cpp – Process technology for the chemical industry 02.2019

02-2019
10 COVER
CLEAR SIGNALS
FOR LNG
20 INDUSTRIAL INTERNET
WHEN EVERYONE SPEAKS
ETHERNET
38 FERTILISER
FLUIDISED BED SPRAY
GRANULATION
52 IN-LINE MEASUREMENT
NO DEAD SPACES AND
NO BLOCKAGES
PROCESS TECHNOLOGY FOR THE CHEMICAL INDUSTRY
WWW.CPP-NET.COM

SEPARATION
HOW CAN A CONTROL
SYSTEM ADD INTELLIGENCE
TO YOUR OPERATIONS?
METRIS addIQ CONTROL SYSTEMS
Metris addIQ control systems, part of
the ANDRITZ digital solutions offered
under the Metris technology brand,
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costs for both new and existing
processes. The portfolio ranges from
smart sensors to collect all relevant
operational data, to sophisticated
data analytics to turn data into
relevant information, to augmented
reality that visualizes the information
for the operator. Whatever you
demand, may it be predictive
maintenance, process monitoring,
troubleshooting, long-term trending,
or any other automation challenge,
your ANDRITZ specialist will help you
to find the perfect solution.
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ANDRITZ AG / Stattegger Strasse 18 / 8045 Graz / Austria / andritz.com/separation

cpp
EDITORIAL
First time in
Shanghai
Achemasia 2019 is setting new standards. Long before the event
opens on 21 May 2019 for three days in Shanghai, the booked
exhibition space already exceeds the final count for the 2016 event.
With about 400 exhibitors from some 20 countries, it will focus on
an exchange of experience between scientists and engineers as well
as between equipment suppliers and users. Achemasia is a prime
opportunity to discover more about current trends in the Chinese
market and see what the Chinese industry has to offer. Especially in
the area of digitalization, China is seen as a global leader and that
will soon show in the process industry as well.
Apart from the move to Shanghai, where Achemasia will take place
at the NECC for the first time, participants can look forward to a
couple more novelties: the International Expo and Innovation
Forum for Sustainable Chemical Production will cast a spotlight on
the latest technologies in this field. Making the process industry
more sustainable means using less resources and less energy; efficiency
in production processes is increased by implementing energy
recovery measures and by using better catalysts and optimized
equipment. It means designing processes from a holistic perspective
while making use of new digitalization and modelling approaches.
Our preview of Achemasia starts on page 30 with a very interesting
article from Andritz dealing with the so-called Metris technology,
an IIoT solution for solid / liquid separation equipment and systems
featuring advanced digital control. Thanks to this technology,
proactive measures to prevent shutdowns and improve monitoring
can become reality by applying smart sensors, big data analytics and
visualisation using both virtual and augmented reality.
CMX 2000
/// Inline mixer for rapid
and homogeneous
incorporation of powders
into liquids
IKA-Werke GmbH & Co. KG
Phone: +49 7633 831-0, Fax: +49 7633 831-98
eMail: process@ika.de
www.ikaprocess.com // IKAworldwide
Günter Eckhardt, Editor-in-Chief
cpp 02-2019 3

cpp CONTENTS 02-2019
10 Cover Linde is
building a medium-sized
natural gas liquefaction
plant near the Russian
Baltic Sea town of Portovaya.
Vegaflex 86 and
Ve gaswing 66 are ideal
for level measurement in
this application.
22 Every operator wants
to benefit from the added
value of cloud-based
evaluations. The Namur
NOA concept explains
how this is possible.
38 The waste-free production
of fertiliser from
phosphorus-containing
ashes using fluidised bed
spray granulation.
INSTRUMENTATION, CONTROL, AUTOMATION
10 COVER Clear signals for LNG
Vegaflex 86 – robust guided radar sensors ensure
measurement accuracy in LNG production
14 Get the most from your level measurement
Selecting the right measurement technology to
maximise operational efficiency
18 In-line sensors for bio processes
Monitoring critical process parameters in upstream
processes
FOCUS: IIOT IN CHEMICAL INDUSTRY
20 When everyone speaks Ethernet
Seamless communication from field to enterprise level
22 Implementation of the NOA concept
Security by design is mandatory
25 PRODUCTS
28 Valve island 4.0
High availability and safe shutdown in the
pharmaceutical industry
30 How separation processes profit from IIoT solutions
Intelligence for machine and process control
PROCESS ENGINEERING
36 Design software for mass transfer columns
Packings and trays
ENVIRONMENTAL ENGINEERING
38 Fertiliser from phosphorus-containing ashes
Waste-free process using fluidised bed spray
granulation
PLANTS, APPARATUS, COMPONENTS
44 Efficiency throughout the line
Dry vacuum systems for the centralisation
of vacuum supplies
46 More efficiency for asset management
Predictive and preventive maintenance
PHARMACEUTICAL ENGINEERING
48 Goodbye manual work
Automated particle measurement in the hot air tunnel
50 Modular mills adapted without specification sheets
From laboratory to process
52 No dead spaces and no blockages
In-line measurement technology instead of
instrumentation with tees
54 Microencapsulation of active ingredients
Electrostatic spray drying combines drying
and agglomeration
4 cpp 02-2019

46 The availability of
digital technologies
which enable predictive
maintenance brings
more efficiency in asset
management.
54 Using an electro -
static spray drying process,
sensitive pharmaceutical
ingredients can
be microencapsulated
especially gently.
OUR ENGINEERING IS
YOUR SYSTEM SOLUTION
Rapid delivery
Made in Germany
ISO 9001
COLUMNS
3 Editorial
4 Contents
6 News
33 Trade Fair Preview Achemasia 2019
40 Trade Fair Review Powtech 2019
57 PRODUCTS
58 Advertisers
58 Contact the Editors
58 Imprint
WWW.CPP-NET.COM
More news, facts, products and
solutions for the process technology
in the chemical industry can be found
on our Internet page!
www.cpp-net.com
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cpp 02-2019 5
Pump Technology · Metering Technology · Coupling Technology

cpp
NEWS
Picture: Bilfinger
Picture: Zeppelin
Strong order book
BILFINGER CONTINUES GROWTH COURSE IN 2018
Tom Blades is Chairman of the Executive
Board of Bilfinger SE
Industrial services provider Bilfinger continued
to grow in the financial year 2018.
CEO Tom Blades: “We delivered on our
2020 strategy and on our commitments to
both internal and external stakeholders. I
am particularly pleased with the successful
conclusion of the DPA and our Monitor’s
Certification that Bilfinger is on an irreversible
course towards compliance self-sufficiency.
I think we can confidently say that
2018 was a year of achievement for Bilfinger.”
Bilfinger continues to fine tune and adopt
its 2–4–6 Strategy to better serve customers
and drive margin development. Its engineering
resources delivering both project management
consulting and maintenance engineering
have now been fully integrated
into the regions. Consequently, the divisions
are renamed E&M effective January 1, 2019.
The technology companies delivering Energy
& Emissions, Biopharma and Automation
products remain grouped together and serve
Bilfinger customers globally from their
European manufacturing base. Together they
form the Technologies division also effective
January 1, 2019.
Orders received in financial year 2018 increased
by 10 % to 4,459 million euros
while organic growth was 12 %. At yearend,
order backlog amounted to 2,818 million
euros and was thus 11 % above the figure
for the prior year. Revenue increased by
3 % to 4,153 million euros, organically it
increased by 6 %. EBITA adjusted of 65 million
euro was well above the prior-year figure
– that was burdened by risk provisions
for legacy projects in the USA. In relation to
revenue, the EBITA adjusted margin was
1.6 %. Net profit was -24 million euros. Adjusted
net profit from continuing operations
increased to 36 million euros and was thus
positive for the first time since 2014.
Targeted digitisation and acquisitions contribute to success
ZEPPELIN COMPLETES FINANCIAL YEAR WITH A RECORD
The Management Board of the Zeppelin
Group: Michael Heidemann, Peter Gerst -
mann, Alexandra Mebus, Christian
Dummler
The Zeppelin Group finishes the 2018
financial year having achieved the highest
revenue in its history, and has once again
exceeded the previous year’s result. Group
sales totaled 2.9 billion euros (previous
year: 2.62 billion euros) , Group earnings
before tax increased to 131 million euros.
In 2018, Creditreform Rating AG rated the
Zeppelin Group’s creditworthiness as A- for
the third consecutive time, and stated that
its outlook is stable. The total investment
volume was around 279 million euros. The
company is forecasting largely stable financial
conditions for 2019. “With revenue of
2.9 billion euros, the Zeppelin Group has
just completed the best financial year in the
company’s history,” comments Peter
Gerstmann, Chairman of the Management
Board of Zeppelin GmbH. “We have further
increased both our order entry and revenue
in 2018. We also concentrated on driving
forward the digital transformation of our
existing business and the development of
new digital business models.”
The Zeppelin Group is working on the assumption
of fundamentally stable economic
conditions for the 2019 financial year, although
there may be slightly less dynamic
growth in some market segments. The uncertainty
of the political situation may have
a dampening effect on markets in Russia
and the CIS countries in particular.
Picture: Kaeser Kompressoren
A tradition of innovation
100 YEARS OF KAESER
KOMPRESSOREN
Kaeser is selling its compressors worldwide.
The size of the customers ranges from craftsmen‘s
businesses to large-scale industry.
Kaeser Kompressoren is celebrating its
100th anniversary in 2019. Established in
1919 as a machine workshop in Coburg by
Carl Kaeser Sr., the company has developed
into a compressor manufacturer and provider
of compressed air system solutions
with a global presence – while remaining
true to its roots. It all began with a small
operation producing gears and overhauling
automobile engines. Capitalising on its expertise
in engine manufacturing, in 1948
Kaeser took the groundbreaking decision to
add reciprocating compressors to its range
of products. Further challenges emerged
during the mid-1960s. Screw compressors
came onto the market and Sigma Profile was
born. Developed in-house, it is a rotary
screw airend with a special energy-efficient
rotor profile that was groundbreaking at the
time. Since then, Sigma Profile has been the
centrepiece of every Kaeser rotary screw
compressor. This innovative spirit pervades
the company to this day. From the refrigeration
dryer to the controllers Sigma Air
Manager 4.0, from the portable compressor
to completely new business models, where
the customer basically only purchases the
compressed air, through to digitalisation and
“Industrie 4.0”, Kaeser still blazes a trail in
the industry for the cost-effective, reliable,
efficient generation and use of compressed
air. The company‘s early international expansion
was a vital aspect of its growth. The
first branch opened in Switzerland in 1978,
with Austria and France following hot on its
heels. Today, Kaeser has more than 50 own
subsidiaries and is represented by exclusive
contract partners in over 100 countries.
Kaeser Kompressoren employs in excess of
6000 staff worldwide. Despite its truly global
presence, this family-owned company
has never lost sight of its German roots and
has been a byword for “Made in Germany”
quality for 100 years.
6 cpp 02-2019

Natural gas processing technology
BASF AND LINDE COLLABORATE
Picture: Linde
High-efficient membrane plant from Linde
BASF and Linde collaborate to serve natural
gas processing applications using BASF’s adsorbent
technology and Linde’s adsorption
& membrane technology. With the combined
capabilities of materials expertise
from BASF and engineering expertise from
Linde, the two companies are well positioned
to expand their global leadership
position in natural gas applications.
BASF’s Durasorb adsorbents will be used
to improve Linde’s high-performance membrane
processes, which provide stability
and selectivity advantages over competitive
membrane processes. BASF and Linde will
perform the required design work to ensure
that the adsorbent is well suited to the
membrane. Linde will supply both units to
the customer required to process natural
gas: the membrane unit and the pretreatment
unit located upstream, applying Durasorb.
This arrangement will simplify the
technical and the procurement processes for
the customer as well as increase the reliability
and performance of the membrane process.
The collaboration is a strong signal to
the natural gas industry and will open access
to previously inaccessible gas compositions
for treatment, e.g. high in heavy
hydrocarbons and CO 2 .
Topping-out ceremony: KNF’s new building nears completion
MILLIONS INVESTED IN GROWTH
Numerous guests gathered in the district of Munzingen, Freiburg for the topping-out
ceremony on March 15, 2019. Together with the construction companies
and architects carrying out the project, the staff and management of
KNF Neuberger GmbH celebrated the end of the second stage of construction
for the new building, which will house administrative offices and additional
production areas. With the new building the company’s production areas will
total 5000 m 2 . KNF wants to make use of its new space to exploit the possibilities
of Industry 4.0 more systematically. The work spaces will be structured
based on the latest lean management approaches and kitted out with state of
the art technology. This will allow the specialist in pump manufacturing technology
to work even more ergonomically and efficiently. The family-owned
Freiburg company has invested more than 5 million euros in the expansion of
its location in Freiburg-Munzingen. The existing administrative building is set
to be renovated following the completion of the new build.
Picture: KNF Neuberger
5 million euro expansion project at the KNF head office in
Freiburg-Munzingen
cpp NEWS TICKER
maintenance, and performance
curity Assurance (SSA) Level 1
and condition monitoring. “Auto-
certification for cybersecurity.
mate & Optimize“ includes sol-
The certification, issued by indus-
Thyssenkrupp receives
award for digital services
Picture: Thyssenkrupp
utions such as fully automated
storage systems, remote-controlled
ship unloaders, and digital
inventory management.
try consortium ISA Security Compliance
Institute (ISCI), independently
certifies that Emerson’s
Delta V distributed control and
safety systems are robust against
network and system attacks.
Picture: Eppendorf
Thomas Heydler appointed
to Supervisory Board
As part of a benchmarking study
Delta V, an advanced automation
Thomas Heydler is member of
carried out by the University of
system that simplifies operational
the Supervisory Board of Eppen-
St. Gallen, Thyssenkrupp
complexity and lowers project
dorf AG since January 25, 2019.
Industrial Solutions has been
presented with the Successful
Practice award for digital services.
The digital services fall into
two main categories: “Evaluate &
Emerson earns certification
for cybersecurity
Picture: Emerson
risk, provides smart control capabilities
for key industries in oil
and gas operations, refineries,
chemical plants, power and life
science facilities.
He succeeds Dr. Michael
Schroeder, who resigned for personal
reasons. Thomas Heydler
has been CEO of Definiens AG,
Germany, a specialised software
Predict“ includes solutions such
Emerson has received the indus-
and solution provider in the phar-
as drone inspections, remote
try’s first ISA-Secure System Se-
maceutical industry, since 2004.
cpp 02-2019 7

cpp
NEWS
Siemens introduces web-based process control system
THE NEXT LEVEL OF DIGITAL TRANSFORMATION
Picture: Siemens
Klaus Helmrich, Managing Board Member
of Siemens AG and CEO of Digital Industries
at the Hannover Messe press conference
At Hannover Messe, Siemens presented numerous
additions to its Digital Enterprise
portfolio for the next level of digital transformation:
“Through the integration of cutting-edge
technologies into our portfolio,
we can help industrial companies to benefit
from rapidly growing data volumes in new,
wide-ranging ways. With the use of technologies
such as artificial intelligence, Edge
computing and additive manufacturing, we
are paving the way for the future of industry.
We are also rethinking process control
technology, introducing the web-based
Simatic PCS neo process control system,”
Klaus Helmrich, Member of the Managing
Board of Siemens AG and CEO of Digital Industries,
explains at the Hannover Messe
press conference. Under the slogan “Digital
Enterprise – Thinking industry further!”
Siemens demonstrates how companies of
any size can use industry-specific solutions
to increase their flexibility and productivity
and to develop new business models. For
process automation, Siemens is breaking
new ground at the Hannover Messe. With
Simatic PCS neo, Siemens is presenting a
system software package, which offers new
opportunities in the age of digitalisation.
This includes global web-based cooperation
in engineering and operations as well as usability
with a seamless object-oriented data
model and an open system architecture. In
addition, the system offers the option of
scalability from small process modules
through to the largest process plants.
Solid export business
VDMA LARGE INDUSTRIAL PLANT ENGINEERING GROWS
Picture: VDMA
Jürgen Nowicki, VDMA Large Industrial
Plant Manufacturers´ Group (AGAB) spokesman
and Managing Director at Linde Engineering
In a volatile environment VDMA large industrial
plant engineering was able to record
the first increase in its orders since
2013. This growth is attributable to solid
export business and a number of mega
orders for chemical plants. “In addition, we
are seeing that the efforts being made by
the plant engineering industry to open up
new areas of business – such as services, digitisation
or plant operation – are increasingly
paying off,” says Jürgen Nowicki,
AGAB (VDMA Large Industrial Plant Manufacturers´
Group) spokesman and Managing
Director at Linde Engineering, commenting
on current developments. In 2018, the export
ratio in large industrial plant manufacturing
was 81 %, and the order level rose
from 14.0 billion euros (2017) to 14.8 billion
euros. Russia was the most important
foreign market for VDMA large-scale plant
construction due to several mega orders.
The members of AGAB are optimistic about
the future. According to a current VDMAsurvey,
60 % of plant manufacturers expect
orders to rise in the current year, while
20 % expect bookings to remain constant.
cpp NEWS TICKER
Picture: Bilfinger
Duncan Hall appointed as
Chief Operating Officer
The Supervisory Board of Bilfinger
SE has appointed Duncan Hall
member of the Executive Board
with effect January 1, 2019. He
will assume the newly created
role of Chief Operating Officer.
Alongside with CEO Tom Blades,
Duncan Hall will help to drive the
company’s build-up and build-out
phases forward.
Picture: SPX Flow
Duncan Hall has been serving as
an Executive President at Bilfinger
since 2015, at last holding this
role at the MMO Northwest Europe
division. He previously led
the Oil & Gas division.
SPX Flow with new service
partner in Australia
As part of its continuous service
improvement program, SPX Flow
is pleased to announce a new service
partner, FDPI Spares & Maintenance,
in Victoria Australia.
Family-owned FDPI is a welltrusted
and rapidly growing business
with expertise in liquid processes
within the dairy, food and
beverage industries. The partnership
will complement SPX Flow’s
existing service coverage and enhance
service response times.
Lewa joins the SPA
The Star Pump Alliance (SPA) is
an information platform for professional
pump users that was
founded by companies from the
pump industry offering various
application technologies. It
launched at Achema 2018. Since
July 2018, process diaphragm
pump expert Lewa has also been
an official member of this alliance
(www.starpumpalliance.com).
Praxair Europe turns into
Nippon Gases Europe
Since 3rd, December 2018, the
European industrial gases business
of the US group Praxair Inc.
belongs to Taiyo Nippon Sanso
Corporation (TNSC). The only exception
is the Russian part of the
company. Therefore, the name of
the European business changes
to Nippon Gases Europe.
8 cpp 02-2019

ADVERTORIAL
THE NEW STANDARD FOLDABLE IBC FOR INTERNATIONAL LOGISTICS
The Combo Excelsior ®
Schoeller Allibert’s new standard foldable intermediate bulk container (IBC)
is designed for international logistics. The Combo Excelsior ® was created to meet
the latest expectations of the food processing, cosmetics and pharmaceutical
industries. Safe, hygienic and efficient, it offers the best logistics solution on the
market for maximised profitability.
The best performance on the market
“With the new Combo Excelsior ® we offer
the new standard and safe foldable IBC on
the market: smooth design from base to lid,
70% folding ratio, outstanding performance,
improved handling and labour saving.
The new Combo Excelsior ® is your Visa for
International Logistics” stated Ludo Gielen,
Chief Strategic Growth Officer at Schoeller
Allibert Group.
Thanks to its double wall structure, the
combo Excelsior ® offers an exceptionally
strong and durable performance with a
1500 kg unit load and a stack load of
8000 kg. Its standard footprint 1200X 1000,
its 1000L capacity and 3200 kg dynamic
load ensure an optimised payload in road,
railroad and sea containers transportation.
The reverse logistics is optimised: with a
70 % folding ratio, piles of 7 Combo fit in
a standard truck, lowering environmental
impact and increasing profitability.
Safe, hygienic and easy to clean
To meet the requirements of the food
processing, cosmetics and pharmaceutical
industries, Schoeller Allibert launches the
most hygienic and safe reusable IBC, ideal
for high value liquids and ingredients
logistics. Hence, the Combo Excelsior ® is
water, dirt, bug tight and needle proof with
a 100 % safe, easy-to-clean design from base
to lid. Its 100 % smooth and double wall
sturdy structure increases internal volume
and ensures compatibility with high speed
filling and emptying processes.
Reusable and sustainable
The Combo Excelsior ® is reusable and
sustainable: its UV and deep frost resistant
material is suitable for all harsh industrial
environment and can be stored outside on
long time range. With a minimized number
of parts that can all be easily replaced,
maintenance costs are minimized and life
span increased. After its long service life,
the Combo Excelsior ® can be fully recycled
further lowering its carbon footprint.
Labour saving
The Combo Excelsior ® is operator friendly
and saves labour. The non-sequential folding
system and its unique side-walls locking
while erecting, enable one operator to
handle it. The large self-locking drop door
on front combines easy operator access
while maintaining the panel strength thanks
to its V shape. With an improved bottom
discharge zone, the liner and valve set up
and removal is much faster. A larger access
and easy connection design for most valves
on the market has been included to this
model. Fork tine guides on base, strong
three skids base and anti-slip plugs reinforce
safety and speed handling.
The new standard foldable IBC for international logistics
cpp 02-2019 9

cpp
INSTRUMENTATION, CONTROL, AUTOMATION
Picture: The Linde Group/Vega
Vegaflex 86 – robust guided radar sensors ensure measurement accuracy in LNG production
CLEAR SIGNALS FOR LNG
Liquefied gases such as LNG or LPG can be transported much more flexibly and
often have a higher commercial value. A good example of this can be found in the
Russian Portovaya Bay, where natural gas will soon be processed and loaded directly
onto ships in cryogenic liquid form. Once the natural gas liquefaction plant is completed,
guided radar sensors from Vega will make a significant contribution to safe
and efficient production.
10 cpp 02-2019

Picture: The Linde Group
Picture: Vega
Guided radar sensors of type Vegaflex 86 measure robustly and independently
of the medium. This makes them suitable for almost all substances
and measuring tasks in the LNG process.
Well packed and ready to travel: guided radar sensors of type Vegaflex 86
and vibrating level switches of type Vegaswing 66 awaiting transport to
the LNG construction site in the Russian Baltic Sea bay of Portovaya
LNG processes are among the most challenging in the process
industry. A single plant can produce anything from 40,000 to
8 million tons annually. Processing facilities can range from very
small to world-scale. Two trends are becoming apparent in liquefaction
plants.
First, the future can swim. LNG plants are increasingly being designed
as “floating facilities” (FLNG). Gigantic floating liquefaction
plants, sometimes as big as several football pitches, can produce
LNG exactly where natural gas is available, without first having to
transport it ashore through expensive pipelines. The industry is thus
achieving an unprecedented level of flexibility and service quality
true to the motto “We come to you and deliver to your door”.
Second, large-scale natural gas liquefaction plants need staying
power and the willingness to make large investments. Current projects
are therefore tending to move away from the huge dimensions
the growth market demanded in the past. Medium-sized projects
are becoming more and more the thing. These allow both the project
duration and the financial investment to be scaled and closely
matched to demand, so that production can still be profitable in regions
with smaller gas reserves. What’s more, such facilities can be
expanded later with comparatively little effort to meet increased demand.
After all, extending an existing facility is faster and easier
than starting from scratch somewhere else. An additional compressor
train, turbine or cold box, i.e. the cryogenic chamber where
natural gas is cooled down to -162 °C, requires relatively little
bureaucratic red tape.
All-round reliability with a complete measuring point
The Linde Group delivers comprehensive turnkey solutions for the
LNG processes at its customers’ plants. Just as comprehensive are
the level measurement solutions Vega creates for these same processes.
A complete measuring system consisting of a bypass tube
and sensor offers much more than just the sum of its parts. It includes
an instrumentation concept tailored to the process and
rounded off with broad engineering and support services. The
ready-to-install sensors, which are shipped with customised features,
documentation and necessary test certificates – all from a
single source – are a building block Linde can rely on. Using Vegaflex
86 guided radar sensors, most of which come already fitted in
bypass tubes, and Vegaswing 66 for point level detection enables
considerable savings, amongst other things due to the simplified
planning, fast plug & play installation and reduced maintenance
requirements. Since they have no mechanical moving parts, Vegaflex
bypass measuring systems are wear-free and need almost no servicing.
Besides pre-assembly and adaptation to existing plant conditions,
the scope of delivery also includes detailed parameterisation,
such as false signal suppression. Only SIL functionalities, as required
by law, have to be calibrated live on site with the original medium
that will later be measured.
Documentation included
When designing LNG facilities, the top priority is to make sure all
system components have sufficient robustness and performance reserves.
Only then are the sensors able to reliably monitor the complex
processes the media are put through. The core task hasn’t
changed much in spite of all the technical advances over the last
few decades. Yet in terms of efficiency and process reliability, today’s
measuring systems are almost unrecognisable. On their journey to
the LNG construction site, the client’s level sensors are accompanied
by a thick bundle of papers. The aim is to comply with strict legal
cpp 02-2019 11

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INSTRUMENTATION, CONTROL, AUTOMATION
regulations and the often stricter still, country-specific requirements
of end customers. Apart from production acceptance tests,
the focus is on numerous certificates and licenses.
The challenge of short-track projects
The Portovaya project is a so-called short-track project. “The entire
plant is being built in an unusually short period”, explains Business
Development Manager Sebastian Harbig, who is in charge of global
projects at Vega. “Delivery time was therefore a major criterion
when awarding the contract.” This is not the first time that Vega has
supported the engineering, procurement & construction (EPC)
specialist on medium- or large-scale projects. Vega is responsible for
the complete, ready-to-install measuring point, the customer-specific
documentation and all necessary certificates. Especially for international
projects, delivery from a single source is an advantage
that has multiplication potential because a project like the one in
Portovaya involves Linde teams, locations and suppliers all over the
world. The work across national borders has to function like a welloiled
machine, with every gear wheel syncing perfectly with all the
others. Any delay can cause multiple delays downstream.
Two for all levels
Machines in an LNG plant, particularly those used in the liquefaction
process, are exposed to extreme operating conditions. Between
start-up and full operation of the cryogenic processes, the temperature
expansion of the equipment is immense. The components are
subject to extreme loads and even small changes in the composition
of the processed natural gas can significantly reduce the overall
serv ice life of a machine. The mid-scale plant now being built in the
Russian Baltic bay liquefies gas from a compressor station that has
been operating there since 2010. The process for converting natural
gas into LNG is based on three steps: pre-treatment, compression
and cooling including liquefaction. Since natural gas contains impurities
such as water, mercury or corrosive components that can
freeze during the compression phase, it has to be pre-treated. Methane
is only allowed to enter the liquefaction trains of the LNG plant
in a highly concentrated form. In the various storage and process
vessels, only two sensor types monitor the very diverse media –
from dry natural gas, condensed hydrocarbons and cold flare gas to
ethane, LNG, hydrocarbons, fuel gas and wastewater – during the
entire production process.
SENSORS:
IN THE LNG/LPG PROCESS CHAIN
Maximum performance, minimal loss
Consistently high quality is essential for LNG processes. In today’s
competitive environment, industry must strike a balance between
cost pressure and environmental awareness. Yet when it comes to
quality, no compromises are tolerated. Efficiency and plant availability,
which are significantly improved through standardisation in
all areas including instrumentation, guarantee high quality and a
real cost advantage. Guided radar sensors are especially suitable here
because they can reliably withstand extreme pressure and temperature
conditions. Vibrating level switches, with their compact design
and millimetre accuracy, are also ideal for many applications in an
LNG plant.
Vegaflex 86 (left) and
Vegaswing 66 are ideal
for LNG applications
Liquefaction plants are relatively complex and extend
over multiple process stages. In each stage, the level is
an important variable playing a major role in protecting
the compressor. Vegaflex 86 is a hard-wearing guided
radar sensor which is ideal for this task, because it
measures without being affected by media properties
such as density or dielectric constant. Its rugged me -
chanical design and second seal, the so-called second
line of defence, protect the sensor effectively.
The Vegaswing 66 vibrating level switch has a patented
inductive drive that excites the tuning fork effortlessly
even under extreme temperature conditions. Users
benefit especially from the simple handling and operation
of this device. Notwithstanding its simplicity, it
has an extensive application range down to -196 °C
(normal temperature in the LNG environment) and is
rated for pressures from -1 to +160 bar. Since the sensor
measures so reliably irrespective of density, even in
widely different products, it is perfect for high and
high-high alarms on cargo tanks.
Communication that counts
Vega’s global projects team, to which Sebastian Harbig belongs, has
developed into an experienced partner for worldwide plant projects
with extensive knowledge of critical interfaces. To be able to supply
customers optimally, it is important to provide comprehensive so -
lutions that are far removed from daily business. Mature technology,
as the project in Portovaya shows, can merely be the basis on which
to build. In practice, there is far more to it than that: working out
the technical details, preparing quotations and communicating
regularly with the client. The project does not end with setting up
and commissioning but continues throughout the entire lifecycle
of the instruments, ensuring the best possible availability and efficiency.
www.cpp-net.com
Online search: cpp0219vega
AUTHOR:
CLAUDIA HOMBURG
Marketing,
Vega
12 cpp 02-2019

GLASS FILTERS
High quality material for demanding
tasks: VitraPOR® glassfilter apparatuses
made from pure borosilicate glass 3.3
fulfill many requirements in chemical
and pharmaceutical labs as well as for
industrial, biological and environmental
technology applications.
Properties such as heat resistance to
over 500 °C and resistance to most
acids, alkalis and solvents make our
VitraPOR® glassfilters, which conform to
international standards, suitable for use
in many chemical, pharmaceutical and
technical procedures.
Custom VitraPOR® sintered elements
according to your specifications are
characterized by their neutral properties
and open-pore structure. They are
suitable for even the most unusual
applications.
VitraPOR® glassfilter apparatuses can
be supplied in different pore size classes,
from smaller than 1 micron to over 500
micron and as custom-made solutions in
many shapes and sizes.
ROBU Glasfilter-Geräte GmbH
Schützenstrasse 13
57644 Hattert
Germany
Made in Germany
www.robuglas.com
cpp 02-2019 13

cpp
INSTRUMENTATION, CONTROL, AUTOMATION
Selecting the right measurement technology to maximise operational efficiency
Get the most from your
level measurement
Many applications in the chemical industry make arduous demands on the measuring
instruments. In particular, steam, dust, foam, turbulence and condensation make life
difficult for level measuring instruments and affect their accuracy and reliability.
However, today’s instruments are rising to these challenges, increasing the safety of
processes, equipment and personnel and enabling plant operators to cut running
costs by streamlining their processes.
Chemical processing plants are challeng -
ing environments for instrumentation, and
the demands placed on level measuring devices
are particularly arduous. Applications
can involve toxic, corrosive, flammable or
explosive materials, with wide variations in
temperature and pressure as well as problematic
media characteristics such as steam,
dust, foam, turbulence and condensation.
Such factors can influence level measurement
accuracy and reliability. However, the
enhanced functionality provided by the lat -
est generation of devices is helping to overcome
these challenges, increasing the safety
of processes, plants and personnel and helping
plant operators cut their running costs
by making processes more efficient.
Blending tanks
In mixing applications, there are several
challenges that must be mastered by level
measuring devices including heavy turbulence,
whirlpooling, foam, condensation,
antenna build-up and disturbances such as
multi-level agitators, inlets and heating coils.
For this type of application, non-contacting
radar transmitters are the most appropriate
technology to deploy. Although they can
handle agitation, their success depends on
the amount of turbulence in the tank, as this
can cause a loss of signal strength. Among
the advances in this area are dedicated software
algorithms, which can counteract the
effects of turbulence as well as obstacles,
foam and rapid level changes. Alternatively,
bypass pipes featuring self-contained
chambers or stilling wells can be used to
isolate the surface from turbulence.
Pictures: Emerson
Steam, dust, foam, turbulence and condensation make life difficult for level measuring
instruments in the chemical industry
14 cpp 02-2019

Industrie
The
network of
expertise
for industry
In mixing applications, there are several
challenges for level measuring devices like
whirlpooling, foam or condensation
Non-contacting radar transmitters use either
pulse radar or frequency modulated continuous
wave (FMCW) techniques to perform
the measurements. Although FMCW
technology is a perfect match for this kind
of application due to its greater accuracy
and sensitivity, it traditionally uses more
electrical energy and thus has typically only
been deployed within four-wire devices. Installing
four-wire devices often necessitates
additional cable infrastructure, which is disruptive,
costly and time-consuming. This has
led to some users sacrificing the additional
accuracy and reliability of FMCW devices
and opting instead for two-wire transmitters
based on pulse technology. Emerson’s Rosemount
5408 Level Transmitter gets to grips
with the problem of high energy requirements
for FMCW technology. Its superior
energy efficiency allows power and communication
to be provided by two wires,
hence avoiding the need for additional infrastructure
and enabling quick installation.
As a result, the FMCW devices can be installed
in a far greater number of mixing
and blending applications, helping to improve
measurement accuracy and reliability.
Reactor vessels
Vapours, foam and turbulence are usually
present in reactor applications. In addition,
The Rosemount 5408 offers all-polytetrafluoroethylene
(PTFE) process seal antennas,
developed specifically for demanding
applications such as reactor vessels and
ideal for handling corrosive media and high
condensation levels
the density of liquids can change as part of
the reaction, and high temperatures and
variable pressures are standard. All these
challenges can affect level measurement accuracy.
Non-contacting radar transmitters
are again a very good measurement solution
as they do not need to compensate for
changes in density. Also, pressure variations,
high temperatures and reaction vapours will
not affect the accuracy of the measurements.
The Rosemount 5408 offers all-polytetrafluoroethylene
(PTFE) process seal antennas,
developed specifically for demanding applications
such as reactor vessels and ideal for
handling corrosive media or high condensation
levels. These antennas provide better
pressure and temperature ratings compared
to older devices. Wetted parts are likewise
made from PTFE to maximise corrosion resistance.
The Signal Quality Metrics diagnostics
package, which detects abnormal
process conditions such as a dirty antenna
or foam and enables preventative mainte -
nance to be scheduled, avoiding process
upsets or shutdowns, is a further benefit.
Steam generation
Accurate level control in boilers is critical as
a means of ensuring safe and efficient operation,
but it can be very challenging to perform
level measurements in such high-
18 media brands for all major
sectors of industry
Information, inspiration and
networking for professionals
and industry executives
Practical knowledge spanning
all media channels: Trade journals,
websites, events, newsletters,
whitepapers, webinars
Discover the appropriate
media for your specific
industry sector:
konradin.de/industrie
media.industrie.de
cpp 02-2019 15

cpp
INSTRUMENTATION, CONTROL, AUTOMATION
A Rosemount 5300 Series Level Transmitter using dynamic vapour compensation (left)
measures the liquid level in a tank with saturated steam (middle). Right: Emerson’s
Rosemount 2140 Vibrating Fork Level Detector.
pressure and high-temperature applications,
where the steam is saturated. Media density
changes can result in measurement errors of
up to 30 %. Traditional technologies such as
displacers and differential pressure (DP)
transmitters must compensate for these
changes, in order to provide an accurate
reading. These methods tend to require extensive
maintenance, which adds to the lifecycle
cost of the device. GWR transmitters,
which can withstand extreme temperatures
and pressures, represent a good solution
here. Since GWR technology measures the
surface of a liquid directly, it is completely
independent of density, thus eliminating the
need to compensate for density changes.
GWR also has a robust design and no moving
parts, leading to increased reliability
and minimal maintenance costs.
One important consideration within this
application is that the dielectric properties
of feedwater are altered during the phase
change from liquid to steam. For example,
in saturated steam conditions when steam is
under high pressure, its dielectric increases.
This affects radar technology, as the propagation
of the microwaves used to perform
level measurements will slow down, provoking
a measurement error of up to 50 % if
the level reading is not compensated. Emerson’s
Rosemount 5300 Series Level Transmitter
overcomes this challenge by using
dynamic vapour compensation, which continuously
compensates for changes in the
dielectric constant in the vapour space. The
compensation takes place in the transmitter
electronics and a corrected level measurement
is provided to the control system. No
additional compensation is required and the
error rate can be reduced to 2 % or less.
Storage and process tanks
Agitation, heating and condensation are
common challenges associated with general
storage and process tanks. Traditional level
measurement technologies such as pressure
sensors, load cells and mechanical or ultrasonic
devices are density-dependent as well
as sensitive to contamination and require
frequent maintenance. Many organisations
therefore use either non-contacting radar or
GWR devices for level measurement to determine
inventory accurately and maximise
the use of available storage capacity. Vibrating
fork level switches are typically employed
in conjunction with radar devices to
perform essential safety functions.
Level measuring devices used as part of a
safety instrumented system, for example for
overfill prevention, must undergo regular
proof-testing to ensure they meet the
required safety integrity level. This can involve
considerable time, effort and cost and
present a safety risk. Both the Rosemount
5408 Level Transmitter and Emerson’s Rosemount
2140 Vibrating Fork Level Detector
enable proof-testing to be performed remotely
from the control room with minimal
process interruptions, since they do not
need to be removed from the vessel to be
immersion tested. This makes the procedure
significantly safer, as operators no longer
have to physically access the device, allowing
them to stay off the top of the tank and
avoid working at height, where they could
potentially be exposed to hazardous substances.
Shutting down the process is expensive, so
minimising downtime for testing saves
money. Modern remote proof-testing is far
quicker than complex, conventional
methods, enabling substantial savings to be
achieved. The process is taken offline for
only a matter of minutes, during which
time multiple devices can be tested simultaneously
‘on the bus’. Furthermore, selecting
a modern overfill prevention device with
high diagnostic coverage, resulting in a significant
reduction in dangerous undetected
failures, means proof-testing can be carried
out less frequently, again cutting down the
test time needed to meet regulations.
Solids
For bulk storage of solids in larger vessels or
warehouses, measurement inaccuracy can
16 cpp 02-2019

Having a visual representation of the material’s distribution
within a silo improves safety while optimising storage
capacity and improving production efficiency
Users of the Rosemount 5708 3D Solids
Scanner can now automatically calculate the
centre of gravity for the vessel’s contents
with every reading
Emerson’s Rosemount 5708 3D Solids
Scanner supports the continuous analysis
of product flow and movement by dividing
a large vessel into as many as 99 smaller,
virtual sections
lead to a serious discrepancy in product volume.
Highly accurate measurement technology
is therefore essential and acoustic scanning
is a popular choice. The latest scanner
generation not only provides continuous online
volume measurement but also offers
3-D visualisation of the peaks and troughs
formed by a shifting solids surface. By showing
how the material is distributed within
the vessel, this 3-D mapping helps to prevent
the threat of structural damage due to
uneven loading while optimising storage capacity
and improving production efficiency.
Emerson’s Rosemount 5708 3D Solids
Scanner offers functionality to further improve
safety and support the continuous
analysis of product flow and movement by
dividing a large vessel or warehouse interior
into as many as 99 smaller, virtual sections.
The operator can then monitor each section
individually, so that if too much material
builds up in one area, filling points can be
switched and/or trucks alerted of the risk.
This improved control over filling and emptying
enables an even distribution to be
continuously maintained across the surface,
allowing the vessel’s capacity to be utilised
more efficiently. It also helps to increase
safety, as filling and emptying operations
can be performed automatically from the
control room rather than requiring someone
to climb inside the vessel.
Users of these devices can now automatically
calculate the centre of gravity for the
vessel’s contents with every reading. The
software generates an alert if the centre of
gravity moves out of its predefined space,
enabling remedial action to be taken immediately.
This minimises the risk of structural
damage and lets maintenance be carried
out only when actually necessary.
In smaller vessels used for process control
applications, the surface level can change
rapidly because of the speed at which material
enters and exits. Radar devices respond
quickly to level changes, making
them an appropriate solution. GWR is especially
well-suited for vessels with a diameter
of less than 10 m (33 feet) and containing
powders or small granular materials,
where the installation area is restricted. As
the vessel height increases, wear on the
probe becomes more of a factor for its suitability
of use. Non-contacting radar has no
restrictions with respect to the weight of
the material and can be used in applications
where GWR may not be ideal because of
pull forces or concerns about probe breakage.
Non-contacting radar can see more of
the surface than GWR, so it will be slightly
more accurate.
Pump lubrication
Level measuring devices can also be used to
help protect critical pumps. A continuous
supply of lubrication oil is typically provided
from a lube oil reservoir and it is crucial
that the level is monitored accurately.
Too low and there is a risk of equipment
damage, which could lead to a costly process
shutdown. Too high and the potential
overspill or leakage will constitute a safety
hazard. Among the common challenges for
level measurement technology are high vibration
and limited access in skid-mounted
or smaller tanks. Floats or DP transmitters
with a wet reference leg system have high
maintenance requirements and there is a
risk of leakage with the piping for DP transmitters,
while floats are prone to sticking.
Consequently, automated monitoring systems
are becoming much more prevalent.
Vibrating fork level switches are a more reliable
solution for these applications. When
the oil level drops to a defined low point,
the switch sends a signal that alerts maintenance
workers, who can address the issue
before there is any risk of pump damage.
Similarly, if the oil level rises to a defined
high point, an alarm is output to prevent
the threat of overspill. A lack of cable infrastructure
can be a problem when implementing
automated technology, but the lat -
est vibrating fork level switches overcome
this by offering wireless connectivity. This
streamlines the installation process and delivers
real-time data to maintenance staff,
resulting in increased pump protection and
lower operating costs.
Advanced diagnostics in the latest generation
of devices further support reliability
by enabling operators to continuously
monitor their electronic and mechanical
health. Any build-up, fork blockage or excessive
corrosion is detected, indicating that
maintenance may be required and allowing
it to be scheduled during planned downtime,
therefore increasing efficiency.
www.prozesstechnik-online.de
Online search: cpp0219emerson
AUTHOR:
MARIANNE WILLIAMS
Marketing Manager,
Emerson Automation
Solutions
cpp 02-2019 17

cpp
INSTRUMENTATION, CONTROL, AUTOMATION
Pictures: Hamilton
Critical process parameters can be monitored in real time with the help of in-line sensors
Monitoring critical process parameters in upstream processes
In-line sensors for
bio processes
Critical process parameters can be monitored in real time with the help of in-line
sensors and by implementing PAT in bioprocesses. The data obtained in this way
provides important insights into the process and goes hand in hand with improved
efficiency and reliability.
Manufacturing biopharmaceuticals is not
only a costly but also – due to their origin,
namely living cells – a highly complex and
time-consuming process. The cells’ hetero -
geneity and their sensitivity to chemical influences,
such as changes in pH, require
profound process understanding. Even very
minor changes to process parameters can
impact either positively or negatively on the
yield and quality of the target molecule,
which is why identifying critical parameters
and monitoring them continuously is so
important.
Process analytical technologies
The cultivation of sensitive organisms in
biotechnological processes can best be improved,
analysed and controlled using process
analytical technologies (PAT). The principle
is based on a deep understanding of
science and technology as well as on the
identification of variables with an influence
on the quality and quantity of target molecules.
The goal is to monitor critical quality
attributes and process parameters through
continuous measurements in order to ensure
the quality of the final product. PAT
puts the emphasis on process understanding
rather than on the product itself. The explanation
is simple: the quality of the final
product is assured if the process is understood
in the first place. The critical quality
attributes and process parameters, which
may vary depending on the culture or target
molecule, are first of all identified. After determining
the optimal process conditions in
this way, they can be set and monitored accordingly
within defined limits. This is an
important step for the commercial success
of the upstream process, in which cells,
yeast and bacteria grow gradually. Critical
process parameters such as pH, dissolved
oxygen or cell growth should be determined
continuously and recorded in-line.
pH, dissolved oxygen and cell growth
Cells of different origins have different optimal
pH. The ideal pH for animal cells is
mostly between 6.8 and 7.4, whereas that
for insect cells is slightly lower at about 6.3.
If the pH is not ideal, or close to it, this
could impact negatively on the cell growth
and yield of the desired target molecule. The
use of pH sensors is therefore very common
18 cpp 02-2019

The Incyte sensor measures permittivity by only polarising viable cells within an
alternating electrical field
Versioned
catalog
production
when preparing and cultivating media for
this purpose. The pH sensors in the Easyferm
plus family are compatible with all
common controllers and process control
systems. They are particularly suitable for all
upstream process steps due to their robust
design, high measurement accuracy and reproducibility.
Another important process
parameter is the dissolved oxygen content.
The desired oxygen saturation can easily be
monitored using the Visiferm DO optical
dissolved oxygen sensor. Owing to the optical
measurement principle, Visiferm DO
needs neither polarisation nor electrolyte
refill, unlike the traditional Clark sensors.
Furthermore, the measurement is not influenced
by the metabolism by-product CO 2
as a result of changes in the electrolyte’s pH.
The conditions for ideal cell growth are ensured
by monitoring and setting optimal
values for pH and dissolved oxygen saturation.
In-situ measurements of the viable
cell density show whether this is successful
and the cells grow as expected. The Incyte
sensor measures permittivity by only polarising
viable cells within an alternating electrical
field. An increase in permittivity correlates
with growing cell numbers, which
can be calculated after preparing a cell typedependent
calibration curve. Continuous
permittivity measurements allow conclusions
to be drawn about the nutrient
supply and the subsequent yield of the target
molecule.
Visiferm DO optical dissolved oxygen
sensor installed in a bioreactor
Conductivity measurement
The quality of the water used in an upstream
process is very important for its success.
This applies to the water employed for
the production of the culture media as well
as to that for cleaning and rinsing. Compliance
with the strict requirements for
ultra-pure water as defined by the EP and
USP pharmacopoeias is crucial. One of the
most important parameters is conductivity
measurement. The Conducell UPW (ultrapure
water) conductivity sensor measures
low conductivities reliably and complies
with the requirements of legal pharmacopoeias.
The principle is based on measurements
of the electrical resistance using a bipolar
sensor. As required by the above-mentioned
pharmacopoeias, warnings can be issued
if the conductivity is too high, so that
corrective action can be taken.
Off-line sensor calibration
All the sensor types described here are available
in an Arc version. This means that offline
calibration can be conducted in a laboratory
under defined conditions because
the micro-transmitter in the sensor head
stores all calibration data. Using an optional
wireless adapter, measured values and sensor
information can be sent to a mobile device
via Bluetooth. The Arc version thus
allows the sensor configuration and calibration
to be adjusted in situ, in order to
determine and resolve the cause of a malfunction.
A robust signal, either 4 to 20 mA
or Modbus, and hence smooth and seamless
processes are further characteristics of the
Arc technology.
www.cpp-net.com
Online search: cpp0219hamilton
AUTHOR:
DR. KNUT GEORGY
Senior Market Segment
Manager Process Analytics,
Hamilton Bonaduz
We are well-equipped for the production
of your multilingual or multi-version
catalogs – especially when it comes to
managing your highly complex jobs.
Individual tools, perfectly adapted for your
project, accelerate and simplify the
entire process.
We can do much for you, please contact us.
druck@konradin.de
www.konradinheckel.de
cpp 02-2019 19

cpp FOCUS IIOT IN CHEMICAL INDUSTRY
Picture: monsitj – Fotolia.com
In an Ethernet-only world, there are no language barriers anymore
Seamless communication from field to enterprise level
When everyone speaks
Ethernet
Better communication is the key to better understanding. This is true with humans
as well as with technical processes. For people to engage in deep conversation they
need to agree on a common language. The process industry is about to embrace
such depth of communication by adopting Ethernet as a common standard from
enterprise to field level.
We all know the buzzwords that stand for
the fully digitised enterprise of tomorrow:
Industry 4.0, Big Data, Industrial Internet of
Things (IIoT). Ethernet is the enabling factor
that will make all these developments come
true. It will provide deeper insight and deliver
better information for well informed
decisions. Because in an Ethernet-only world,
there are no language barriers anymore. Instead
of translating between systems, information
can flow seamlessly and free from
time and location constraints. Ethernet/IP is
an industrial Ethernet solution based on the
Common Industrial Protocol. It uses the
well-established Ethernet standard and will
dramatically change both manufacturing and
process industries. It fully integrates with
standard Industrial Ethernet and provides the
basis for a homogeneous communication infrastructure
reaching from field devices distributed
throughout a plant via the PCS all
the way to a company’s ERP system. The
chemical industry will especially benefit
from this development. Ethernet/IP not only
allows Ethernet to the field, thereby overcoming
the inherent limitations of present
fieldbus systems; it can also provide intrinsic
safety to allow the connection of devices inside
hazardous areas. In addition, it supports
the functional safety required for many applications
in chemical process plants. Moreover,
with Ethernet/IP it is pos-sible to retrieve
a wealth of device data to enable preventive
maintenance concepts which can dramatically
increase process reliability and
plant availability.
Transition into the digital future
Changing a plant to Ethernet/IP communication
does not require a radical cut. Instead,
there are multiple migration paths to allow a
gradual transition from the traditional fieldbus
world to an enterprise-wide Ethernet infrastructure.
This is especially important,
since process plants in the chemical industry
are usually long-term projects that
rely on well-proven technologies in order to
guarantee utmost process reliability.
Many existing plants are still using analogue
field devices integrated into a digital control
system via the Hart communication protocol.
In the autumn of 2018, ODVA announced an
enhancement to the Ethernet/IP specifications
that will allow seamless integration
of Hart devices into an Ethernet/IP infrastructure.
ODVA is a global association made
up of the world’s leading automation companies.
ODVA’s mission is to advance open,
interoperable information and communication
technologies in industrial automation.
Ethernet/IP is a network adaption of the
media-independent Common Industrial
Protocol (CIP).
“The integration of conventional Hart I/Os is
another step in fulfilling ODVA’s vision for
optimising process integration”, stated Olivier
Wolff, chair of the ODVA technical working
group for Ethernet/IP in the Process Industries
and Global Marketing Manager In-
20 cpp 02-2019

Olivier Wolff, Global Marketing Manager
Industrial Communication at
Endress+Hauser and chair of the ODVA
The ODVA ecosystem allows seamless communication from field to enterprise level
dustrial Communication at Endress+Hauser.
“Now that the initial focus to integrate conventional
field devices with industrial control
systems and asset management systems is
complete, the organisation will continue to
adapt Ethernet/IP to the full spectrum of
process industry needs.”
Optimised process integration
The key strategy of ODVA is called Optimised
Process Integration (OPI). The focal
point of OPI is the production domain in
process plants. This is where the action takes
place and field devices need to be tightly integrated
into the automation system. Presently,
this integration is anything but trivial.
For many decades, process plants relied on
4...20 mA analogue communication with
field devices. Although digital fieldbuses are
increasingly reaching the chemical industry,
they are far from easy to implement. Remote
access requires special gateways and
although devices often provide large
amounts of data, the practical use of such
data to the ICS tends to be hindered by
fieldbus limitations. The basic approach of
OPI fulfils three major requirements of the
global chemical industry. Convergence is
achieved by the use of standard Ethernet
technologies for the complete communication
structure from plant to enterprise
level. Compatibility is guaranteed by individual
migration paths, allowing the integration
of new devices that seamlessly work
with the installed base. Scalability ranges
from simple field devices to complex, enterprise-wide
systems. The emphasis on open
systems ensures interoperability while plant
operators are not dependent on any specific
vendor.
Evolution, not revolution
Automation systems in the chemical industry
are facing the same development that the
manufacturing industries experienced years
ago. The trend is towards Industrial Ethernet
and other open standards. Ethernet/IP incorporates
standard Industrial Ethernet network
interface components (NICs). By being able
to use such commercial off-the-shelf hardware
(COTS), plant operators not only benefit
from competitive prices. They are also able
to leverage the existing know-how of a broad
base of engineers familiar with standard
Ethernet and Internet technologies. With an
Ethernet/IP infrastructure, a chemical plant is
also prepared for IIoT as well as a range of
totally new devices and applications. With its
OPI approach, ODVA leaves the industry with
the option of gradually migrating to an automation
system that can access any layer in
the production domain and derive detailed
device and process information for improved
asset management and proactive maintenance.
The transition to a homogeneous and
scalable Ethernet/IP infrastructure according
to the OPI approach requires plant operators
to address three primary use cases:
• Device-to-ICS Integration: When it comes
to the integration of field devices into the
ICS, the communication requirements for
both existing, fieldbus-based field devices
and Ethernet enabled devices need to be
taken into consideration. Field devices connected
via Ethernet/IP not only offer access
to a wealth of instrumentation data that
provide the required information for enhanced
diagnostics. They also include physical
layer options such as Power-over-Ethernet
and conform to emerging standards for
an intrinsically safe Ethernet.
• Device-to-PAM integration: Especially for
the chemical industry, with its emphasis on
process plants that are expected to operate
for long periods of time without shutdown,
field device-to-PAM integration is a
vital aspect of OPI. This aspect ensures that
field devices provide optimal performance
at all stages of their life-cycle – from commissioning
and operation to calibration and
maintenance.
• Holistic field-to-enterprise communication:
A holistic field-to-enterprise communication
architecture is the key factor of any successful
OPI strategy. It results in a paradigm shift
from the classical, restrictive automation
pyramid towards a flatter and more inclusive,
distributed network architecture. A unified
and transparent, enterprise-wide communication
architecture can provide full
communication between the process automation
systems of individual chemical plants
and the organisation’s ERP system.
The OPI approach as suggested by ODVA represents
a practical migration path for the
chemical industry. It paves the way from the
heterogeneous communication infrastructures
typical of today’s chemical process
plants to the future of unified communication.
This will be a future where devices
and systems all speak one common language:
Ethernet.
www.cpp-net.com
Online search: cpp0219odva
AUTHOR:
ADRIENNE MEYER
Vice President of Operations and Membership,
ODVA
cpp 02-2019 21

cpp FOCUS IIOT IN CHEMICAL INDUSTRY
Security by design is mandatory
Implementation of the
NOA concept
Every operator wants to be able to use data from existing systems for new technologies
and thus benefit from the added value of cloud-based evaluations. The Namur
NOA concept explains how this is possible without changing those systems completely.
As the key element, the data diode must collect all data which is important
for the cloud applications and ensure continued system security.
To be able to use Industry 4.0 technologies
in an existing process-related system,
the operating data must first of all be collected
(Figure 1). The objective is to avoid
modifying the system significantly. The
automation pyramid in the NOA concept is
therefore expanded by a side channel that
provides horizontal, secure and impact-free
access to the process data on all levels. The
well-known automation pyramid is made
up of four levels. However, it is not possible
to establish cross-communication between
the lower sensor/actuator level and the
upper control level (Figure 2).
The NOA concept therefore adds a side
channel to the automation approach used to
date. Cross-communication can be established
using this channel, so that the operator
can evaluate the data recorded by the
field devices. New analysis and monitoring
methods are easier to use if full access is
granted to the process system data, which is
securely extracted from the system based on
the NOA concept. The symbolic data diode
is used for this purpose. It allows data to be
removed from the system but the processes
cannot be accessed. The data is readily available
in this way as a starting point for any
evaluation. It can be saved on servers or in a
cloud and forwarded to those points where
an evaluation takes place. This can be done
by internal specialists or external service
providers (Figure 2).
Figure 1: In the first step, operating data must be collected without modifying the
system significantly
Pictures: Phoenix Contact
Secure and impact-free data access
However, the concept described here is only
advantageous to the operator if data can be
accessed securely and without any impacts.
It must also be possible to integrate the approach
into the information security management
system (ISMS) that is part of
ISO 27000, as already stipulated in the IT
Security Act for critical infrastructures. Such
a system is often implemented in non-critical
systems in any case to ensure secure operation.
In cooperation with the German
Electrical and Electronic Manufacturers’
Association (ZVEI), therefore, Namur has set
up new working groups that focus on IT
security and the implementation of data
diodes in actual hardware. When it comes to
22 cpp 02-2019

automating systems, there are various directives
and standards in which the actual IT
security situation is defined on different
levels. The basic IT security stipulated by the
German Federal Office for Information Security
(BSI) and IEC 62443 “IT Security for
industrial automation and control systems”
are examples of general process models.
Holistic security approach
IEC 62443 is a series of general security
standards for industrial automation and
control systems. It is made up of 13 parts
documenting process security requirements,
functional measures and the current state of
the art (Figure 3). According to NOA, the
most important parts are:
• IEC 62443 Part 2-1 – Security management
system requirements for operators of
industrial automation systems
• IEC 62443 Part 2-4 – IT Security program
requirements for service providers of industrial
automation systems
• IEC 62443 Part 3-3 – System requirements
for IT security and security level of industrial
automation systems
• IEC 62443 Part 4-1 – Life cycle requirements
for secure product development of
industrial automation systems
• IEC 62443 Part 4-2 – Technical IT security
requirements for automation system components.
When developing a device with data diode
functionality it makes sense to implement a
security-by-design approach for the hardware
and software. The necessary security
processes and functional measures for device
manufacturers, system integrators and
machine and system operators can thus be
implemented.
Product development process
IEC 62443-4-1 describes the product development
process for automation devices. The
main element is a process that enables a reliable
determination of whether all security
requirements have been implemented and
verified. This process is rounded off by
other security implementation features, for
example a threat analysis based on the security
context, i.e. the operational scenario
for the product, the defence-in-depth concept
and security vulnerability management,
which nowadays is generally implemented
by a product security incident response
team (PSRIT).
Figure 2: The standard four-level automation pyramid is expanded with a NOA side
channel
Figure 3: To ensure smart monitoring, the data from transmitters and valves is
secured by a security router and transferred via the NOA side channel to a cloud by
means of OPC UA
vices. Based on the security threat, a secu -
rity level (SL) from 0 to 4 is determined
and adapted to the attacker’s capabilities
(Figure 4). Different functional requirements
are set out for the products according
to the attack vector and the security
level (Figure 5).
However, the implementation of functional
measures must not be considered in isolation.
An SL can only be achieved if the
Devices and system requirements
IEC 62443-4-2 defines the technical
requirements for industrial automation deframework
conditions stipulated in
Part 4-1 regarding a secure development
process are met. The security level of a device
or system can therefore only be
achieved by combining processes and functional
measures.
The functional security requirements concerning
the capabilities of automation systems
are detailed in IEC 62443-3-3. Here,
an evaluation assesses the extent to which
cpp 02-2019 23

cpp FOCUS IIOT IN CHEMICAL INDUSTRY
the components comply with the operator’s
functional requirements. This part of
the standard simultaneously determines the
interface between the system integrator
and the device manufacturer. The devices
needed to implement the security level defined
by the operator can be selected on
this basis.
Requirements for system integrators
IEC 62443-2-4 specifies the requirements
for the capabilities linked to the IT security
of industrial automation system services. It
describes the interface between the operator
and the system integrator as well as the core
processes during integration, commissioning
and maintenance. Amongst other things,
this comprises the architecture and configuration
of the automation solution, the
management of user accounts, processing of
events and patch management including
backing up and restoring the automation
solution.
IEC 62443-2-1 covers the requirements regarding
the operator’s IT security programme.
A table specifies all requirements
which should basically enable a transition to
the ISMS as per ISO 27000. This part of the
standard also determines the security level
of the system based on a threat analysis.
The requirements for implementing the
NOA concept are currently being defined in
various working groups. These will ultimately
decide which standards, technologies
and processes should be used. To enable
a gradual introduction of the approach,
it is important to establish a secure connection
from the NOA side channel to external
systems, such as a cloud or server, using
existing security routers. Devices specially
developed for implementing data diodes can
then be utilised in subsequent steps.
www.cpp-net.com
Online search: cpp0219phoenix
Figure 4: Overview of IEC 62443’s various parts
AUTHOR:
BORIS WALDECK
Senior Product Manager,
Business Unit Automation
Systems,
Phoenix Contact Electronics
AUTHOR:
THILO GLAS
Senior Specialist Engineering,
Industry Management
Process,
Phoenix Contact Electronics
Figure 5: Definition of the security level as per IEC 62443-4-2
Figure 6: Definition of functional measures for the security level as per IEC 62443-4-2
24 cpp 02-2019

Predictive maintenance in drive applications
Complete sensor range with IO-Link
Picture: Danfoss
Proven to be effective in the
field, the VLT Automation Drive
from Danfoss provides dedicated
predictive maintenance
features for industrial applications.
Condition monitoring
for motor isolation and me -
chanical vibration using an external
sensor, as well as load-envelope
monitoring convert the
AC drive into an intelligent sensor
that detects issues at an early
stage and reports them before
they can lead to a standstill
caused by the resulting damage.
Condition monitoring for
motor isolation can, for
example, be relevant for motor
applications where failures frequently
occur, with the failure
leading to time-consuming re -
pairs and loss of revenue due to
the production line being forced
to a standstill. The mechanical
vibration monitoring function
helps to detect when motors are
running unevenly due to improper
setup or worn bearings,
and can be useful when it
comes to identifying mechanical
issues at a very early stage.
Load-envelope monitoring is a
special function that enables a
change in a fan's load, e. g. excessive
friction or increased resistance
in the air flow due to
clogged filters.
www.cpp-net.com
Online search: cpp0219danfoss
Bühler Technologies, a German
supplier of advanced accessories
for oil hydraulic and lubrication
systems, introduces a complete
range of connective sensors for
OEM’s and end users. For a
more effective condition monitoring,
the production programme
already includes some
sensors with IO-link controllers
Picture: Bühler Technologiex
according to IEC 61131-9. Now
this type of controllers is available
across almost the whole
range of sensors and cover relevant
operation information
such as liquid level, temperature
and pressure as well as filter and
moisture monitoring. Particularly
outstanding are the integrated
versions of level and
temperature controls, which can
be combined with other essential
functions like breather and
return filter, as well as filling
and sample ports.
IO-Link stands for standardised
wiring and bi-directional communication.
This enables
parametration automatically if
units need to be changed, simplifies
maintenance and opens
opportunities for factory internal
standardisation just to mention
a few advantages.
www.cpp-net.com
Online search: cpp0219buehler
Condition monitoring of pumps, fans & Co.
The Vibguard IIoT from Prueftechnik
with 16 analogue channels
for online machine and
plant monitoring has an MQTT
interface allowing it to be integrated
seamlessly in the IIoT.
The major advantages of the
MQTT protocol include global
data availability at all times, reduced
data volume, and improved
data security. The online
condition monitoring system
can be fully networked via a
broker-client structure. Vibration
measurement data is provided
in a standardised manner and
can be used seamlessly by other
machines and programmes. As a
result, vibration measurement
data can be linked directly with
other measurement data (e. g.
weather, flow rate, etc.) thanks
to machine learning programmes,
for example. Evaluat-
ing such data allows machine
and production processes to be
sustainably improved. Measurement
data can be scaled thanks
to the „Publish-Subscriber“
principle. The user is only
shown the data that is really relevant
via a „Tweet“ (similar to
Twitter). At the same time, live
visualisation is possible, too.
The Vibguard IIoT with 16 analogue
channels was developed
especially for continuous online
condition monitoring of standalone
machines: pumps, conveyor
belts, fans, mixers, compressors,
centrifuges etc. For
global data availability Prueftechnik
supplies the browserbased
Omnitrend asset view
software.
www.cpp-net.com
Online search:
cpp0219prueftechnik
Smart gearboxes with integrated sensor module
Picture: Wittenstein
Wittenstein alpha presents smart
gearboxes as standard products –
gearboxes with cynapse. The innovation
will be available for
gearboxes in the alpha Premium
Line from the launch date and
then gradually extended to all
Wittenstein alpha series. Gear -
boxes with cynapse are identical
with the existing models in
terms of design, size and contour,
so that a drive solution
which has already been designed
needs no further modification.
It is the sensor module integrated
in the smart gearbox that
makes the difference. Thanks to
this sensor module, influencing
quantities in the process and the
environment which impact on
gearbox operation can be iden -
tified, measured and output via
an IO link. So these smart gear -
boxes allow parameters such as
temperature, vibration and operating
hours to be recorded and
communicated to the cloud level
using the standardised connec-
tivity of the IO link interface and
an IO link master. Both there and
in the machine’s immediate environment
this information can
be used, for instance, to improve
the availability and productivity
of processes and equipment in
condition monitoring or predictive
maintenance applications.
www.cpp-net.com
Online search:
cpp0219wittenstein
cpp 02-2019 25

cpp FOCUS IIOT IN CHEMICAL INDUSTRY
Direct access to the control valve
Ethernet communication in hazardous areas
Emerson has released its Severe Service app developed
for process control engineers in need of quick and easy
control valve diagnosis and maintenance. The free mobile
app enables engineers to quickly perform initial sizing
for Fisher globe control valves, as well as diagnose
potential valve problems before damage occurs. Once
sizing and diagnosis have been completed by entering
the valve and application specifics, the app will display a
C v value and potential issues that can arise, such as cavitation
or noise. Users can then share the results with
their internal maintenance teams or their local Emerson
sales office. Features of the app include instant access to
a Fisher control valve sizing tool, severe service control
valve diagnosis information, a large technical library
and a severe service industry application library to keep
users up-to-speed on severe service topics with educational
videos and reference collateral. Severe service
control valves are used in the most difficult installations
within process plants and can fall victim to common issues,
such as cavitation, erosion, high pressure, and
other environmental challenges. The app can help maximise
the longevity of these critical assets.
www.cpp-net.com
Online search: cpp0219emerson
Picture: R. Stahl Schaltgeräte
R. Stahl forcefully drives the
realisation of an explosion-protected
field Ethernet. The IS1+
Remote I/O system already
allows Ethernet communication
in hazardous areas via Profinet,
Modbus TCP and Enternet/IP.
Optical cables with transmission
rates of 100 Mbit/s are used for
fast, explosion-protected data
transmission in zone 1. The fibre
optic, which can cross distances
of up to 30 km depending on
the optical fibre used, has type
of protection „inherently safe“
according to DIN EN 60079-28.
Along the lines of intrinsic
safety „i“, this type of protection
ensures that potentially ignitable
optical energy is limited
to a non-ignitable level even
under error conditions. For
zone 2 and distances of up to
100 m, the more affordable
CAT 5 copper cables with type
of protection „ec“ can also be
used. Even in explosive atmospheres
all modules can be exchanged
during operations (hot
swapping), and IS1+ stations
can always be easily expanded
without disconnection. For the
connection of field devices in
zone 0, 1 or 2, R. Stahl has a
comprehensive range of I/O
modules of series IS1+ with up
to 16 channels that are available
with intrinsically safe, non-intrinsically
safe and even pneumatic
interfaces. With Profinet
connection and comprehensive
diagnosis functions, IS1+ is
ideally suited for predictive
maintenance concepts as well as
for the implementation in plant
asset management systems.
www.cpp-net.com
Online search: cpp0219stahl
Picture: Emerson
Ultra-compact IPC for edge computing
Picture: Beckhoff
By integrating comprehensive
IoT and analytics functionality,
PC-based control technology
opens up a wealth of options to
optimise production. The ultracompact
C6015 Industrial PC
(IPC) is a space-saving, highperformance
IoT edge device to
fully utilise these advantages in
the process industries. Measuring
just 82 x 82 x 40 mm, the
compact C6015 IPC with multicore
technology can be flexibly
installed even in highly confined
spaces. Equipped with an
Intel Atom processor offering
up to four CPU cores, the
C6015 provides sufficient processing
power for simple collection,
processing and provision
of process data and for the more
complex tasks required of a
modern IoT gateway. The Microsoft
Azure certification of the
C6015 underscores that the device
is ideal for state-of-the-art
Industry 4.0 applications.
www.cpp-net.com
Online search:
cpp0219beckhoff
Picture: Bürkert
Positioners with Ethernet interface
The Bürkert positioners and
controllers Type 8692/8693 and
8792/8793 support Ethernet/
IP, Profinet (Conformance Class
B (CC-B)) and Modbus TCP. The
protocols enable extensive diagnostics
functions (e. g. monitoring,
limit value definition of operating
parameters, messages in
accordance with Namur NE107)
and thus improve plant availability.
The integrated two-port
switch allows for star, line and
ring topologies and, thanks to
MRP and DLR, ensures fail-safe
communication right up to the
valve. The integrated BüS interface
facilitates efficient communication
between individual
sensors and actuators of the
Bürkert device platform (EDIP).
This enables rapid networking
of system solutions. All platform
participants can be parameterised
and configured via the
standard software tool “Communicator”.
The positioners
have been optimised for combination
with Bürkert process
control systems (Element) and
enable an array of combinations
with all control valve types, also
from third party manufacturers.
www.cpp-net.com
Online search:
cpp0219buerkert
26 cpp 02-2019

Interoperability test kit
Fieldcomm Group has released version 6.3.1 of the H1 Interoperability
Test Kit (ITK), which further reinforces support for Standardised
Connection Points (SCP). This developer-oriented tool allows
automation suppliers to run a battery of tests against their field devices
to ensure robust and effective support for SCP. SCP represents a
major milestone within Fieldcomm Group’s Foundation Fieldbus
Usability Initiative, which has already delivered backwards compatibility
enabling end users to replace an existing field device with a
like device and have the new device seamlessly operate in the preexisting
state.
www.cpp-net.com
Online search: cpp0219fieldcomm
ES-FLOW TM
Low-flow ultrasonic
liquid flow meter/controller
Hardware platform for Edge applications
Flow ranges from 4 up to 1500 ml/min
Innovative sensor with fast response and high accuracy
Low pressure loss due to the straight stainless steel tube
Dosing with integrated PID controller
Medium independent and temperature insensitive
Hygienic design with capacitive touchscreen
IP67 rating and CIP cleanable
www.bronkhorst.com
Picture: Siemens
Valve Experience.
Made in Germany.
Siemens developed a hardware
platform for edge applications
as part of its Siemens Industrial
Edge concept: the compact Simatic
Edge Device works on the
basis of the embedded industrial
PC Simatic IPC227E, and
features integrated connectivity
to automation on the machine
level. This allows manufacturing
data to be captured and processed
directly at the point of
production. If there is a change
to the framework conditions
underlying the industrial application,
Industrial Edge offers
facility to adjust software applications
on the Edge Device,
keeping them right up to date
using functional, feedback-free
updates. The hardware comes
with a closed all-metal housing,
ensuring maximum industrial
functionality for flexible, maintenance-free
use under even the
harshest of conditions. Rapid
commissioning is guaranteed
using pre-installed Edge software.
Edge computing enables the
local feedback-free processing
of large data volumes practically
in real time. Industrial Edge also
enables users to cut the costs of
data storage and transmission,
as large volumes of data are
processed in advance and ex
clu sively relevant data is subsequently
sent to the cloud or the
company’s own internal IT infrastructure.
Siemens Industrial
Edge supports cloud transmission
protocols for Mindsphere,
the open cloud-based
IoT operating system from
Siemens. In future, it will also
support Message Queuing
Telemetry Transport (MQTT),
which will additionally guarantee
the flexible exchange of data
with other systems and clouds.
www.cpp-net.com
Online search: cpp0219siemens
Check valves | Sampling valves | Bottom valves
We engineer with care
RITAG Ritterhuder Armaturen GmbH & Co.
Armaturenwerk KG | Industriestraße Industriepark Heilshorn 7-9
Sachsenring D-27711 Osterholz-Scharmbeck 30 | 27711 Osterholz-Scharmbeck | Germany | Germany
Phone Tel. 047 +49 95 -(0) 55047 42-0 91-92 | Fax 09-0 047 | Fax 95- 550 +49 42-850 (0) 47 91-92 09-85
eMail contact@ritag.com | Internet | www.ritag.com
cpp 02-2019 27
0001538071_000002.indd 1 08.05.14 09:14

cpp FOCUS IIOT IN CHEMICAL INDUSTRY
High availability and safe shutdown in the pharmaceutical industry
Valve island 4.0
Today, high-performance valve islands that integrate electrical and pneumatic functions
form the basis for pneumatic automation. Process plants benefit from the fact
that they can be controlled via just one bus line and programmed faster. Bürkert
valve terminals fit seamlessly into the process control world, as the following
example shows.
Bild: Bürkert
The treatment of diabetes mellitus was
revolutionised by insulin. For more than a
quarter of a century, this life-saving medication
has been produced industrially with
the help of genetically manipulated bacteria
and yeasts. The requirements placed on the
applied process technology are strict. The
plants not only have to meet stringent
stand ards and legal rules with regard to hygiene
and cleaning; they must also operate
with a high level of precision and reliability.
The Zeta Group, based near Graz in Austria,
is considered a specialist for tailor-made
process solutions for these sterile and aseptic
applications. This technology supplier to
the biotech and pharmaceutical industries
designs, manufactures and installs customised
solutions for renowned companies
worldwide. One example of this is a turnkey
automation solution for a fermentation
plant for insulin production, which was put
into operation in Russia at the end of 2018.
The scope of this project was considerable:
18 tanks, 30 control cabinets and the entire
measurement, control and regulating technology
had to be designed, installed, tested
and certified. A total of 20 valve islands
from Bürkert (Type 8647 Airline SP), which
control about 600 valve functions as part of
the fermentation process, are responsible
The Airline SP Type 8647 valve island is fully integrated into the distributed I/O system
Simatic ET 200SP, guaranteeing seamless integration into the Siemens automation
environment with corresponding software
for electropneumatic automation in combination
with the ET 200SP distributed I/O
system.
Easy integration
There were several reasons for this choice,
as Andreas Rauscheder, project engineer at
Zeta, explains: “Even at the planning stage,
we were able to recognise the advantages of
the new valve island generation compared
to standard pneumatic solutions. Hardware
and software integration into our world of
automation from Siemens facilitated installation,
start-up and parameterisation. Thanks
to the option of fully parameterising the
valve islands using an HSP file in the
Siemens TIA portal, we managed to save a
considerable amount of time and money.”
Another of the system’s decisive advantages
is the external valve shutdown (EVS). A potential-free
contact in the supply power circuit
is used here to cut off the load voltage
of the valves. “It enables us to safely shut
down individual valve modules according to
the Machinery Directive and EN 13849 or
the corresponding SIL requirements.” By
using the EVS function, individual safe
emergency stop circuits can be implemented
on the valve island with little effort.
In the event of an external shutdown, internal
communication on the valve island remains
unaffected and indicates the EVS
function both on the integrated LC display
and via Profinet to the higher control level.
“We were also able to reduce the time and
effort needed; if an emergency stop pushbutton
is actuated by a member of staff, the
valve island at the corresponding plant section
goes into a safe state immediately and
the control centre is also informed of this”,
says a delighted Rauscheder.
28 cpp 02-2019

Bild: Zeta
Bild: Bürkert/Zeta
Fermentation plant for insulin production: A total of 20 valve islands
provide electro-pneumatic integration
By using the EVS function, individual safe emergency stop
circuits can be implemented on the valve island with little
effort. In the event of an external shutdown, the internal
communication on the valve island remains unaffected.
High reliability and availability
In addition to displaying and forwarding
the EVS function, the standard integrated
diagnostics offer further options that help
to increase operational reliability. An integrated
pressure measurement module monitors
the supply pressure and forwards warning
and error messages to the control level
in the event of deviations from the specified
values. Switching cycle counters can also be
used independently of each other for the
pilot valves and the downstream actuators.
Moreover, the switching position of the
process valve can be shown directly on the
display of the valve island by means of an
integrated software function. “Pilot and
process valves can therefore also be iden -
tified visually on site for greater clarity”,
Rauscheder adds. Broken wires, short circuits
and open valve outputs are likewise
detected, displayed directly on the valve island
in plain text and as symbols and forwarded
via the communication interface of
the ET 200SP.
To increase pneumatic availability, Zeta also
opted for the integrated P channel shut-off.
This allows the valve to be changed during
operation without having to depressurise
the rest of the valve island. The non-return
valves, too, are integrated in the valve island’s
exhaust air ducts and additionally ensure
that the process actuators are switched
safely without any adverse effects. “Because
the valve islands have a modular design, we
were able to relocate certain functions to
another control cabinet at a later date. We
only had to replace the corresponding modules
and change the threaded connection”,
Rauscheder comments.
Fast certification
Since the fermentation plant is intended for
the Russian market, the Eurasian conformity
mark of the Eurasian Customs Union was
also required for the valve islands. Zeta was
pleasantly surprised at the speed with
which the fluid experts reacted and pre -
sented the relevant documents. Yet cooperation
proved to be just as rewarding in
other respects. “Delivery deadlines were
strictly adhered to, all advice was spot on
and minor software adjustments that had to
be made were performed quickly”, the project
manager reports. Hence, nothing stands
in the way of continued cooperation for future
projects.
As intelligent electropneumatic automation
systems, valve islands are not only used
widely in the pharmaceutical industry. Very
similar tasks and requirements exist, for
example, in the cosmetics industry, food
and beverages or the water treatment sector.
www.prozesstechnik-online.de
Suchwort: cpp0219buerkert
AUTHOR:
HEIKO KURTZ
Field Segment Manager
Hygienic,
Bürkert
cpp 02-2019 29

cpp FOCUS IIOT IN CHEMICAL INDUSTRY
Pictures: Andritz
Modern IIoT solutions like Metris addIQ Monitoring and Metris addIQ Connect enable plant operators to monitor their plant 24/7
from anywhere in the world
Intelligence for machine and process control
How separation processes
profit from IIoT solutions
IIoT (Industrial Internet of Things) technologies have found their way into solid/
liquid separation plants and processes of all shapes and sizes. Automation solutions
using the IIoT have not only been launched but are already up and running – e. g. the
Metris addIQ control systems. Over the past few years, solutions from the Metris
addIQ portfolio have been tailored and installed in all kinds of solid/liquid sepa -
ration applications and are showing promising results.
Not only higher plant efficiency and increased
profitability but also proactive
measures to prevent shutdowns and improve
monitoring can become reality by applying
new technologies such as Smart Sensors,
Big Data Analytics and visualisation
using both virtual and augmented reality.
Particularly in the fields of operator training
and on-time support, technical information
and guidance are provided by virtual and
augmented reality technologies exactly
where and when they are needed – at the
machine, during the process or in the plant.
Andritz took this approach when pioneering
its IIoT solutions for solid/liquid sepa -
ration equipment and systems featuring advanced
digital control systems, all combined
under the brand name Metris addIQ. (addIQ
control systems are part of Metris, the Andritz
brand for digital solutions). Metris
technologies include state-of-the-art Industrial
IoT solutions as well as any kind of
smart service. These can be fully tailored to
individual requirements, uniting physical
and digital worlds. Metris technologies
form the basis for the digital separation so -
lution portfolio by connecting plant operator
specialists to one another as well as to
Andritz experts. This value-adding inter -
relation not only results in professional
preparation of the collected data, hence improving
the plant’s performance, but moreover
enables plant operators to practice successfully
applied business intelligence.
Communication with the machine
The sharing of knowledge is one of the central
pillars of both the human and the technology
world. In fact, Industry 4.0 is highly
communicative: not only do operators communicate
with each other or with their machines
but the individual machines within a
30 cpp 02-2019

The Metris addIQ dashboard gives a comprehensive overview of the most critical parameters and can be individually configured to the customer’s process needs
plant also communicate both with one another
and with their operators and the
World Wide Web. Communication is thus
key in the world of IIoT – and humans are
not alone in causing errors due to misunderstandings.
Operating errors sometimes
occur because the machine operator has
problems entering the correct commands
into their machine or plant. Andritz was
aware of this and developed an optimised
HMI design, leading to better usability, for
example by incorporating factors such as
eyesight or whether the user is left-handed
or right-handed, and by improving communication
between the machine and the
user. Other features of the HMI are operating
concepts for handling workforce diversity
and cultural requirements, one-look
analysis, mobile connectivity, structured
user access levels for personnel and a multilingual
user-interface, all of which enable
enhanced usability and smoother operation.
Communication with the cloud
If the concept of communication in the
world of IIoT is taken a step further, one
encounters even more opportunities – for
example, the equipment uses the facilities
offered by the World Wide Web to communicate
with its operator irrespective of
its current location. Metris addIQ Monitoring
adopts this approach by displaying the
most important process parameters, as predefined
by the plant operator, for either a
single machine or an entire plant and links
them to a secure data cloud when used together
with Metris addIQ Connect. The
monitoring module not only enables these
parameters to be uploaded online, making it
easy for the operator to access 24/7 from
anywhere in the world; it also includes an
automatic e-mail notifier for the most critical
process alarms. As being notified about a
problematic situation does not actually solve
the problem, the Metris addIQ Monitoring
and Metris addIQ Connect so lutions additionally
permit remote support in any situation
where fast action is needed. Metaphorically
speaking, this solution is a combination
of an observation security system for
the operator and an emergency online chat
facility from the plant’s point of view.
Metris addIQ Optimizing boosts the plant’s
performance based on the data collected as
well as human expertise. The analysing tool
identifies opportunities to improve the
equipment’s performance and increase production
by combining long-term data trending
with analytical software, collecting and
analysing information about every control
loop, control valve, motor and variables in
the process. Process parameters with the potential
to boost performance are iden tified
and their economic impact predicted before
the specialists take over, working together
with the operations and maintenance team
to prioritise the opportunities for improvement
and correct the process where needed.
Processes operating by themselves
The driving force behind IIoT is the fact
that modern machines are more accurate
and more consistent when it comes to capturing,
processing and communicating realtime
data. Andritz decided to include this
claim in the name of its automation line –
the Metris addIQ control systems promise
to “add IQ” to machines, giving them a
brain to function and making them smarter.
This has great potential for quality control,
sustainable practices and overall supply
chain efficiency. As the terms connected
with IIoT have been circulating for a few
years now, more and more systems are fully
developed and more and more practical
examples proving the benefits of this technology
keep appearing. One typical instance
is a wastewater plant in Southern Europe
that installed Metris addIQ Rheoscan, an
automated polymer measurement and dos -
age system.
Prior to installing this new system, there
were numerous requirements to be met, the
most important being reduced polymer
consumption at the belt thickener (to
achieve at least 5 % dry solids at the thickener
discharge). This criterion had to be fulfilled
despite the challenging process entailing
highly dynamic incoming sludge consistency.
The results after using the Rheoscan
module were annual polymer savings of
33.8 % in the belt thickening stage plus
16 % less polymer in the dewatering stage,
cpp 02-2019 31

cpp FOCUS IIOT IN CHEMICAL INDUSTRY
information must be analysed and interpreted,
especially if there is a lot of it to be
processed. This is where big data analysis
comes into play: deviations are predicted
based on the material collected. This provides
the basis for Metris addIQ Optimizing,
allowing predictive maintenance by
drawing on the sensor equipment and the
data analysis. As a result, servicing needs can
be identified at an early stage without running
the risk of plant downtime.
The optimised HMI greatly improves usability and thus communication between the
machine and the user
Andritz overhead filter press A4 2500: The intelligent filter presses operate fully
automatically thanks to a Metris addIQ control system
while producing 11.7 % more biogas. The
fully automated system moreover reduced
the need for operator supervision and increased
performance while at the same time
reducing polymer dosage in the digester, increasing
biogas production and lowering
polymer consumption in centrifuge dewatering.
The plant as a clairvoyant
As machine and plant shutdowns are the
scenario every production company fears
the most, a prognosis of when productionthreatening
errors could occur represents a
real blessing. IIoT solutions target precisely
this goal, making use of existing experience
and data, which they connect and analyse as
a starting point for predicting future events.
Smart Sensors are one element in this predictive
solution. In addition to conventional
sensors, there are micro and wireless sensors
that can be used to collect even more
detailed machine and plant data from
predefined areas relevant for optimising operation.
It is not enough simply for Metris
addIQ Monitoring to collect data: important
Intelligent filter presses
One specific project to be mentioned in
connection with IIoT is an intelligent filter
press, a machine uniting most of the automation
solutions already mentioned. This
filter press operates fully automatically
thanks to a Metris addIQ control system. In
many processes, the filter cake needs to
reach a certain target moisture content, and
this is where the intelligence of the filter
press and its control system is a huge advantage.
The intelligent filter plate in the press
measures the residual moisture content inside
the cake and allows online monitoring.
In this way, filtration can be stopped at the
ideal moment, saving valuable cycle time
and increasing production capacity. As a result,
the plant provides a more consistent
residual moisture content in the filter cake,
leading to more uniform energy consumption
in the thermal dewatering process.
Smart Sensors around the filter press collect
all relevant operating data. A sophisticated
data analytics tool turns this into information
that is relevant during operation.
The Metris addIQ control system monitors
the degree of contamination of the filter
press package, measuring and controlling
the hydraulic and feed pressure as well as
the feed temperature, and makes adjustments
where needed. Other measured val -
ues are supplied by Metris addIQ Monitoring.
The plant operator is kept informed
about the status of the filter press 24/7
around the globe.
www.cpp-net.com
Online search: cpp0219andritz
AUTHOR:
JÜRGEN KERN
Head of Global Separation
Automation,
Andritz
32 cpp 02-2019

Evenly air distribution over the tablet bed
Picture: Lödige
Picture: Dechema
Moving into its fourth decade, Achemasia is
setting out for new horizons. Apart from the
move to Shanghai, where Achemasia will
take place from 21 to 23 May 2019 at the
NECC for the first time, participants can
look forward to a couple of novelties: The
International Expo and Innovation Forum
for Sustainable Chemical Production brings
the latest technologies in this field to the
spotlight. This focus matches China’s strive
to modernise its industrial foundation following
the “Made in China 2025” strategy.
With about 400 exhibitors from some 20
countries Achemasia focuses on the exchange
of experience between scientists and
engineers as well as between equipment
suppliers and users. The booked exhibition
space 2019 exceeds the final count of the
2016 event.
The accompanying congress, composed of
satellite symposia on hot topics of the Chinese
process industry, takes place right in
the exhibition hall. Thus, visitors can make
the most of their day, exploring the exhibition,
joining presentations and finding
the applications at the exhibition stands, all
without the need to cover long distances.
Picture: Heinkel
With the aim of improving process and tablet quality in film coating,
Lödige Process Technology introduced a technical solution by
which the air and thus heat energy is evenly distributed over the
tablet bed. The air in the Lödige coater flows in via a distributor
pipe and circulates around the drum of the coater. The air thereby
enters the drum over an enlarged area, ensuring a very even, almost
turbulence-free airflow inside the coater especially in the nozzle
zone to guarantee optimum coating results. Thermal imaging cameras
were systematically used in the development of the process – the
first time in this area of application.
www.cpp-net.com
Online search: cpp0219lödige
Vacuum contact dryer for toxic products
The Bolz-Summix conical screw
dryer is a vacuum contact dryer.
Due to its contained closed system
and indirect heating of the
product it is particularly suited
for drying hazardous and toxic
products to a very low final
moisture content. As a result of
its unique, gentle mixing character,
even mechanically sensitive
products are not destroyed.
The product quality after the
drying process is reproducible
and as good as that of the initial
product, whereas the driving
forces required are very low. The
achievable, high endvacuum ensures
low drying temperatures
which is a clear advantage when
drying temperature-sensitive
products. It also ensures good
heat transfer rates and short
drying times, while at the same
time requiring only little energy.
The short drying times and the
high containment level of the
fully closed system make the
conical dryer the best choice in
instances where environmental
and/or product requirements
are strict and remarkably high.
www.cpp-net.com
Online search: cpp0219heinkel
cpp 02-2019 33

cpp
TRADE FAIR PREVIEW
Hygienic twin screw pump range expanded
Smart end position monitoring
Picture: Fristam
Fristam Pumps is expanding its
range of hygienic twin screw
pumps to include a Twin Speed
Gearbox (TSG) model. The TSG
model is available as an additional
option for all standard
sizes in the FDS range. In terms
of its construction, it is a simple
and robust mechanical drive
solution with various advantages
compared with the purely
standard three-phase or servo
motors. For applications in
which pumps need to cope with
extreme speed and flow rate
ranges, the TSG offers a very
simple, robust, and economical
solution. This design ensures
that the FDS twin screw pumps
can fully exploit their technically
feasible speed range without
being subject to the limitations
of a standard motor. Another
important advantage is
that by using the Twin Speed
Gearbox in the FDS, the installed
motor power can be reduced
by one to two sizes. Thus,
it not only lowers the investment
costs, but also improves
the energy efficiency of the
powertrain across the entire
speed range of the pumps. And
last but not least, this design facilitates
better and more stable
pump regulation, since it works
in the comfort frequency range
of a standard three-phase motor.
www.cpp-net.com
Online search: cpp0219fristam
Picture: Auma
Auma offers a sensor system for signalling valve end
positions which can be mounted to the company’s
GS .3 part-turn gearboxes. The solution allows plant
operators to monitor the position of manually operated
valves, and hence to collect crucial valve position information
from all the valves in their plants. It can also
be used in combination with electric valve actuators
when redundant valve end position feedback is
required. It uses inductive sensor elements which ensure
contactless monitoring of the end position for 90°
part-turn valves. In contrast to mechanical limit
switches, the electronic sensor system is wear-free and
not subject to corrosion. GS .3 gearboxes can be ordered
with the integral sensor system. The system can
also be easily retrofitted to existing GS .3 gearboxes in
the field. It is available in two versions: a cost-efficient
basic version and a fully-sealed premium version with
aluminium housing offering IP 69K protection. Both
versions are also available with Atex approval.
www.cpp-net.com
Online search: cpp0219auma
Rotating spray nozzles for tank cleaning
Enclosed multilayer filter
Picture: Lechler
Lechler has extended the wide
range of spray nozzles for tank
and equipment cleaning. The
Xactclean HP+ is a technical
evolution of the proven rotating
tank cleaning nozzle Xactclean
HP. It is made for higher flow
rates and offers additional
power especially for bigger
tanks. The Xactclean HP+ closes
the gap between static spray
balls or free spinning nozzles
and cost-intensive, high impact
tank cleaning machines. It enables
the cleaning of tanks and
equipment also at higher pressures
up to 10 bar. Special flat
fan nozzles provide a very
uniform cleaning with high
impact. The robust drive unit
enables optimum rotational
speed and reliable function even
by using contaminated cleaning
media. This increases the process
reliability. The high impact of
the nozzles enables shorter
cleaning and accelerates the
overall cleaning process.
www.cpp-net.com
Online search: cpp0219lechler
The enclosed filtration system
Hermetix from Strassburger
Filter is designed for the demands
of the pharmaceutical industry.
The enclosed multilayer
filter uses depth filter sheets for
filtration. The filter plates are
sealed by circumferential O-ring
gaskets on the filter plates and
the internal filter layers. This results
in 100 % sealing without
leakage. All contact with the
product’s surrounding environment
is eliminated. The system
distinguishes itself by easy
handling and the possibility of
CIP cleaning. The required filter
area can be flexibly adjusted by
the size and number of filter
Picture: Strassburger Filter
plates. A large selection of filter
aids enables the safe separation
of solids and microorganisms.
High yields and drip losses are
of utmost importance for the
economic efficiency of processes
in the pharmaceutical
sector. The Hermetix filter press
was designed with a hermetic -
ally sealed filter plate package to
meet these requirements. Without
drip losses and with maximum
yield. The special design
allows the Hermetix filtration
system to be completely emptied.
www.cpp-net.com
Online search:
cpp0219strassburger
34 cpp 02-2019

Temperature resistant graphite rupture disc
Picture: Rembe
The graphite rupture disc GRX
has been developed for processes
with corrosive media,
low pressure and temperatures
of between -180 and 1500 °C.
The GRX is available with a synthetic
resin coating (process
temperatures up to 200 °C), as
well as a PyC coating, developed
specifically for the GRX (temperatures
above 200 °C). With
the PyC coating, the rupture
disc holds significantly longer at
very high temperatures, while
remaining permanently leaktight.
With an operating pressure
ratio of up to 90 % and
burst tolerances of ±5 %, the
GRX is usable for rupture pressures
from 0.02 bar. Optionally,
a vacuum support can be integrated,
which is installed without
adhesive (which melts at
very high temperatures). The
GRX is also available with a
burst indicator, upon request.
The installation occurs directly
between the flanges. So far, the
GRX has already been installed
in various reactors, tanks, glass
containers and other system
parts in the chemical and petrochemical
industry.
www.cpp-net.com
Online search: cpp0219rembe
Emission control &
energy recovery
Metallic sealing process valves
The butt-weld end version of Zetrix, the metallic sealing, triple
offset premium process valve, is an addition to the ARI range. It
is available in sizes DN 80 to DN 600 for PN 6 to PN 40 (class
150/300). The fully lugged, wafer flange version is additionally offered
in DN 80 to 600 for PN 63/100 (class 600). For several years,
this sophisticated range of process valves with metallic sealing and
a self-aligning sealing ring has been rounded off with a double
flanged version. Zetrix valves combine extreme reliability and durability.
All models have a stellited seat and are firesafe tested with
bidirectional gas-tight shut-off and zero leakage according to
EN 12266–1 and API 598.
www.cpp-net.com
Online search: cpp0219ari
Process integrated solutions
for industrial gas cleaning
GEA is a main supplier of tailor-made
solutions for emission reduction, for
the recovery of valuable substances,
recycling of heat and for conserving
resources. GEA is the partner to contact
when it comes to:
• dust removal
• desulfurization (DeSOx)
• absorption of gaseous pollutants
• NOx reduction
• flue gas cleaning
• gas cooling
• energy recovery
For contact details: gea.com/contact
or visit us at AchemAsia hall 7.1/E31.
Picture: ARI Armaturen
cpp 02-2019 35

cpp
PROCESS ENGINEERING
Packings and trays
Design software for
mass transfer columns
Whether you are a process engineer at a design institute or a technologist working
for a production plant, Sulcol – the design software for mass transfer columns –
helps customers to design a new column and compare the column sizes with different
mass transfer components, calculate the maximum capacity of existing columns,
determine the bottlenecks in column operation and explore the use of internals with
higher performance.
Pictures: Sulzer
The Sulcol design software helps determine the full potential of a mass transfer column
Sulzer first developed hydraulic design
software to support customers with column
rating and design in the late 1980s. Sulcol
now makes Sulzer’s expertise readily available
to customers. It helps users to rate or
design their fractionating or absorption columns
with Sulzer proprietary mass transfer
products. The minimum input to the programme
is the fluid data – mainly the vapour
and liquid mass flows with their respective
densities. Sulcol also supports the
direct import of hydraulic data from simulation
software, e. g. spen Plus or PRO/II
Process Engineering. Since packings and
trays require different design specifications,
different data must be entered and the
graphical user interface (GUI) varies within
Sulcol. When the mass transfer component is
selected, the programme calculates the predicted
hydraulic performance of the column.
A good hydraulic design ensures that the desired
efficiency of the tray or packing is
achieved.
Selection of the packing type
During packing design, users can choose
the most suitable packing type for their process
from Sulzer’s wide range of packing
products. If a Mellapak or Mellapakplus
structured packing is selected, the default
packing efficiency represented as height
equivalent to theoretical plate (HETP) is
shown. This reference value will help engi -
neers to determine the packing height
required for separation. The same fluid data
processed with a different type of packing
will show different HETP and capacity factors,
leading to a different column design.
This information allows users to decide on
the type of packing best suited for their particular
process. Some users prefer a visual
representation of the operating boundaries
36 cpp 02-2019

Functionality of the Sulcol software
Comparison of the capacity limits of MVG trays and UFM trays with
Sulcol
of the selected packing type. Sulcol has a
built-in function to generate a capacity diagram
with just one click. This diagram,
known in the industry as a performance
chart, displays the design point as a red dot
alongside the maximum flood and maximum
capacity curves. Like a “you-are-here”
dot on a city map, you know where your
column capacity level is and you see clearly
how far it could go. The diagram gives you
an idea of how much more capacity you
could achieve with the specified column diameter
and the selected structured packing.
Apart from structured packings, generic
rings as well as the entire range of Sulzer
proprietary Nexring random packings are
available in the software.
Help with tray design
Tray design requires additional geometrical
input such as the column diameter, tray
spacing, number of passes and downcomer
dimensions. If a user is designing a new tray
section from scratch and is unsure how to
start, the design software is the ideal tool.
The “Initial Design” button automatically
calculates an optimised column diameter
based on the selected tray type. Pressing the
“Optimise D.C.” button calculates the downcomer
size based on the specified liquid
inlet velocity. These two wizards allow users
to work up a preliminary tray design within
minutes.
Sulcol helps users to design columns with
Sulzer proprietary tray types such as BDH
valves, V-Grid valves like MVG and UFM and
UFM AF – the latest valve products. The
UFM is a mini floating valve that offers a
high capacity and broad operating flexibility.
The UFM AF is a larger, fixed valve featuring
the same special umbrella shape,
which provides both high capacity and
great fouling resistance.
Other wizards are also available. With a
single click, users can quickly assess the hydraulic
performance of VGPlus and UFM -
Plus, the two high-performance trays. The
software presents the extra throughput and
operating range of these high-performance
trays, which is achieved through a combination
of enhanced downcomers and highcapacity
valves. The help section contains a
user guide to the programme as well as
product information on Sulzer’s mass
transfer components.
Practical use in a refinery …
A reformate splitter is used to separate benzene
and lighter components from the reformate
received from the upstream catalytic
cracking reformer. This reformate
splitter was built in Texas ten years ago. The
column was originally installed with MVG
trays. Some years later, the United States Environmental
Protection Agency (EPA) stated
that blended gasoline in the US must have
less than 0.62 % benzene by volume. This
would have inevitably led to an increase in
feed to the reformate splitter. As the column
was already operating at maximum capacity,
the existing MVG trays could not handle the
estimated extra 15 %.
With Sulcol, the client was able to explore
the different types of trays available for a revamp.
The column was eventually revamped
with UFM trays with sloped downcomers,
running at 110 % of the original feed rate.
The UFM trays were designed for 115 %,
but this capacity was not realised due to the
limitations of the refinery’s existing reboiler.
… or in a petrochemical plant
The technologists at a South-East Asian
petrochemical plant were leading a revamp
study for their aromatics unit. They were expecting
a change in feedstock flowrate and
composition, and process simulation was
conducted to determine the internal vapour
and liquid loadings of the columns. Using
Sulcol, the technologists were able to perform
a preliminary hydraulic evaluation of
the existing columns with the new loadings.
The depentaniser, which removes C5 hydrocarbon
and lighter components in the top
stream, was identified as the bottleneck. The
internal vapour loading was set to increase
by 36 % while the liquid loads were predicted
to increase by 30 %. The existing
BDH trays were not able to handle these
new loadings. With the help of Sulcol wizards,
the technologists identified UFMPlus
as a possible solution for the revamp and
contacted Sulzer regarding a further
optimisa tion of the UFMPlus trays.
www.cpp-net.com
Online search: cpp0219sulzer
AUTHOR:
CHEW PENG ANG
Tray Product Manager,
Technology Management
and Process Innovation,
Sulzer Singapore
cpp 02-2019 37

cpp
ENVIRONMENTAL ENGINEERING
Waste-free process using fluidised bed spray granulation
Fertiliser from phosphoruscontaining
ashes
More than 90 % of the world’s phosphorus reserves are outside Europe. For this
reason, Germany regulates the recovery of phosphorus by law. As the amended
Fertiliser Regulation restricts direct soil-bound recycling of sewage sludge containing
phosphorus, many disposal companies will be forced to establish alternative
recycling methods. Phos4green is a two-stage method that extracts phosphorus
from sewage sludge ash and converts it into ready-to-use fertiliser granulates.
Current phosphorus recovery processes
have the disadvantage of producing large
quantities of waste and being restricted to a
certain raw material matrix. The German
Fertiliser Regulation (DüMV) also places
high demands on recycled fertilisers, which
in many cases are not yet met. In cooperation
with an industrial partner and the
Material Research and Testing Institute at
Bauhaus University Weimar (MPFA), Glatt
Ingenieurtechnik has developed a highly
efficient process: Phos4green extracts phosphate
from sewage sludge ash, which is
then converted into residue-free, ready-touse
standard fertilisers using fluidised bed
spray granulation. The project was funded
by the German Federal Environmental Foundation
(DBU). The process is an ideal way to
close the gap in the phosphorus cycle by
combining recycling with manufacturing
and creating an end product that can be
sold directly.
Two-stage process
To initiate the conversion reaction, a
suspension is prepared from the phosphatecontaining
ash with a mineral acid. This step
is necessary to make the ash-based nutrients
available to the plant. The suspension is always
produced specifically for the desired
end product and adapted to the available
raw materials. Depending on the application,
water and other solid or liquid
nutrient components, including additional
phosphate sources, can be added. To
homogenise the raw material components,
the phosphate conversion reaction is sepa -
rated from the granulation process. This
offers a number of advantages: the spontaneous,
high-energy reaction that normally
occurs when phosphate-rich ash and a mineral
acid are combined takes place in a controlled
manner because the free acid has already
reacted in the suspension. In addition,
the process is suitable for a variety of ash
types. The subsequent spray granulation
process refines the digested phosphate to
create a marketable product.
Continuous fluidised bed process for products in organic and conventional farming
Pictures: Glatt
Granulation in the fluidised bed
When it comes to particle-forming, fluid -
ised bed technologies are among the leading
processes and are ideally suited for
economical manufacture of tailor-made fertilisers.
The process permits liquids to be
dried while simultaneously producing dustfree
granulates with a compact, homogeneous
structure, a dense surface structure and
high abrasion resistance. In addition, the
solubility of such granulates can be easily
adapted to the application. If required, the
particles can then be coated with a functional
layer to protect the active substances
from storage, transport or application-related
influences, mask unpleasant off-notes
and facilitate both branding and the targeted
release of active ingredients. The outcome
is fertiliser granules with a pronounced
depot effect and a defined nutrient
supply to ensure optimum dosage and the
38 cpp 02-2019

The fertiliser granules can be coated with a coloured branding or with a pH-controlled
release profile
The spray granulated, ready-to-use fertilisers can be
packed, marketed and dosed directly
reduction of any undesirable drift phenomena
during application.
In the case of phosphate recovery for fertiliser
production, the process duration can
vary widely depending on the raw material(s)
and the end product. In addition, the
different formulations in the suspension
also behave very differently; some substances
tend to stick together, which can be
compensated by adjusting the operational
parameters. The mixture of solid and liquid
components in the phosphate suspension is
sprayed into the process chamber and the
solvent evaporates immediately. The remaining
solids serve as carrier germs for the
formation of new fertiliser granules. In a
cyclic process, the entire surface of each of
these primary particles is wetted with spray
liquid and subsequently evaporated to form
a solid shell consisting of several layers. As
soon as the required target size is achieved,
the product is discharged and can be
packed, marketed and dosed directly.
Complex fertilisers
Complex fertilisers (such as NP, PK and
NPK) can be produced using the same process
and an adapted recipe. Parameters such
as particle size, residual moisture and solids
content can be specifically manipulated to
achieve a broad spectrum of product properties.
Thanks to the high particle density
and low specific surface area, this also
applies to the subsequent application of a
functional coating. Combinations can be
easily integrated into the process and their
product properties optimised. From an ecological
point of view, the new fertilisers –
with a phosphate content of up to 46 % –
are suitable for both soil- and plant-specific
fertilisers in organic and conventional farm -
ing. Fluctuations in the ash composition can
be compensated without any problem by
adjusting the recipe.
The Phos4green process is particularly
economical and meets current market
requirements for the production of readyto-use
standard and multicomponent fertilisers
based on recycled phosphate (no raw
phosphate is required). Compared with
other recycling processes, this method is
100 % waste-free and the ash is completely
reused. No harmful intermediate products
or waste gases are created during the entire
process. In addition, the fertilisers contain
92 % less cadmium and around 9 % less
uranium than other recyclates; also, the pollutant
content is well below the legal limit
values.
www.cpp-net.com
Online search: cpp0219glatt
AUTHOR:
JAN KIRCHHOF
Senior Sales Manager Process
and Plant Engineering,
Glatt Ingenieurtechnik
cpp 02-2019 39

Industrial rotary tablet presses
International representatives of almost all
user segments gathered at Powtech, when
825 exhibitors from 35 countries showcased
their innovations and best practices in
six halls. The high quality of the event was
not just reflected in the exhibitors but also
in the first-class programme of the Partec
Congress and the exhibitor presentations in
the exhibition halls. “In its scope and diversity,
the pairing of Powtech and Partec
makes for an event that is not to be missed
by industry representatives,” stressed Beate
Fischer, Director of Powtech and Partec.
One highlight of the Partec Congress was
the presentation of the Friedrich Löffler
Prize by the VDI-GVC during the official
opening of Partec. This award recognises
young experts from industry or the research
community who have demonstrated particular
merit in the fields of particle research,
particle technology and product design.
Jun. Prof. Dr.-Ing. Carsten Schilde from
the Institute for Particle Technology at the
TU Braunschweig received the award for his
outstanding engineering achievements and
knowledge in the field of particle characterisation
and modification.
Picture: GEA
Range of dispersion equipment
Particle measurement without
dispersion does not work.
Therefore Parsum offers a wide
range of dispersion equipment
for their inline probes – the IPPseries.
These small accessories,
mounted directly on the probes,
are being operated with compressed
air and dilute and sepa -
rate various particle streams
with different properties. There
are dispersers with low shearing
forces ensuring a sensitive treatment
of the granules, while particles
below 100 μm can be dispersed
with high shearing
forces, such as found in milling
processes. Thus, sticky, wet and
most adhesive particles can be
separated as needed. As well as
GEA’s R-series rotary tablet
presses allow for short cleaning
and format changeover times
and the tool-free disassembly
and reassembly of all removable
parts. The R55 is a versatile industrial
rotary press for a wide
range of powder product processing
applications. It can be
supplied with a number of optional
features to improve and
expedite the tablet production
process and provide higher lev -
els of control. The hold-up/
hold-down system, in combination
with an optimised die
design, prevents tablet lamination
or capping, and features
such as die wall and punch face
lubrication are designed to optimise
tablet ejection. In addition,
proprietary punch holders with
bearings rolling on cams mean
that ejection forces up to 10 kN
can be tolerated. Steel, carbide
and ceramic compression tools
can be supplied as standard, but
the customer is free to use a
third-party source. GEA will
provide the necessary tool
drawings with the press.
www.cpp-net.com
Online search: cpp0219gea
for dispersion in liquids and the
extraction of dispersed partial
currents, there are suitable so -
lutions available.
This means that the growth of
particles in fluidised beds or
high shear processes can be
tracked in real time. A moisture
content of 20 % and more does
not interfere the measurement.
Even if layers of powder settle
on the surface and the windows
of the processing chamber, the
optics of the probe remain free,
due to an elaborate beam design.
In continuous processes
this enables cleaning intervals of
up to several weeks and months.
www.cpp-net.com
Online search: cpp0219parsum
Picture: Mareike Bähnisch
Picture: Parsum
40 cpp 02-2019

Smart vacuum conveying
Picture: Piab
As it becomes ever important to
ensure the ingredients are conveyed
in a controlled manner to
dosing and mixing equipment,
the autotuning feature of Piab’s
Piflow Smart vacuum conveyor
automises the process of
powder and bulk conveying.
Based on its renowned Coax
ejector technology, the Piflow
Smart is pre-programmed with
advanced algorithms to elimi -
nate complex manual timer settings
and allows continuous
adaptive automatic fine tuning
of the conveying process as well
as recipe handling. Equipped
with advanced sensor technology,
it optimises and increases
throughput up to 50 % higher
compared to conventional conveyor
systems. Smart electrical
control data collection and
analysis for overall process optimisation,
and real-time adjustment
become part of the daily
routine.
Moreover the Piflow Smart
vacuum conveyor is equipped
with further elements that allow
easier and safer product handling.
These are among others,
automatic filter cleaning,
multiple filter shock, material
safety blockage function and
antistatic filters and seals upon
request. For usage in the pharmaceutical
and food industries
all materials in contact with the
conveyed product fulfil the
requirements of FDA and EC No.
1935/2004 and are designed
according to USDA guidelines.
www.cpp-net.com
Online search: cpp0219piab
Modular vacuum processing plants
The modular vacuum processing
plants Zoatec BG structured in
assembly groups can be used
when dry powders and liquids,
or liquids and liquids, have to
be mixed, dispersed and emulsified.
As a result, they cover a
wide product spectrum for
liquid to semi-solid applications
in the food industries. In addition,
they are characterised by
short batch times. The complete
processing plants from AZO
Liquids are assembled from
Picture: AZO
standardised modules. The modules
are independent from the
process parameters, and can be
adapted to the requirements. The
entire series is designed according
to similar geometrical principles,
thereby making scale-up
considerations much more precise.
As a result, it is possible to
concentrate on the actual process
parameters in the planning
phase, in order to make realistic
predictions. Furthermore, the
design offers advantages in the
areas of production, cleaning
and maintenance. The vacuum
processing plants range from
10 l pilot plants through to
12,000 l production plants; and
from 100 up to 5000 l/h in the
case of plants for continuous
production processes.
www.cpp-net.com
Online search: cpp0219azo
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TRADE FAIR REVIEW
Self-cleaning sight glass
Docking system for big bags
Picture: Riera Nadeu
Conventional sight glasses are
often dirty and hinder a clear
view in process rooms. The selfcleaning
sight glass from the
Catalan process equipment
manufacturer Riera Nadeu can
be used for any kind of equipment
which requires permanent
visibility into the interior. The
Rina RSG – Rina rotating sight
glass – is a dynamic sight glass
that stays clean during the entire
operation. It uses the centrifugal
force to keep itself clean
and dry. The Rina RSG consists
of a static frame on which a
pneumatically driven motor is
mounted. In this frame, both – a
static glass and a dynamic glass
are mounted one behind the
other. On the frame is a purge
line for nitrogen (or clean air)
which permanently flushes the
space between the static and dynamic
glass. The continuous circulation
of nitrogen is used for
blanketing as well as for generating
an overpressure in order
to avoid fogging and/or ingress
of media which would hinder
clear visibility through the
windows. The extremely high
rotational speed of the dynamic
glass (18,000 min -1 ) prevents
the adhesion of moisture or
sticking of products. In addition,
there are no rotating parts
causing friction. The air of the
drive ensures cooling and thus
supports the nitrogen purge
while avoiding heat transfer of
the rotating glass.
www.cpp-net.com
Online search:
cpp0219rieranadeu
Picture: Dietrich Engineering Consultants
The Dec docking system for emptying and filling big
bags and bags guarantees a very high containment value
of

Milling slurry with high viscosity
Clean packaging of powdery products
Compared to a conventional ball mill, the super fine
mill Micros from Nara Micros is a wet milling machine
with a completely different milling mechanism. The
compression and shear force applied to the materials
are generated by the movement of the milling rings
against the lining of the vessel. In addition, the grinder
is directly driven by a powerful electric motor. Therefore,
Micros is suited for milling and dispersing slurry
with high viscosity in a short processing time.
www.cpp-net.com
Online search: cpp0219nara
Picture: Haver & Boecker
Picture: Nara
The Adams technology of the
Haver & Boecker Machinery
Division allows clean packaging
of powdery, bulk products into
watertight PE packaging. The
completely closed packaging
protects highly sensitive products
from loss and secures the
quality against environmental
impacts. Packaging in watertight
PE containers offers precisely
these advantages. The bags are
both tear-resistant and waterproof.
They offer high UV and
aroma protection, which is a
critical advantage especially for
hygroscopic products. At the
same time, the environment is
protected against contamination
by potentially hazardous substances.
www.cpp-net.com
Online search:
cpp0219haverboecker
Constant monitoring of PW and WFI
Combined drying and cooling
Picture: BWT
Aqu@sense MB from BWT
monitors microbiological
quality in pharmaceutical water
systems. The use of these alternative
rapid microbiological
methods is assisted by USP
and EP 5.1.6 and supported
by the Online Water
Bioburden Analyzer (OWBA)
Workgroup, formed by leading
pharmaceutical companies.
Compared with conventional
microbial counts, Aqu@sense
MB reduces the per-sample labour
costs. The results are also
produced very quickly, enabling
a rapid response. The increased
number of samples reduces the
potential for errors and stand -
ard deviation. The Aqu@sense
MB can differentiate between
living and dead bacteria and
also measures non-cultivable
bacteria.
The reliable solution it provides
is based on the method of flow
cytometry, which is specifically
adapted to the requirements of
critical utilities. This compact,
ready-to-connect, user-friendly
analyser is suitable both for
continuous online use in processing
for example on a
Loopo, where it controls the
tank feed from the generator
and the return feed from the
distribution system, and for
manual sampling.
www.cpp-net.com
Online search: cpp0219bwt
Picture: Allgaier
The TK-D combined drum
dryer/cooler from Allgaier
Process Technology is based on
the Mozer system. It enables the
previously dried solids to be
cooled to particularly low temperatures
close to the ambient
or cooling air temperature. The
technology is chracterised in
high energy efficiency with
heat recovery.
The system can be used for
processing free-flowing bulk
materials as well as sticky,
clumping or highly abrasive
materials. The individual design
enables a very wide range of
applications for throughput
capacities from 1 to more than
350 t/h, as well as process steps
combined with drying. The
cooling of the solid material
to particularly low temperatures
is made possible by a single
pass design with a separate drycooling
chamber of the drum.
There are no points of contact
between the material cooling
and the hot inner drum in the
inlet area of the dryer.
By using previously cooled
air instead of ambient air,
the solids of special products
can even be cooled down to
temperatures of 10 °C. The
dryer can also be equipped
with a hot inner drum. With a
two-part configuration of the
central chamber, exhaust air
streams from the drying zone
and from the cooling zone can
be ex tracted and dedusted
indiviually.
www.cpp-net.com
Online search: cpp0219allgaier
cpp 02-2019 43

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PLANTS, APPARATUS, COMPONENTS
Pictures: Busch
Central vacuum system with Cobra NX screw vacuum pumps and Panda vacuum boosters
Dry vacuum systems for the centralisation of vacuum supplies
Efficiency throughout
the line
Using the Cobra NX screw vacuum pump, Busch is able to configure complex
vacuum systems for many applications. The operators of these central vacuum
supply systems value the absolutely clean exhaust air, which is entirely free of
contaminants, the extremely low maintenance effort involved and the energyefficient
operation in conjunction with pumping speeds and vacuum levels
adjusted precisely to process requirements.
The concept, design and realisation of
central vacuum supplies is one of Busch
Vacuum Pumps and Systems’ core competencies.
Thousands of such vacuum systems
are in operation worldwide. A wide range of
operating principles are applied for generating
vacuum in the individual pump modules.
In addition to oil-lubricated R 5 rotary
vane vacuum pumps, dry-compressing vacuum
modules can be used, for example in
vacuum systems with Cobra NX screw vacuum
pumps.
The centralisation of the vacuum supply in a
plant should be seriously considered if
multiple processes or machines require vacuum.
Using the Cobra NX screw vacuum
pump, Busch is able to configure complex
vacuum systems for many applications.
These systems are employed whenever absolutely
clean exhaust air is required or
when contamination between the pumped
medium and an operating fluid must be
avoided at all costs. This is the case when a
house vacuum is generated in research and
development departments, laboratories,
production areas in the semiconductor industry
or areas where hygiene is critical,
such as in the pharmaceutical industry.
Individually tailored
Busch tailors the design of these central vacuum
systems to the specific application. The
main modules are Cobra NX screw vacuum
pumps, whose working principle does not
require operating fluids. Vacuum systems
such as these can be adapted to the required
pumping speed by selecting the appropriate
size and number of Cobra NX screw vacuum
pumps. By also using vacuum
boosters, it is possible to increase the
pumping speed and vacuum level cost-efficiently
and effectively.
Cobra NX screw vacuum pumps can be used
without operating fluids since the moving
parts do not come in contact with each
other. Two screw rotors rotate in opposite
directions in the cylinder of the vacuum
pump. The pumped medium is trapped between
the cylinder and the screw chambers,
compressed and transported to the gas outlet.
There is only a very small clearance between
the screws and the housing, so that
the individual components do not touch.
This means that there is no friction, which
would otherwise require a lubricant to be
used in the compression chamber. The
newly developed screw profile and the unimpeded
gas discharge ensure even temperature
distribution throughout the pump
body, leading to a lower thermal load and a
longer life cycle.
Economical operation
Cobra NX screw vacuum pumps require a
lower motor power per se than oil-lubricated
or liquid ring vacuum pumps. A
44 cpp 02-2019

200%
150%
Vacuum Booster
100%
Backing Pump
Saugvermögen V
50%
0
0,01 mbar 0,1 mbar 1 mbar
10 mbar 100 mbar 1000 mbar
Ansaugdruck p
Pumping speed of a vacuum pump combination of backing pump and
vacuum booster
Cutaway drawing of a Cobra NX screw vacuum pump
further advantage is that Cobra NX screw
vacuum pumps can be equipped with a frequency-controlled
motor, which enables demand-driven
operation. This can lead to
further considerable energy savings as compared
with a decentralised vacuum supply.
With a decentralised supply, every individual
vacuum pump must be designed to
meet the maximum demand at the respec -
tive consumer.
However, in practice, it is often the case that
the maximum power is seldom required
simultaneously by all vacuum consumers.
The central vacuum system control concept
ensures that only the number of vacuum
pumps required to meet the demand at a
given time are actually in operation. These
can be powered down even further through
frequency control. Thanks to this dry vacuum
technology and demand-driven control,
central vacuum systems can achieve
energy savings of up to 60 %. In addition to
the lower energy consumption, there is also
a reduction in operating costs: maintenance
is restricted to a minimum due to the contactless
operation. Only the gear oil has to
be changed every 8500 operating hours or
once a year.
Cobra NX screw vacuum pumps are watercooled.
This facilitates the use of pump
waste heat. All vacuum pumps can be connected
to a common cooling water circuit,
for example, and cooled via a heat exchanger,
thereby generating warm water for
other applications in the plant.
www.cpp-net.com
Online search: cpp0219busch
AUTHOR:
ULI MERKLE
Head of Marketing Services,
Busch Dienste
1 9 6 9
2 0 1 9
Gas Analysis
SAMPLE GAS PUMPS
· designed for aggressive
sample gas
· pumps sample gas with
condensate
· ATEX versions category 2
40 Years Atex Experience
BUEHLER-TECHNOLOGIES.COM >> product introduction • data sheets • contact person
cpp 02-2019 45

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PLANTS, APPARATUS, COMPONENTS
Predictive and preventive maintenance
More efficiency for asset
management
Today’s process industries face massive challenges when looking after their
plant-wide assets. Yet tackling these tasks has never been easier thanks to the
availability of digital technologies which enable predictive maintenance and
the additional benefits this brings.
As process industries expand their presence
around the globe, it is increasingly important
to track the condition of connected
assets across different sites in real time and
from one central location. Furthermore, the
need to prioritise asset renewals and capture
process knowledge becomes even greater as
infrastructures and workforces age. The fundamental
questions now being asked are
“Can I avoid unplanned maintenance in my
plant?” and “If failure is inevitable, how do
I get to know well in advance of its likelihood
so that I can prepare?”.
Who is affected?
Plant asset management systems typically
have two different user types. First, there is
the site or plant owner, who has an active
interest in tracking the overall status of all
assets through real-time condition monitoring.
Within the plant there are process engineers
interested in the details of each
component and the likelihood of it provoking
a bottleneck or the reasons why it is
underperforming and causing production to
run at lower capacity. At the same time,
multi-national companies with enterprises
around the world are keen to compare the
performance of assets across all sites. In this
case, it is critical to be able to display the
information in dashboards, in order to see
at a glance how a process is running or
equipment is performing.
The second user type is responsible for entire
fleets. Fleet owners may not be interested
in the plant’s day-to-day capacity performance.
Instead, they may be subject
matter experts (SMEs) who specialise in
equipment such as compressors. By monitoring
a compressor fleet across several
sites, SMEs can then compare performance
data, perform root cause analyses and track
any weak links.
For both these user groups the benefits of
plant asset management include:
• Reduced time for anomaly detection and
root cause analysis
• Increased asset utilisation and uptime
• Reduced maintenance costs by shifting to
predictive maintenance
• Mobile access to asset performance information
• Fleet enterprise view and analytics of asset
performance
What is affected?
Among the assets best placed for real-time
condition monitoring are process automation
systems, connected devices and field
devices such as sensors and actuators. This
includes basic instrumentation equipment
for all processing and manufacturing industries,
motors, transformers, circuit breakers,
complex electrical or rotating equipment
and mechanical handling equipment such as
conveyor belts.
Pictures: ABB
Managing and protecting assets through smarter maintenance practice
Digital solutions
Predictive maintenance is the ability to determine
exactly how an asset is performing
by identifying, diagnosing and prioritising
imminent equipment problems – not just
locally but at an enterprise-wide global
level. In the event of a problem, users can
make informed and quick decisions based
on clear recommendations. The possible actions
range from immediate attention to
46 cpp 02-2019

identifying issues that can be resolved du -
ring routine maintenance. This helps companies
reduce unscheduled downtime, prevent
equipment failures, extend their asset’s
lifecycle and make sure that the installed
base is operating and maintained optimally.
Traditionally, predictive maintenance will be
carried out by SMEs with years of experience
understanding the characteristics of
critical equipment such as compressors,
pumps or motors. Software tools already
available today try to capture the experience
of such experts and apply them programmatically
to diagnostic data.
For example, the performance of a heat exchanger
can be continuously monitored and
alerts generated when that performance
starts to degrade beyond a certain point. The
operator can then decide whether to continue
running the heat exchanger, schedule
maintenance or stop the process immediately
for instant repair. Costly failures are
avoided, or else the operator takes a conscious
decision to continue with a calculated
risk.
Future technologies, such as machine learning
(ML) and artificial intelligence (AI), are
set to offer more advanced analytics that
will make predictive maintenance decisions
quicker. Applying ML and AI to huge chunks
of diagnostic data can automatically cleanse
it, detect anomalies and highlight them for
the SME. Thus, the SME can focus on these
anomalies and rapidly determine why performance
may be slipping.
Flexibility in deployment
With confidence growing in cloud technology,
it is only a matter of time before users
move away from on-premise solutions. In
the interim, some automation vendors are
offering Edge computing devices for those
users preferring on-premise software. Edge
technology acts as a platform for applications
to give customers the option of operating
solely on the premises rather than in
the cloud.
For example, ABB Ability Edge secures the
connection between the cloud, control systems
and smart devices, efficiently separating
information technology (IT) from operational
technology (OT). Data from Edge
can be utilised for plotting, charting, trending
and dashboards. Alternatively, it can be
used by experts in data analytics or connected
to ERP and maintenance systems. The
extensive connectivity capabilities allow
Edge to ingest data from countless devices
and systems and make it available for cloud
applications.
Flexibility in deployment and a consistent
ABB Asset Management: quick comparison and benchmark of key performance
indicators of running process equipment across sites
architecture across the cloud and Edge allow
customers to use the same asset condition
model, either in the cloud or near the
source using Edge. Flexibility in connectivity
is likewise important. As well as the control
system, Edge provides the ability to
connect to many other assets, including the
numerous IoT devices that are meanwhile
being deployed in non-mission critical
monitoring.
While often referred to as low cost sensing,
these IoT devices can make a substantial
contribution to understanding an asset’s
performance. The biggest benefit of using
the cloud is the computation power for
overall analyses on a fleet/enterprise level
together with the ability to share data instantly
between different teams across the
enterprise.
The consistent architecture across Edge and
the cloud enables seamless OT/IT integration
as well as effective asset management,
from individual devices to the entire
fleet.
Asset Management Application
ABB is taking a lead with the launch later
this year of its Asset Management Application,
a comprehensive library of asset
models including a tool for customisation
and advanced analytics. This web-based application
provides fleet and enterprise dashboards
of asset status. The Asset Management
Application allows quick comparison
and benchmarking of key performance indicators
for running process equipment across
different sites. It helps customers achieve
higher levels of productivity and improve
economic return to meet their performance
and quality objectives. The application
Ability Edge for process automation enables
full scale digital enterprise
avoids costly failures in the process industry
by managing and protecting assets through
predictive and preventive maintenance. By
optimising workflows and providing indepth
analyses of data, asset management
strategies are more cost effective and feature
better decision-making.
www.cpp-net.com
Online search: cpp0219abb
AUTHOR:
NEIL SHAH
Global Product Manager for
Device Management and
Asset Optimisation,
ABB
cpp 02-2019 47

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PHARMACEUTICAL ENGINEERING
Automated particle measurement in the hot air tunnel
Goodbye manual work
The measurement method traditionally used for the filter integrity test at the sterilising
tunnel involves a lot of manual work. This has been a thorn in the side of developers
at Bausch+Ströbel for quite some time. Together with Infrasolution, they
have now developed a fully automated solution with Lineartwinscan.
Pictures: Bausch+Ströbel
The old test method required a great deal of manual labour on the part of the operator
Taking meticulous care, an operator guides
an instrument with a measuring funnel
under the sterilising tunnel filter. The entire
surface of the filter has to be scanned. The
test results are printed onto heat-sensitive
paper using a small external printer. The
printouts, which resemble sales receipts,
then have to be glued onto the test report
by the operator. The purpose of the filter integrity
test for hot-air sterilisation tunnels is
to make sure that the filters are not leaking,
that they are properly fitted and that no ingress
of unfiltered air takes place. Considering
the high degree of automation in the
pharmaceutical sector, this might seem too
laborious a way of going about the task.
“Actually, this is best practice today”, explains
Thomas Seiffer, Head of Research and
Technology at filling and packaging machine
manufacturer Bausch+Ströbel.
Seiffer and his team refused to accept this as
given, especially as stationary particle
counters are already integrated in B+S filling
machines. B+S’s developers had been
searching for a better test method for a
while. It had to be much more user-friendly
and, most importantly, it had to deliver reliable
and reproducible results. The breakthrough
came at a trade show in 2017,
when Daniel Engel, a Bausch+Ströbel particle
testing expert, discovered a system by
the Infrasolution Group. This system utilised
robotics for automatic testing of filters in
cleanrooms. “Of course, the conditions inside
a sterilising tunnel are different, mainly
due to the difficulty of access here, but we
thought that this system could be adapted
to suit our application”, Engel explains.
Successful cooperation
Infrasolution was amenable to the plant
constructor’s offer of a development partnership.
“We liked the idea from the very
beginning and saw right away that it had
potential”, says Christian Dorfner, Head of
Research & Development at Infrasolution.
Infrasolution has many years of experience
in cleanroom test systems, having started
out as a service provider before branching
out several years ago into the development
of related test instruments.
The result of this collaboration is a small and
compactly designed instrument named Line -
artwinscan. It has twin particle measuring
funnels and is guided through the sterilising
tunnel on the tunnel conveyor belt in a precisely
predetermined way. “For this purpose,
of course, the measuring instrument has to
be integrated into the controller of our sterilising
tunnel”, Engel adds. The operator
makes all the necessary settings at the tunnel’s
operating panel, where they can also
track the progress of the test while it is running
and call up the test results. Unlike with
the old method, these results are instantly
available in a digital form. They can be saved
and processed as required and therefore
meet the relevant statutory requirements
(21 CFR Part 1/GMP Annex 11).
Lineartwinscan effectively combines two
tests: an ISO classification test (under development)
and a filter integrity test (or
48 cpp 02-2019

Lineartwinscan is inserted directly into the hot-air sterilisation tunnel and controlled via
the tunnel’s operating panel
“DEHS test”, as it is also known). The DIN
EN ISO 14644 standard applies to both
tests. The first involves taking particle
measurements at predefined measuring
points. The second entails admitting a defined
number of particles into the sterilising
tunnel on the non-sterile side above the
filter. A particle count is then taken above
and below the filter on the sterile side to
determine the filter’s separation efficiency.
The entire surface of the filter must be
scanned. “These measurements are neces -
sary several times a year”, Engel continues.
B+S’s service technicians already carry out
the tests at the request of customers. “By
launching Lineartwinscan, we aim to take
this service to the next level”, Seiffer comments.
The benefit for customers is not only
exact test results – the B+S service technician
can also perform any necessary maintenance
work, such as filter replacement,
without delay. Sterilising tunnels can be
retrofitted for use with Lineartwinscan by
the customer’s own qualification personnel.
The advantages of the new system are obvious:
measuring accuracy is no longer dependent
on the meticulousness and experience
of the operator. The test results are
consequently more reliable, exact and reproducible.
What’s more, all data is available
in a digital form. A graphical display allows
users to track the progress of the test at any
time.
www.prozesstechnik-online.de
Suchwort: cpp0219bausch
AUTHOR:
TANJA BULLINGER
Head of Advertising and
Public Relations,
Bausch+Ströbel
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cpp 02-2019 49

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PHARMACEUTICAL ENGINEERING
From laboratory to process
Modular mills adapted
without specification sheets
When planning complex systems these days, it’s difficult to imagine not having a
specification sheet, and mills for pharmaceutical production – which must guarantee
a high OEB level and Atex conformity at the same time – are no exception. However,
Frewitt’s experience with a pharmaceutical contractor from the United Kingdom
demonstrates that under certain circumstances, it can also work without.
The project manager at a contract manufacturer,
accompanied by the end user, was
seeking a new milling and powder-handling
solution and requested a meeting with Frewitt
at the Interphex NYC trade fair. At the
time, neither the project manager nor his
company had any experience with the milling
specialist from Fribourg, Switzerland,
but had previously been working for many
years with competitors’ mills. When the
production areas were reorganised with the
aim of enabling heterogeneous solids, notably
active pharmaceutical ingredients
(API), to be processed using a single multipurpose
system, they decided to look
around for a proven innovator active in this
sector.
In the course of the conversation it was
quickly agreed that a milling test on the site
of the contract manufacturing organisation
(CMO) would be essential to arrive at a
final decision. No sooner said than done: as
a first step, two Frewitt machines were
shipped to the customer’s plant in the UK.
One was a Fredrive-Lab laboratory mill with
a hammer milling head and a conical grinding
head and the other a Fredrive system
designed for production quantities with a
Hammerwitt-3-type grinding head plus an
interchangeable Coniwitt-200-type grinding
head.
The results of the product tests provided
clarity. The successful and significantly
better outcomes of test series with all variants
quickly persuaded the contractor to
purchase the Hammerwitt-3, which was already
under rental at the end user. This decision
also paved the way for the future,
large-scale production system, which Fre-
Pictures: Frewitt
Complete plant for processing heterogeneous solids: a discharge aid feeds the ground
material from the storage vessel into the hammer mill and dosing unit (on the left in
the picture). The material is then filled into an endless liner (right) in a combination of
a storage vessel with a discharge aid and a Profi Dos dosing unit with a Profi-Clean
ventilation system.
50 cpp 02-2019

witt was tasked with supplying as a turnkey
solution. The ease of changing the milling
head and product as well as the general
cleanability and handling of the mills were
key arguments here.
Modular plant concept
Since the contractor did not know in advance
whether they would be required to
process a hard, crystalline, soft, fibrous,
toxic or even potentially explosive product,
the system had to be given a modular design
and seamless product changes enabled.
After multiple rounds of discussion, the
processes were defined, providing a basis
for drafting the system concept and the submission
of an offer to the customer. The system
was initially equipped with a hammer
mill with a conical and a cylindrical grinding
head (sifter), to allow products with
various material characteristics to be pul -
verised, disagglomerated, homogenised,
ground and fine-ground. The Atex directive
was observed to ensure a safe process
whenever the customer needs to mill potentially
explosive products.
All processes monitored
As always, a rigid inspection of the process
parameters is necessary for API production
on account of the high occupational exposure
band level and the Atex zone classification.
Hardly any element or part of the
system exists which isn’t controlled and
monitored by probes, sensors or sensing devices.
For example, fill level sensors prevent
product clogging, oxygen sensors measure
the oxygen content, pressure sensors monitor
the nitrogen pressure and temperature
sensors determine the temperature at sensitive
points on the machine, protecting both
the process and the products. The two buffer
tanks alone – one located at the inlet and
the other in the middle part of the system –
are equipped with a total of eight sensors to
be able to measure products levels, pres -
sures and oxygen content. In addition, the
two 500 l tanks each have a viewing
window to permit visual inspections.
When processing potentially explosive
products, a monitoring system constantly
measures the oxygen content at the Profi-
Clean dust removal system’s outlet. Two
measuring sensors are installed here to be
on the safe side. The arrangement of the
sensors at this location ensures that the entire
system is filled with nitrogen and that
the grinding process begins only after sufficiently
low oxygen levels are detected at the
Profi-Clean outlet.
Oxygen content under control
When processing potentially explosive substances
(Ea ≤ 1 mJ), the product is fed into
the first buffer tank until the specified
quantity is reached. The valve at the container
inlet closes and the buffer tank is rendered
inert while the oxygen content is
monitored. The same thing happens with all
other parts of the system. As soon as the
oxygen content reaches 3 % throughout, the
dosing system and the mill start up. Production
can then begin in the closed system. If
the oxygen content rises, nitrogen is automatically
injected until the oxygen falls
below the critical level again. However, if
the prescribed maximum oxygen content of
5 % is exceeded, the machine stops immediately.
Due the constant monitoring of the
system, oxygen – as a critical risk factor – is
always under control and the system is
therefore protected against explosion.
Integrated insulators
Three large insulators, arranged over three
levels, are combined with the Frewitt mill -
ing system. The first insulator is installed at
the inlet of the buffer tank, the second in
the area around the milling head and the
third close to the dosing, weighing and filling
system at the system outlet. The operator
can enter parameters, set and query
values, evaluate alarms and perform many
other process-relevant functions on a central
HMI. What began with a question and an
idea developed at a trade show in the USA
Hammerwitt-6 hammer mill with dosing
unit
ultimately led to the installation of a hightech
system, which today manufactures
products with very different characteristics
according to the highest standards.
www.cpp-net.com
Online search: cpp0219frewitt
AUTHOR:
MATTHIAS HONISCH
Regional Sales Manager,
Frewitt
cpp 02-2019 51

cpp
PHARMACEUTICAL ENGINEERING
In-line measurement technology instead of instrumentation with tees
No dead spaces and
no blockages
Unconditional product quality can only be achieved in the pharmaceutical industry
if risks are systematically minimised in every process phase. An American supplier
(OEM) redesigned the pressure and temperature control concept for a micronisation
system in cooperation with Wika. With this aim in mind in-line measurement technology
is now used instead of instrumentation with tee connections.
Grinding, often called micronisation, is a
critical part of many modern pharmaceutical
manufacturing processes. The size of the
particles comprised in the pill, tablet or capsule
is crucial for the bioavailability of a
drug – how fast the active ingredient dissolves
and how long it stays in a person’s
system. A very fine particle size often means
higher bioavailability. This is typically the
industry preference because the medication
requires a smaller proportion of active ingredients.
This, in turn, translates into fewer
side effects for the patient and, simultaneously,
lower production costs for the
manufacturer.
With the new design for its compact
micronisation system, this OEM was seeking
to improve product quality and minimise
contamination. Instrumentation connection
methods had been found to be contributing
decisively to these issues. Depending on
how these components are installed, proper
cleaning can be difficult, which invites the
risk of contamination. Or, they can be positioned
in a way that interferes with media
flow, which can impact on product quality.
Measuring points
Wika collaborated with this OEM to develop
the pressure and temperature measuring
points required for their new micronisation
system as well as for being in accordance
with the design specifications. These
Pictures: Wika
In-line measurement technology can significantly reduce the risks involved in pharmaceutical processes: in-line resistance thermometer, in-line diaphragm seals
with a sterile connection in combination with a pressure transmitter and miniature resistance thermometer for orbital welding (from left to right)
52 cpp 02-2019

®
requirements spoke against adapting the
process with tees, which tend to be the
norm in numerous production processes in
the pharmaceutical industry. Instead, in-line
measurement technology was chosen for
both measurands. This OEM now uses inline
diaphragm seals in combination with a
pressure transmitter to control the pressure
in the micronisation system. The seals are
mounted directly into the process line. With
their cylindrical diaphragm design, they
allow a laminar flow of process media, so
that turbulences are not detrimental to the
pressure measurement.
The same method is used to monitor the
process temperature. In-line resistance thermometers
(Pt100) were selected for this
purpose. The stem, which acts like a
thermowell and shields the instrument from
negative effects in the process environment,
is welded into the pipe and likewise does
not interfere with the media flow.
Ensuring product quality
Apart from preventing potential blockages
in the process, the in-line measurement
technology above all helps ensure product
quality through optimal cleanability. The
pressure and temperature measuring points
have no dead spaces or branch legs that cannot
be cleaned – two of the most frequent
causes of contamination. Branch legs are
common in instrumentation with tee connections
because the air pockets which can
form are capable of surviving even pro -
longed cleaning. These bubbles prevent
cleaning solution from wetting all surfaces.
The use of in-line diaphragm seals and resistance
thermometers has also reduced the
risk of contamination elsewhere. The triclamp
fittings which are normally used to
mount instruments in tees, and which are a
potential cause of contamination, are eliminated
with this method: under-tightening
of a gasket can lead to process media escaping
or to unwanted crevices. Over-tightening,
on the other hand, can prompt gasket
breakdown, which can force small pieces of
the gasket into the process or restrict pipe
drainage.
Fewer process interventions
In addition to the resulting calibration process,
the new measuring point concept also
improves quality assurance. Thermometers
generally have shorter inspection intervals
than pressure gauges. Whereas the diaphragm
seal systems must be completely
removed from the pipe for calibration,
with the temperature measuring points
only the resistance thermometers have to
Resistance thermometer for orbital welding
be dismounted. The thermowells make sure
the process remains closed throughout.
That means much less incidence per year of
potentially introducing ambient particles
and exposing the manufacturer to other
costly risks.
Moreover, calibration with the process
sealed has economic and ecological sideeffects.
It saves working time as well as
water and energy because there is no need
to clean the piping and sterilise the system
after checking the instrument.
Conclusion: In-line measurement technology
significantly reduces the risks during
pharmaceutical processes. Although there is
no doubt that the improved product quality
entails higher capital costs, these are more
than offset in the long run by the lower
costs of operation.
www.cpp-net.com
Online search: cpp0219wika
AUTHOR:
MICHAEL MUTH
Market Segment Manager/
Food and Pharma,
Wika USA
AUTHOR:
JOACHIM ZIPP
Global Market Segment
Manager/Food and Pharma,
Wika
Innovations for heating
Flexible
electical
heating technology
• Chemical heated hoses
• Transfer- / delivery hoses
• Ex-heated hoses
• Barrel heaters
• Pipe trace heaters
• Heating plates
• Special solutions
Hillesheim GmbH
Am Haltepunkt 12
D-68753 Waghäusel • Germany
Phone.: +49 72 54 / 92 56-0
E-Mail: info@hillesheim-gmbh.de
www.hillesheim-gmbh.com
cpp 02-2019 53

cpp
PHARMACEUTICAL ENGINEERING
Electrostatic spray drying combines drying and agglomeration
Microencapsulation of
active ingredients
Within the powder ingredient industry, spray drying is an efficient technology that
is widely utilised to produce dry ingredients. Using an electrostatic spray drying
process, sensitive pharmaceutical ingredients can be microencapsulated especially
gently. Powders created in the Polardry system can serve a wide variety of different
industries while demonstrating improved shelf life and material handling.
The heat abusive treatment in spray drying
processes often leads to ingredient loss,
degradation or denaturation with thermally
liable materials. A powder product made
using conventional processes normally
offers particle sizes ranging from 50 to
250 μm. Powder products within this size
range tend to suffer from poor water reconstitution
and dusting issues. Due to these
challenges, conventional spray dry products
are regularly agglomerated or granulated to
increase the particle size and improve their
hydration properties while resolving dustiness
problems. One standard agglomeration
methodology is a fluidised bed top-spray
granulator. Inside this granulator, spray
dried particles are first fluidised with a
heated air stream followed by the addition
of a binding solution. When contact occurs
between the particles and the binding so -
lution, the liquid bridge which is formed
allows those particles to stick to each other.
The particles are agglomerated when the
liquid is evaporated. This additional process
is time consuming, increases cost and potentially
causes further ingredient loss or
degradation from exposure to a secondary
heating step.
Gentle drying technology
Fluid Air, a subsidiary of Spraying Systems,
has co-developed the Polardry electrostatic
spray drying technology, which allows
water evaporation at an operating temperature
well below water’s boiling point. The
technology also enables agglomerated product
to be created during the spray drying
process.
With both the Polardry process and tradi-
The Polardry model 032 is a PLC controlled system for pilot environments in modular design
54 cpp 02-2019

To offer process scalability and easy scale-up, Polardry was designed around a complete line of patent-pending
machines that share similar process characteristics (left: portable PLC controlled system for a laboratory environment,
right: semi-portable PLC controlled recirculating system for R&D environments)
tional spray drying, liquid droplets are at -
omised and sprayed into a stream of drying
gas. Heat is transferred to the liquid from
this gas to drive the evaporation of the solvent.
Once all the solvent has been evapo -
rated, the end product is a dry, powdered
material.
There are two distinct phases in traditional
spray drying: a constant-rate drying phase
and a falling-rate drying phase. During the
constant-rate phase, the majority of heat
transferred to the droplet is latent and used
to drive the solvent’s evaporation. This cools
the surrounding drying gas and the droplet
temperature remains constant. As more and
more of the solvent evaporates from the
droplet, the solid content of the droplet’s
outer layer increases to the point where it
forms a shell. A particle with a solid shell
but a wet core is formed there and the fall -
ing-rate phase begins. During this second
phase, heat is transferred to the particle
from the drying gas as sensible heat. The
temperature of the particle is raised in order
to fully evaporate the remaining solvent
from the particle core.
In the Polardry process, the electrostatic effect
is used to stratify the components of
the droplet during atomisation based on the
material polarities. With a feedstock based
on a polar solvent, the solid materials are
driven to the inside of the droplet while the
solvent is driven to the outside. This prevents
shell formation and eliminates the
need for the falling-rate drying period.
Significantly more of the heat energy from
the drying gas is used for latent heat and
less for sensible heat. This allows fast, efficient
drying without having to raise the
temperature of the product. Moreover, Polardry
is an inerted system, in which the
oxygen level is maintained below 5 %.
Owing to its inert processing environment,
any undesirable oxygen-oriented reactions
are avoided.
Two processes in one
By intermittently controlling the electro -
static charge applied to the feed, Polardry
technology enables particulates to be agglomerated
as they are dried. This patent
pending PWM (pulse width modulation)
feature precludes the need for expensive
secondary agglomeration operations.
By controlling the voltage applied to the
spray droplet as it is atomised, some particles
form an outer shell readily while
others develop their shell gradually, leading
to a wet or tacky particle. As these two types
of particles collide, they bond forming an
agglomerated particle. This results in a finished
product with larger particles and
fewer freely flowing fines.
Comprehensive experiments
The following experiments were conducted
to study and demonstrate the features and
benefits of products processed using this
novel electrostatic spray drying technology.
All the finished samples were collected as
free-flowing dry powders. The samples were
evaluated with respect to moisture content,
particle size distribution, particle structure
and hydration properties.
The moisture content was measured using a
moisture analyser (Mettler Toledo, MJ33).
The product particle structure was inspected
under a scanning electron microscope
(SEM). The particle size distribution was
measured with U.S. standard test sieves #20
(850 μm), #40 (425 μm), #60 (250 μm),
#80 (180 μm), #120 (125 μm), #200
(75 μm) and #325 (45 μm) (Cole-Parmer,
USA) in order to sort the product according
to particle size. The product (50 g) was
measured and added to the stacked sieves
(in ascending order). The sieves containing
samples were then placed onto a Ro-tap for
5 min to facilitate particle separation within
the sieves. The weight of the remaining
products on each sieve was determined and
the particle size distribution percentage (%)
calculated by taking the mass of the remaining
product on each sieve divided by the
total mass of the added sample.
For comparison, all samples were also processed
in a conventional spray dryer with an
inlet temperature of 190 °C and an outlet
temperature of 90 °C.
Modified food starch is widely utilised in
the formulation of pharmaceutical and food
products. It was therefore chosen as an
example to show the low temperature drying
capability with electrostatic spraying
technology. In the experiment, 40 parts by
cpp 02-2019 55

cpp
PHARMACEUTICAL ENGINEERING
Principle of electrostatic
spray drying: with a feedstock
based on a polar solvent,
the solvent is driven to
the outside of the droplet
Encapsulated strawberry flavour produced using conventional spray drying and electrostatic spray drying
hydrated in water after 10 and 60 s
125 μm is formed, leading to a structure
composed of several particles aggregated
with each other. For example, the modified
food starch sample produced by electro -
static spray drying resulted in product with
27.9 % of the sample particles larger than
125 μm as compared with conventional
spray drying, where only 10.6 % of the
sample particles exceeded 125 μm. A similar
trend was also noticed for encapsulated vi -
tamin C and encapsulated strawberry flavour,
where 51.5 % and 68.7 % respectively
of the sample particles were bigger than
125 μm with electrostatic spray drying versus
2.8 % and 10.6 % with conventional
spray drying.
weight of modified food starch were hydra -
ted with 60 parts by weight of water. The
hydrated starch (fed at 10 lbs/hour) was
atomised through the electrostatic spray
nozzle into a drying chamber at 25 psi at -
omising gas pressure. The electrostatic
nozzle was applied to the hydrated starch
with 20 kV charge. Inside the drying
chamber, drying gas (90 °C) was delivered
at 150 scfm to assist water evaporation. The
drying gas that is used in this technology is
a mixture of air and nitrogen gas with the
oxygen level maintained at 5 % or lower.
Encapsulated vitamin C was also produced.
In the experiment, 50 parts by weight of
modified starch were hydrated with 50 parts
by weight of water. After completing hydration,
2 % vitamin C was added per part
by weight of modified starch and high-shear
mixed at 5000 rpm for 5 min until homo -
genised. The vitamin C mixture was ato -
mised through the electrostatic spray nozzle
with the same processing parameters as
modified food starch in the example above.
To produce encapsulated strawberry flavour,
a flavour emulsion was composed of
80 parts by weight of Osan starch as the
wall material and 20 parts by weight of
strawberry liquid flavour as the core mate -
rial. The emulsion was prepared by emulsifying
the liquid strawberry flavour with
pre-hydrated starch in a high shear mixer at
5000 rpm for 5 min. After mixing, the mixture
was homogenised at 3000 psi in the
first pass and again at 500 psi. The emulsion
(fed at 10 lbs/hour) was then atomised
through the electrostatic spray nozzle with
the same processing parameters as in the
above-mentioned modified food starch
example.
Particle morphology
It was observed that all samples produced
using the electrostatic spray dry process resulted
in larger agglomerated particles, with
multiple particles sticking to each other. In
contrast, conventional spray drying yielded
samples with a discrete sphere structure and
smaller particles.
During the electrostatic spray dry process,
the surfaces of the partially dry particles are
assumed to be sticky, which enables particles
to firmly attach onto other particles to
form a larger granulate. As soon as the water
has fully evaporated, a larger dry solid
granulate with a particle size greater than
All advantages at a glance
Electrostatic spray drying technology provides
products with superior instant hydration
for water-based applications compared
to the hydration properties of conventional
spray dry products. Due to its agglomerated
structure, the particle integrity
is strengthened, leading to better product
stability after high pressure processing. In
addition, the larger particle sizes demonstrated
by this technology resolve the dusting
issues commonly observed with smaller
particles. The mild processing enables enhanced
ingredient encapsulation and superior
shelf life. Lastly, electrostatic spray
drying also allows efficient, cost-effective,
one-step unit operation that rivals other
technologies in this field.
www.cpp-net.com
Online search: cpp0219sprayingsystems
AUTHOR:
JOSEPH P. SZCZAP
Director of Engineering und
Operations,
Fluid Air
56 cpp 02-2019

cpp
PRODUCTS
Explosion-proof enclosures
Safety valve for oxygen applications
Picture: Pepperl+Fuchs
Pepperl+Fuchs developed an
enclosure series with the aim of
simplifying planning, mounting,
and maintenance. Adapted
to process industry requirements,
the glass fiber reinforced
polyester (GRP) enclosure series
is being rolled out for terminal
boxes and control units first.
It will be available for all
Pepperl+Fuchs products and
Highly robust positioner
solutions in the future.
As early as the planning phase
for a terminal box or control
station in the GR series, plant
designers will benefit from flexible
device configuration. Based
on customers’ needs, terminals
and switching elements can be
individually positioned on the
10 mm mounting rail—without
the need for an additional
mounting base. Spacers ensure
that every single component can
be mounted efficiently at different
heights. Beyond the planning
phase, the explosion-proof
enclosures also offer a broad
range of applications: Because
the GR series can withstand
temperatures of up to -60 °C, it
can be used for applications in
harsh environments.
www.cpp-net.com
Online search: cpp0219pepperl
Picture: Goetze
Goetze offers a safety valve with
swivel body outlet for gaseous
oxygen and oxygen mixed
gases. Oxygen handling requires
extreme care as regards all materials,
sealing materials and lubricants
used and in contact
with oxygen to prevent application
risks. Goetze takes account
of these requirements: By
offering a production process
specifically designed for oxygen
valves. They are installed in a
separate, isolated clean room,
which is pressurised with conditioned
air at 20 mbar, so that
the ingress of particles and contamination
from the outside is
avoided. Qualified and trained
staff, compliance with all relevant
codes and regular process
monitoring of oil and greasefree
cleaning, installation, inspection,
packaging and labelling
grant customers an oxygencompliant
valve for their applications.
Optimum material selection, the
appropriate studies by the Bundesanstalt
für Materialforschung
(BAM, Federal Agency for Materials
Research and Testing), as
well as inspections by C.T.E. (Air
Liquide) exclude all possibilities
of an oxygen reaction (burnout).
A special property of the
safety valve 492GOX is that it
was explicitly inspected and approved
for oxygen with adiabatic
pressure shocks in a range
between 50 and 420 bar at
60 °C.
www.cpp-net.com
Online search: cpp0219goetze
With the Sipart PS100, Siemens is presenting a positioner
that is impressively easy to commission and
highly robust. The Sipart PS100 can be initialised
quickly at the touch of a button, automatically adjusting
itself to the attached valve. If required, it is possible to
optimise the positioner for a specific application with
just one further touch of a button. Just as some cameras
feature portrait, sport or night mode, the positioner can
be set to different modes for precise and fast adjustment,
open/close operation and other applications. The
Sipart PS100 is fitted with a large, easy to read display
that allows users to see the status of the device at a
glance. With its four-button operation and Namur
NE107 support, the device can be configured quickly
and conveniently.
www.cpp-net.com
Online search: cpp0219siemens
Picture: Siemens
Digital light management in hazardous areas
R. Stahl offers linear luminaires
and emergency luminaires with
an optional integrated Dali interface
according to IEC 62386.
So consistent and modern light
management can be implemented
in hazardous areas in
zones 1/21 and 2/22. Digital
networking makes it easier to illuminate
industrial plants
whereby the lighting is adapted
to the relevant tasks. It enables a
reduction in energy consumption
and simultaneously extends
the service life of general and
emergency lighting. Per Dali
bus, 64 actuators can be linked
in various topologies. Every network
can be integrated into the
higher-level building automation
system via a gateway.
Lighting ballasts that are controlled
via the Dali protocol can
Picture: R. Stahl
be switched individually and
synchronously. Around 200 programmable
commands are available.
Different lighting levels
and dimming behavior for LEDs
can be defined for every luminaire
and light group.
www.cpp-net.com
Online search: cpp0219stahl
cpp 02-2019 57

cpp
CONTACT THE EDITORS
GÜNTER ECKHARDT
Editor-in-Chief
Phone +49 711 7594-291
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lukas.lehmann@konradin.de
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daniela.held@konradin.de
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Editor
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janosch.menger@konradin.de
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cpp
LIST OF ADVERTISERS
Andritz AG, AT-GRAZ 2
Bronkhorst High-Tech B.V., NL-Ruurlo 27
Bühler Technologies GmbH, Ratingen 45
FAMAT SA, CH-SAINT-SULPICE 15
GATHER INDUSTRIE GmbH, Wülfrath 5
GEA, Ettlingen 35
Hillesheim GmbH, Waghäusel 53
IKA-Werke GmbH & Co. KG, Staufen 3
Pumpenfabrik Wangen GmbH, Wangen 39
Rembe GmbH Safety + Control, Brilon 42
RITAG RITTERHUDER ARMATUREN
GmbH & Co. Armaturenwerk,
Osterholz-Scharmbeck 27
Robu Glasfilter-Geräte GmbH, Hattert 13
Schoeller Allibert Services B.V Françoise
Pomes, NL-Hoofdoorp 9
VIBRA MASCHINENFABRIK Schultheis
GmbH & Co., Offenbach 41
58 cpp 02-2019

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Reach the entire European
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60 cpp 02-2019