vision put into practice. Not every idea will work, but using the collective resources will lead to successful innovation and companywide benefits. Challenge the Process is the practice of business growth. If we are unable to adapt, change and grow, it becomes more difficult for Bürkert as an organisation to produce better results over an extended period of time. However, it is crucial that any changes within a process do not affect the values or standards of the company. These are specifically set very high and form the core of the company and its reputation. The aim of this philosophy is to maintain those systems that work well and find improvements for those which are less efficient. By discovering and implementing new and improved methods Bürkert strives to constantly innovate, improve and grow. reporting on results and more time on pursuing new possibilities and encouraging new ideas. As leaders, there are several ways we can help others embrace the process and see the benefits of challenging the way things are done. Challenge the Process is more than discussing new ideas and possibilities. Once a consensus is reached, it should be acted upon in a timely fashion. We should encourage open dialogue to ensure that innovative ideas get a fair hearing. Holding Kaizen events involving those people who actually do the tasks is a particularly effective way of achieving this. The people directly involved in the process are much better placed to challenge the process than others who merely see the process from a remote viewpoint. Remember, some ideas work and some do not. People must be allowed the opportunity to do some experimenting. Andy Reid, Logistics Manager Employees should be encouraged to question assumptions. When a suggestion is made as to how a process will work better (or how it won’t), give them the freedom to justify their beliefs. Innovation and growth requires discipline and thoughtfulness. Less time should be spent in reviewing and The Bürkert Customer Survey 2014 If you have purchased a Bürkert product this year, you are eligible to take part in a customer perception survey. Bürkert is seeking ways to improve the service provided to you and so the results of the survey will be reviewed internally and included as part of our continuous improvement process. There are 5 easy questions which should only take you a few Bürkert INSIGHT The Newsletter seconds to complete, as a thank you for completing the questions, your details will be entered into a prize draw to win £250 of John Lewis vouchers. The closing date is 28th November 2014. Your time and feedback are appreciated To take part visit: www.burkert.co.uk October 2014 InspIrIng ansWers | Type 8905 – Online analysis system “Who‘s to say that you have to constantly keep an eye on a number of different meters to guarantee clean drinking water?“ With our new Online Analysis System Type 8905, this is no longer just wishful thinking. Compact and modular, it meets all water sensor system needs from a single source – at a single glance. www.inspiring-answers.com Please call +44 (0)1285 648720, email [email protected] or visit www.burkert.co.uk Meet the Team by going to www.burkert.co.uk or email [email protected] to find your representatives Contact Details! Please take a few minutes to update your records with Bürkert UK’s contact details:. Bürkert Fluid Control Systems Fluid Control Centre 1 Bridge End Cirencester Gloucestershire GL7 1QY United Kingdom Tel: +44 (0)1285 64 87 20 Fax: +44 (0)1285 64 87 21 email: [email protected] Web: www.burkert.co.uk
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