cpp – Process technology for the chemical industry 01.2020

01-2020 

12 COVER 

LONG LIFE SPAN 

RUPTURE DISCS 

16 SMART PRODUCTION 

MAKING THE WEALTH OF 

DATA USEABLE AT LAST 

20 INDUSTRIAL SECURITY 

UPDATE MANAGEMENT 

FOR THE PLANT NETWORK 

40 OFF TO THE CLOUD 

DIGITAL SERVICES IMPROVE 

PLANT AVAILABILITY 

PROCESS TECHNOLOGY FOR THE CHEMICAL INDUSTRY 

WWW.CPP-NET.COM

www.efficiency-to-the-i.com 

easy handling with 

tactile HMI and wizard

cpp 

EDITORIAL 

OUR ENGINEERING IS 

YOUR SYSTEM SOLUTION 

Hannover Messe 

and Ifat postponed 

Rapid delivery 

Made in Germany 

ISO 9001 

In the April issue of cpp, the emphasis is normally on pre-fair reports 

linked to the Hannover Messe, which takes place every year 

around this time. A comprehensive Special Subject section was also 

planned for this year. However, the global developments surrounding 

the coronavirus have completely overturned both our plans and 

those of the exhibitors and organisers. Like many other exhibitions 

and events, the Hannover Messe has now been postponed from the 

original April date until the week from 13 to 17 July in consultation 

with the Hannover regional health authority, the Exhibitor Advisory 

Committee of Hannover Messe and VDMA and ZVEI, the HMI’s 

partner associations. From the health and safety point of view, this 

is undoubtedly the only right option for exhibitors and visitors 

alike; it remains to be seen whether the new July date which has 

been fixed for the Hannover Messe is an equally good decision. 

Against this background, the April issue of cpp has been amended 

to take account of current developments and the Special Subject 

section put off until the June issue. 

In view of the recommendation by the German Federal Ministry of 

Health and the Bavarian state government, Messe München felt 

similarly compelled to postpone Ifat 2020. The world’s leading 

trade fair for environmental technologies should have opened its 

doors on 4 May. Modern water and waste water technologies are 

key themes of this exhibition, which will now be staged from 7 to 

11 September 2020. Our Special Subject section on Ifat has also 

been dropped from this issue for this reason. The coronavirus is 

causing considerable disruption all over the place and maximum 

flexibility is called for. We hope you enjoy reading this issue in spite 

of it and that you remain healthy throughout the coming months! 

Metering Box – 

The universal controller 

The PLC for any kind of pump control loop. 

High precision metering or filling of liquids 

at the press of a button. 

• Intuitive user interface needs no 

programming ability 

• AUTO-TUNING to determine 

PID parameters 

• Freely selectable instrument and 

control parameters 

• Integrated wear alarm 

www.gather-industrie.de 

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

Günter Eckhardt, Editor-in-Chief 

cpp 01-2020 3 

Pump/Metering/Coupling Technology

cpp CONTENTS 01-2020 

12 Cover CPX rupture 

discs provide exceptional 

performance benefits 

while eradicating 

common industry concerns 

associated with 

traditional, mechanically 

scored discs. 

20 BASF has a large 

number of PLCs that need 

to be automatically updated. 

But with multiple 

firewalls to navigate and 

many third-party devices 

involved, integrating 

them into a single network 

is a challenge. 

30 The Magio series 

complements the Julabo 

product range with 

bridge mounted circulators, 

refrigerated circulators 

and circulators for 

most demanding temperature 

applications. 

SAFETY, SECURITY 

8 Lightweight explosion protection 

Future-proof alternative to enclosure encapsulation 

in zone 1 

10 Smart safety storage cabinets 

Safe storage of lithium-ion batteries 

12 COVER Long life span rupture discs 

Process safety in demanding applications 

14 All-rounder for hazardous areas 

Multi-function process calibrators with explosion 

protection 

PROCESS ENGINEERING 

30 Constant temperature in all processes 

High-end circulators for demanding tasks in the 

laboratory and industry 

ENVIRONMENTAL TECHNOLOGIES 

36 Radar as real alternative to ultrasonic 

Compact level measurement in the waste water industry 

38 F-Gas Regulation forces action 

Future-proof drying in compressed air treatment 

FOCUS: INSTRUMENTATION, CONTROL, AUTOMATION 

16 Making the wealth of data usable at last 

With enhanced connectivity for smart production 

20 Update management for the plant network 

How to improve industrial security in large 

brownfield plants 

24 PRODUCTS 

26 Step by step into the future 

Valve islands as electro-pneumatic all-rounders 

28 Distillation column trimmed for efficiency 

Control loop analysis reduces energy use 

PLANTS, APPARATUS, COMPONENTS 

40 Off to the cloud 

How digital services improve plant availability 

44 Keeping cool when controlling cryogenic media 

Optimised cryogenic valve 

46 Pump and product are a perfect match 

Positive displacement pump transfers viscous 

suppository masses 

48 Nothing but air and water 

Mobile pipe cleaning system for BASF 

4 cpp 01-2020

Industrie 

38 For businesses that 

rely on refrigeration 

dryers for their compressed 

air treatment, 

there will be no getting 

around the new F-Gas 

Regulation. This new 

standard will be the end 

of many dryers in use 

today. 

40 Thomas Knecht and 

Kevin Nietupski, both 

staff members of Auma at 

Service Center Cologne, 

explain the advantages of 

the Auma Cloud. 

The 

network of 

expertise 

for industry 

COLUMNS 

3 Editorial 

4 Contents 

6 News 

32 PRODUCTS 

43 PRODUCTS 

50 List of Advertisers 

50 Contact to the Editors 

50 Imprint 

17 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 

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 

Discover the appropriate media for 

you and your specific industry sector: 

konradin.de/industrie 

media.industrie.de 

cpp 01-2020 5


NEWS 

Business to focus on intelligent and sustainable technologies 

BOSCH PACKAGING TECHNOLOGY BECOMES SYNTEGON 

Picture: Syntegon 

The new Syntegon flags in front of the 

company headquarters in Waiblingen 

Syntegon Technology is the new name 

among the market leaders in the processing 

and packaging industry. Known as Bosch 

Packaging Technology until late 2019, the 

former Bosch division today presents itself 

as an independent enterprise at the company 

headquarters in Waiblingen (Germany). 

Syntegon Technology’s business focus is on 

intelligent and sustainable technologies for 

the pharmaceutical and food industries. Extending 

the service range is a priority for 

the company that employs 6100 people at 

more than 30 locations worldwide. It posted 

1.3 billion euros in sales in 2019. Bosch 

disclosed its plans to sell the packaging machinery 

division to a newly incorporated 

entity managed by CVC Capital Partners, a 

leading private equity and investment advisory 

firm, in July 2019. The sale of Bosch 

Packaging Technology was completed on 

January 2, 2020. A new corporate brand 

was developed over the past few months. 

The name Syntegon stands for synergy, 

technology, and focus on the future. The 

corporate colour green underscores the importance 

of sustainability and health. The 

square in the logo symbolises a package as 

well as packaging technology’s ability to 

protect products. 

This newly gained independence enables 

Syntegon Technology to be even more flexible. 

And newly added departments at the 

headquarters such as Purchasing and IT 

shorten the distances between in-house 

units and facilitating interaction with customers 

and suppliers. 

Acquisition of ultrafiltration membrane business finalised 

BASF SELLS INGE GMBH TO DUPONT 

Picture: Dupont Water Solutions 

The Inge multi-bore PES ultrafiltration 

technology now complements Dupont’s 

portfolio of water purification and separation 

capabilities 

Dupont now signed all agreements to acquire 

the Ultrafiltration Membrane business from 

BASF – Inge GmbH – including ultrafiltration 

and membrane technologies. The acquisition 

is now in place. „As a global leader of innovative 

water solutions committed to investing 

in specialty solutions, the integration of 

Inge’s technologies extends our water purification 

capabilities and helps meet growing 

customer demand for ultrafiltration,“ said 

Rose Lee, President, Dupont Safety & Construction. 

„Inge is an ideal fit for enhancing 

our ability to design tailored, integrated solutions 

for drinking water, and industrial and 

wastewater treatment applications.“ 

Inge's multi-bore PES ultrafiltration technology 

complements Dupont’s portfolio of 

water purification and separation capabilities. 

The product lines will join Dupont’s 

trusted Filmtec Reverse Osmosis and Nanofiltration 

Membranes, Integraflux/Integrapac 

Ultrafiltration Portfolio, and Amber 

series of Ion Exchange Resins to provide 

more options for customers. 

cpp NEWS TICKER 

Pictrure: Wacker Chemie 

Wacker extends the 

contract of Tobias Ohler 

Oldenburg. Following his studies, 

he was a consultant at McKinsey 

until 2004 and joined Wacker 

Chemie in 2005 as head of Corporate 

Controlling. 

from the Executive Board as of 

December 31, 2019. His responsibilities, 

including his role as Labor 

Director, will be assumed by Chief 

Executive Officer Tom Blades (on 

the left). Bernhardt was appointed 

member of the Executive 

Europe and based on the recommendations 

of the German 

Ministry of Health and the Bavarian 

State Government, Messe 

München as oganizer feels compelled 

to postpone Ifat 2020. 

This measure is taken in consul- 

Wacker Chemie AG’s Supervisory 

Board and Labor Director at Bil- 

tation with the Executive Board 

Board re-appointed Chief Financial 

Officer Dr. Tobias Ohler (49) 

to the Executive Board for another 

five years. Ohler’s current 

contract expires on December 

31, 2020. He joined the Executive 

Board in 2013. 

Ohler studied economics, business 

administration and industrial 

Picture: Bilfinger 

Bilfinger reduces the size 

of its Executive Board 

Beginning with the next financial 

year, the size of the Executive 

Board at industrial services provider 

Bilfinger will be reduced 

finger SE sinceNovember 1, 2015. 

Ifat is postponed to 

September 

Picture: Messe München 

of the Exhibitors’ Advisory 

Board, the conceptual partners 

and in responsibility for the 

health of exhibitors and visitors. 

IFAT will take place from September 

7 to 11, 2020. 

Purchased tickets and redeemed 

vouchers will of course remain 

valid for the upcoming event. 

engineering and took a doctorate 

from four to three members. 

Due to the increasing spread of 

in economics at the University of 

Michael Bernhardt stepped down 

the coronavirus (Covid-19) in 


Nouryon uses technology from Semiotic Labs 

BOOST PLANT RELIABILITY 

Nouryon has signed a framework agreement to implement selflearning 

technology developed by Semiotic Labs that helps predict 

when to maintain and replace pumps and other rotating equipment. 

Semiotic Labs was one of the winners of Nouryon’s 2018 Imagine 

Chemistry open innovation challenge. 

The technology uses electrical waveforms that can accurately predict 

90 % of upcoming maintenance needs in rotating equipment 

such as pumps, compressors, and conveyors, up to five months in 

advance. This gives time to repair or replace critical equipment during 

planned stops, preventing unexpected interruptions to production 

and improving reliability of supply and process safety. The 

technology has been successfully implemented at Nouryon’s chlorine 

plant at Ibbenbüren, Germany, and will now be rolled out to 

seven other sites in Europe. Nouryon and Semiotic Labs will also 

look at ways to generate more value from waveform analysis by developing 

features that will enable significant reductions in CO 2 

emissions. The first large-scale implementations are planned for 

early 2020. 

Semiotic dashboard for waveform analysis 

Picture: Semiotic 

Group increases profit in 2019 

ENDRESS+HAUSER STILL 

ON COURSE FOR GROWTH 

Matthias Altendorf, CEO of the 

Endress+Hauser Group 

Endress+Hauser remains on course for 

growth. In 2019 the Group increased its net 

sales by almost 8 % to over 2.6 billion euros. 

The Swiss measurement and automation 

technology specialist created 400 new jobs 

worldwide. At the end of the year the company 

had more than 14,300 employees. “We 

have grown across all fields of activity, industries 

and regions,” said Matthias Altendorf, 

CEO of the Endress+Hauser Group. Strong 

impetus came from Asia. Europe, the Americas, 

Africa and the Middle East developed 

positively, but at a much slower pace. “With 

good product innovations, we have set a 

clear benchmark in the industry,” emphasised 

Altendorf. In 2019, order entry rose faster 

than sales. Endress+Hauser expects slower 

development in 2020. The Group anticipates 

sales growth in the mid-single-digit percentage 

range and aims to maintain profitability 

at a good level. 

Picture: Endress+Hauser 

Neste and Ravago join forces 

COLLABORATION IN CHEMICAL RECYCLING 

Neste has set a target to process annually 

more than one million tons of plastic waste 

from 2030 onwards 

Neste, provider of renewable diesel, renewable 

jet fuel, and an expert in delivering 

drop-in renewable chemical solutions, and 

Picture: Neste 

Ravago, distributor and recycler of polymers, 

are joining forces to develop chemical 

recycling of plastic waste with the aim to 

reach significant industrial scale. Neste and 

Ravago have set a joint target to reach an annual 

capacity to process over 200,000 t of 

plastic waste. Through collaborating in 

chemical recycling, Neste and Ravago wish 

to accelerate circularity of materials and improve 

resource-efficiency in the petrochemical 

industry. The two companies also want to 

provide more sustainable alternatives to primary 

fossil feedstock. Chemical recycling of 

plastic waste will enable the petrochemical 

industry to meet its recycling targets and develop 

a more sustainable, climate-friendlier 

offering. 

“Our aim is to process annually more than 

one million tonnes of plastic waste from 

2030 onwards. With this, we could contribute 

to increasing the annual recycling 

rate of post-consumer plastic waste by 25 to 

30 % from the current level in Europe,” says 

Mercedes Alonso, Executive Vice President, 

Renewable Polymers and Chemicals at Neste. 

Chemical recycling will enable the companies 

to upgrade even coloured and mixed 

plastic packaging waste into high-quality 

raw material for the production of new 

plastics, chemicals and fuels. Unlike me - 

chanically recycled plastics, chemical re - 

cycling enables waste plastic to be used as 

raw material even in the most sensitive applications, 

such as in primary food packaging 

as well as pharmaceutical and healthcare 

applications. 




Future-proof alternative to enclosure encapsulation in zone 1 

Lightweight explosion 

protection 

Quintessential explosion protection requires comprehensive expertise of various 

types of protection especially with the increase of highly networked switching, 

control and communication systems that are incorporated in hazardous areas. The 

Expressure technology for Ex-protected enclosures is a solution that boasts a whole 

host of advantages over conventional enclosure encapsulations. 

The Expressure concept from R. Stahl is a 

far superior solution to the existing enclo - 

sure encapsulation methods for many applications. 

This concept enables the construction 

of large yet lightweight Ex d switch 

cabinets that allow standard electrical and 

electronic components to be safely used in 

zone 1. Besides power distribution boards 

and control systems, Expressure switch cabinets 

can also house large pieces of equipment, 

such as transformers or frequency 

converters, providing reliable explosion protection 

for everything installed within them. 

Pressure relief for zone 1 

The PTB- and Dekra-certified Expressure 

switch cabinet series features a unique 

The Expressure technology leads to more compact and lightweight housing designs. As a result, 

Expressure is up to 50 % lighter than conventional Ex-d solutions with the same internal volume. 

Pictures: R. Stahl 

pressure relief system. Special stainless steel 

wire mesh on both sides of the enclosure 

ensures that the pressure within the enclo - 

sure can be reduced effectively, serving as a 

flameproof barrier that allows for controlled 

flow of gas combined with heat absorption. 

If an explosion occurs inside the enclosure, 

the energy released is absorbed swiftly, 

safely and effectively. Regardless of where 

the ignition source is located, only harmless 

incombustible and non-explosive gas/air 

mixtures are able to exit the enclosure. The 

special mesh is also designed to absorb a 

significant amount of the heat energy that 

has been generated by the chemical reaction 

thereby safely lowering the internal pressure 

within the enclosure. These features effectively 

reduce the internal pressure in the 

event of an explosion to a maximum value 

of less than 1 bar; sparks that might otherwise 

cause an explosion are safely contained 

inside the enclosure thanks to the special 

mesh structure. The maximum surface temperature 

falls under temperature class T4. 

Covering the Expressure enclosure‘s pres - 

sure relief elements are explosion vent panels 

with a target pressure of 0.1 bar; these 

panels seal the enclosure and, under normal 

operating conditions, offer IP 66 protection. 

More capacity, less weight 

This innovative, Ex d-certified pressure relief 

technology offers up to 50 % space and 

weight savings compared to conventional Ex 

d solutions. Expressure is a highly efficient, 

cost-effective alternative to Ex p pressurised 

enclosures. Moreover, the new protection 

concept makes it much simpler to install 

switching and control units in zones 1 and 

2, near to the machinery that they control, 

rather than having to position them far 

away in a non-hazardous area. R. Stahls‘s 

Expressure technology comes in a choice of 

four enclosure sizes, ranging from 

300 x 400 x 200 to 1000 x 1400 x 700 mm, 

and with either a single-leaf door or a 

double door. With walls just 2 mm thick, 

these stainless steel enclosures are extraordinarily 

light, making transportation, handling 

and installation much easier. Their optimised 

design also benefits from a smaller footprint. 

The large, undivided space inside the enclo - 

sure provides easy access for installing and 

wiring switching components and for performing 

maintenance and inspection work. 

The volume available within the enclosure 


The Ex d-certified Expressure enclosures boast a 

large internal capacity 

Explosion vent panels with a target pressure of 0.1 bar 

provide IP 66-rated protection; in the event of an 

explosion, these blow open to relieve pressure 

for installing equipment is comparable to 

that of many conventional industrial switch 

cabinets and control boxes, and allows the 

switchgear layout used for non-hazardous 

areas to be used unchanged for hazardous 

areas without any additional engineering 

work. Thanks to the futureproof design of 

the enclosure concept, even last-minute 

changes to the order can be accommodated 

with little difficulty at the commissioning 

and SAT stages. Cable entries can easily be 

retrofitted at any point in time, and new 

components can be added to pre-installed 

equipment. Control elements that have been 

approved for use with Ex d solutions, e. g. 

rotary switches, pushbuttons, mushroom 

buttons, key-operated switches and control 

lamps, can all be used without modification. 

Additional accessories include Ex e connection 

shafts and inspection windows that are 

available in six different sizes. 

Light and easy 

In terms of weight and size, as well as the 

amount of maintenance, conversion and 

retrofitting work required, Expressure enclosure 

combinations are often a better 

choice than conventional Ex d enclosures. 

The most widely used types of protection 

are flameproof enclosures. These are usually 

incredibly bulky structures which are built 

this way to withstand extreme explosion 

pressures in the region of 7 to 12 bar. To 

achieve the necessary pressure resistance 

properties, very thick walls of 10 to 20 mm 

are required. Realistically for economic and 

for technical reasons, this limits the enclo - 

sure capacity to not more than around 

500 l. Large, complex electrical control panels 

and distribution boards must therefore 

be divided between a number of smaller 

flameproof enclosures. Compliance with the 

applicable explosion protection requirements 

complicates the production and installation 

processes for these flameproof 

bushings, which are required in order to establish 

the necessary electrical connections. 

All joints running through the enclosure 

wall must be flameproof; this is to ensure 

that sufficient energy is removed from any 

flames or hot gases in the area to prevent 

them from causing an explosion. The encapsulation 

also makes operation, maintenance 

and repair more difficult. Any subsequent 

changes to the internal electrical wiring inevitably 

require extensive, time-consuming 

and costly modifications, which must 

normally be accepted by an explosion protection 

expert before the equipment can be 

put back into service. With the advent of the 

new Expressure technology, complete 

switchgear assemblies and distribution 

boards can now be housed in a single enclosure, 

saving significant amounts of space 

and cost, and making maintenance a whole 

lot easier. The amount of planning required 

is also considerably less. Additionally, components 

can be retrofitted, modified or replaced 

quickly and without additional costs. 

Spacious without pressurisation 

In order to house complex control and distribution 

systems within an explosion-protected 

enclosure alongside large-scale 

equipment and special machinery, solutions 

using pressurised enclosures (Ex p) have 

been required to this date. Enclosures with 

this type of protection have air or an inert 

gas forced through them. The positive pres - 

sure created prevents explosive gases from 

entering the enclosure. To start operation inside 

Ex p pressurised enclosures, inert gas 

must be flushed through the enclosure to 

force out gas mixtures that have entered 

from hazardous areas and to create the positive 

pressure required for operation. This 

takes time – frequent maintenance, replacement 

and conversion requires significant 

down time. However, installing equipment 

in line with EN 600792 requires various inspections 

and tests for positive pressure, 

leakage, test gas supply and pre-flushing 

time, which makes Ex p structures particularly 

complex. Compared to this protection 

concept, the Expressure is by far the more 

cost-effective alternative. Firstly, it elimi - 

nates the need for many expensive design 

and test steps. Secondly, the Ex protection 

remains intact at all times – during equipment 

start-up and after maintenance and 

retrofitting work – without additional time 

consuming procedures. And of course, there 

is no need of equipping Ex p enclosures 

with a control unit, a feed air station and a 

pressure monitoring system. 


Online search: R. Stahl 

AUTHOR: 

HARALD WASKOW 

Product Manager, 

R. Stahl 




Safe storage of lithium-ion batteries 

Smart safety 

storage cabinets 

Lithium-ion batteries are an integral part of everyday life and, with good manufacturing 

standards and proper handling, are also a sufficiently safe technology. However, 

handling lithium-ion batteries is a risk that is difficult to determine in hazard 

assessment. This is because new findings and the rapid pace of development make it 

necessary to continuously review preventive fire and hazard protection measures, 

re-evaluate them if necessary and adapt them to the state of the art. 

Although lithium-ion batteries are 

relatively safe in regular operation, they are 

not designed for temperatures above 60 °C, 

among other things. As the temperature 

rises, lithium-ion batteries react with pres - 

sure build-up in the cell, intensive emission 

of flammable gases, cell fire, and even explosive 

burning of the battery (thermal runaway). 

The dangers result, among other 

Smart safety storage cabinets from 

Düperthal can be used for the safe 

storage of lithium-ion batteries 

things, from deficiencies in production or 

improper handling of the storage medium. 

A further risk arises if, for example, the respective 

ingredients are released due to 

thermal stress. According to the technical 

data sheets of the manufacturers, corrosive, 

toxic, carcinogenic, but also flammable hazardous 

substances can escape. Accordingly, 

preventive measures for fire protection and 

Pictures: Düperthal 

In the event of burning lithium-ion batteries, 

the cabinet doors close automatically 

and a special mechanism locks the doors 

early detection of damage are important 

building blocks to ensure safe workplaces. 

Safety storage cabinets 

In the classical solution, Type 90 safety storage 

cabinets according to DIN EN 14470-1, 

the stored media are shielded from external 

thermal influences, e.g. fire generation outside 

the safety cabinet, and are regarded as a 

fire-resistant separated area (fire compartment). 

They offer 90 minutes of fire resist - 

ance – sufficient time for evacuation and a 

safe buffer for fire fighters to intervene. This 

prevents uncontrollable fires and explosions 

and, as a result, increased personal injury 

and material damage if a fire occurs – exclusively 

– outside the cabinet. 

Düperthal safety cabinets of the Battery line 

Type 90, on the other hand, are specially 

designed to meet the high requirements for 

the safe storage and charging of lithium-ion 

batteries. In the event of a malfunction, lithium-ion 

batteries can ignite themselves 

and the thermal load or fire then occurs inside 

the cabinet. In this scenario, the cabinet 

doors will close automatically and a special 

mechanism will lock them. This prevents 

employees from igniting a possible flue gas 

explosion (backdraft), by simply opening 

the doors. Only authorised persons and fire 

brigade experts will be able to unlock the 

doors in this case. With the classification 

Type 90 and the explosion-like burning of 

the batteries in the cabinet interior, tested 

by the independent Fraunhofer Institute, the 

Battery line offers double fire protection – 

sufficient time for evacuation and a buffer 

for extinguishing the fire. 


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

Early detection 

The success of extinguishing a fire is essentially 

dependent on the fire brigade being 

on-site as early as possible in the fire phase. 

For the storage and use of lithium-ion batteries, 

early detection and automatic transmission 

of thermal events, e.g. fires, is 

therefore almost indispensable. With the intelligent 

Smart Control assistance system 

with touch display, temperature sensors can 

be used as an early warning system to detect 

thermal events inside the cabinet, e.g. 

threshold value adjustment to detect deviations 

from normal cases. For preventive 

risk management, in addition to monitoring 

temperatures using sensors for door status 

and ventilation, fault messages can also be 

sent by SMS, e.g. to the fire brigade and to 

those responsible. Individual connection to 

fire alarm systems is also possible. The Battery 

station models are additionally prepared 

ready to plug in with Schuko sockets 

and a fused power supply for chargers. The 

Battery line’s prepared ventilation system 

can also safely dissipate the heat energy 

generated by the charging process. 

State of the art safety at work 

Within the framework of a risk assessment, 

operators are obliged to assess the dangers 

which may emanate from technical equipment 

and devices and to implement the resulting 

protective measures in accordance 

with the state of the art. The Battery line and 

the additional systems for early fire detection 

with automatic alarm forwarding capability 

ensure sustainable process safety. The 

resulting danger containment in case of selfignition 

of the batteries can be considered 

as state of the art in the hazard analysis. The 

use of the Battery line also helps to meet 

legal requirements, in particular the guidelines 

for storage in accordance with the GDV 

data sheet on loss prevention for lithiumion 

batteries of the VdS and FM Global. 


Online search: Düperthal 

AUTHOR: 

CHRISTIAN VÖLK 

Head of Marketing, 

Düperthal 

Versioned catalog production 

intelligent 

Medien 

produzieren 

Perfect project management for highly complex jobs 

Tools for an efficient workflow 

www.konradinheckel.de 




Pictures: Rembe 

Process safety in demanding applications 

LONG LIFE SPAN 

RUPTURE DISCS 

Using advanced, precise, in-house technology, the German 

manufacturer Rembe has developed a performance-improved 

range of rupture discs. CPX rupture discs provide exceptional 

performance benefits while eradicating common industry concerns 

associated with traditional, mechanically scored discs. 


With chemical manufacturers focused on maximising output, 

reducing energy costs and ensuring that plants reliably conform to 

strict safety and environmental regulations, there is increased pres - 

sure for plant engineers to source components that will provide 

long-term stability and improve overall operational competitiveness. 

Recognising the challenges faced by the industry has driven 

rupture disc manufacturers to upgrade their designs. The German 

company Rembe has taken an approach to further develop its products, 

leading to serious technological and operational benefits for 

customers in the chemical sector. Rembe uses Contour Precision 

manufacturing to enable highly accurate digitalisation of the rupture 

disc surface while high cutting speeds ensure excellent surface 

quality, resulting in the manufacture of very accurate, consistent and 

high performing rupture disc solutions. 

Advantages of Contour Precision manufacturing 

The precision manufacturing methods – Contour Precision Lasering 

(CPL) and Contour Precision Profiling (CPP) – permit high quality, 

accurate burst control even in the harshest of chemical manufacturing 

environments. When used as an alternative to traditional rupture 

disc scoring methods, this technology can provide many advantages, 

as it does not influence or weaken the material structure 

during the manufacturing process. The move from traditional 

mechanical scoring to such advanced manufacturing methods eliminates 

most common industry concerns associated with earlier rupture 

disc designs such as pin holing, corrosion build-up and low 

life-cycling capability. Switching to precision manufacturing eradicates 

the main causes of premature failure to offer a longer lifespan 

solution and less downtime for customers. 

Pin-holing – a common concern 

Pin-holing on rupture discs has been a common concern for the 

chemical sector for decades. Due to the highly corrosive nature and 

harsh operating conditions within the chemical manufacturing process, 

it was not at all unusual for process media to weaken the score 

lines on the installed rupture disc, leading to an unwanted leak path 

in the process and ultimately to the disc’s premature failure. Frequent 

premature failures are costly problems for chemical manufacturers, 

with unplanned downtime impacting on production and 

overall output. The move to precision manufactured rupture discs 

provides a more long-term, cost-effective solution with superior 

performance behaviour even in harsh operating conditions. Additionally, 

as chemical operators face increasing pressures to conform 

to strict regulatory and environmental standards, the need to install 

a rupture disc which does not create an unwanted leak path in the 

process is critical. Eradicating the risk of pin-holing, in turn, eliminates 

the risk of such leak paths and thus reduces the loss of costly 

or hazardous process media into the environment. 

No fear of corrosion 

Irrespective of the material, size or burst pressure, no heat is applied 

to the rupture disc during the manufacturing process when precision 

manufacturing techniques are employed. These techniques create 

the most accurate lines of sublimation across the rupture disc 

surface, resulting in the most precise opening upon burst and enabling 

improved process control for plant operators. Furthermore, 

the opening pattern, unlike scored opening patterns, is completely 

smooth – no witness marks, notches or indentations on the rupture 

disc surface facing the process, meaning it is not prone to being affected 

by corrosion or product build-up and ensuring the longest 

lifespan capability of any rupture disc solution. Ideal for aggressive 

Rembe uses Contour Precision manufacturing to enable 

highly accurate digitalisation of the rupture disc surface 

process media or in polymerisation processes, the CPX range of rupture 

discs is compatible with the most diverse process conditions, 

even in processes which must comply with strict hygienic standards. 

Increased life-cycling capability 

Precision manufacturing techniques ensure greater accuracy during 

the manufacturing process, allowing predefined – and lower – burst 

pressures as well as tighter tolerances to be achieved. Rupture discs 

manufactured with such technology are known to be more robust 

than discs manufactured using alternative scoring methods, meaning 

individual chemical processes can be challenged. Pushing the process 

operating pressures closer to the rupture disc’s opening pressure 

without risk of the rupture disc bursting prematurely produces a 

positive outcome – greater efficiency and output, helping to improve 

the overall competitiveness of the facility. Not only is increased 

life-cycling capability achieved through these manufacturing techniques, 

it is also possible to manufacture rupture discs with lower 

burst pressures. Fewer rupture disc designs are consequently needed 

site-wide, so that a greater number of process points can benefit 

from this technology, all while simplifying purchasing routines. 

Wide range of applications 

Rembe’s CPX rupture discs not only offer direct cost benefits over 

rupture discs which are prone to fail prematurely; their reliability 

also allows a reduction in, and simplification of, maintenance 

schedules as well as – even more importantly – less costly downtime. 

From the most accurate and consistent burst openings to 

smooth surfaces and robust constructions, the CPX range consists of 

advanced forward and reverse acting rupture discs. There is a CPX 

solution for even the most demanding applications in the chemical 

industry. The IKB, IKB-X and SFD cover an extensive range of burst 

pressures and specifications to meet most operational requirements. 


Online search: Rembe 

AUTHOR: 

CLAIRE LLOYD 

Team Leader, Process Safety Europe, 

Rembe 




Multi-function process calibrators with explosion protection 

All-rounder for hazardous 

areas 

Anyone who has to calibrate intrinsically safe pressure transmitters on site in a 

plant obviously needs test equipment that is approved for use in hazardous areas. 

Yet explosion protection is much more complicated to ensure when using the 

new hand-held generation of portable multi-function calibrators than when using 

conventional devices. 

In processes in the chemical industry, safety 

and efficiency go hand in hand. This is why 

the process control functions are almost always 

based on electronic measuring instruments 

such as pressure transmitters. In 

order to determine whether the monitoring 

instrument is doing its job properly and 

with the necessary precision, it must be 

calibrated regularly. However, even if the instrument 

check is not required to be DAkkS 

compliant, calibration processes can often 

be a time consuming affair. Inspections in 

The chemical industry places specific requirements on measuring devices 

an external laboratory result in significantly 

more downtime because apart from anything 

else, the instruments have to be 

shipped there and back again. 

Picture: werbefoto-burger.ch – fotolia.com 

On-site calibration 

A growing number of firms today choose 

on-site calibration for this reason. One German 

chemical company, for instance, 

adopted this approach for a multi-purpose 

plant in its agricultural segment. Amongst 

other things, the plant, whose various sections 

can be flexibly interconnected depending 

on the process, is equipped with 

more than 200 pressure transmitters. Since 

the operator feeds it with different, frequently 

changing media, the pressure 

measuring instruments require regular calibration. 

Such checks are carried out before 

and after every process. By comparing key 

parameters, it is possible to verify the 

measurement quality throughout the process. 

If a production process lasts for a very 

long time, the transmitters are also calibrated 

in-between as a kind of functional 

check. 

A considerable amount of equipment is 

generally necessary for conventional on-site 

calibration. Apart from the actual calibrator, 

this entails a means for producing the pres - 

sure as well as – in the case of transmitters – 

a power source. Handling such a wide range 

of devices is not only complicated; it also 

costs time and holds many unknowns due 

to the numerous manual activities. 

Against this background, the above-mentioned 

company decided to check the pres - 

sure transmitters using Wika’s CPH7000 

portable multi-function calibrator, which 

combines all the equipment needed for the 

on-site calibration process in one instrument. 

In addition to a highly precise reference 

(0.025 % FS), it also features an electrical 

voltage and current supply module, so 

that the values can be read out automatically, 

and a mechanical pressure pump. 

Hand-helds with Atex approval 

The intrinsically safe calibrator version 

required for this application is Atex approved 

(Ex ib IIC T4 Gb classification). This 


ules out any risk of explosion, regardless of 

whether the ignition temperature is reached 

because a surface overheats, an ignition 

spark is produced owing to static charge on 

the case or a fault occurs during electrical 

operation. 

A more complex design compared to other 

hand-helds was necessary to obtain this approval, 

especially where the battery was 

concerned. The capacity of the CPH7000’s 

“powerhouse” must match the instrument’s 

multi-functionality and enable eight hours 

of operation as a minimum. The lithium-ion 

cell is specially cast in a protective sheath, 

which prevents overheating in the event of 

a short circuit or other fault, so that the 

battery cells are neither destroyed nor can 

they leak. 

An emergency interrupt function limits the 

power if it rises excessively. The battery 

never supplies more than the maximum 

24 mA of current and 30 V of voltage which 

are output via the integrated electronic 

module. An additional safety cutout feature 

was installed as a condition of the Atex approval. 

The test pressure needed for calibration can 

only be produced using a hand pump because 

electrical alternatives would not meet 

the Atex requirements for explosion protection. 

There were two other reasons why a 

mechanical component was integrated: the 

battery power is protected and the final 

value is approached faster owing to the 

larger stroke. The hand pump has Atex compliant 

conductivity: all metal parts are permanently 

connected to one another, so that 

they cannot become charged. This simultaneously 

prevents matchstick effects due to 

friction from trapped particles such as 

chips. Furthermore, the pump’s piston-cylinder 

system is fine-tuned so that there is 

virtually no self-heating during pumping. 

The CPH7000 and the calibration processes 

are parameterised and controlled on an intuitive 

touch screen similar to a smartphone. 

The big GUI permits easy navigation. 

It is made from shatterproof glass 

because it could otherwise break if the instrument 

were to be dropped, resulting in 

exposed electrical cables in the hazardous 

area. More severe impacts than a simple fall 

might cause the screen to splinter, but it 

would still form a closed surface. 

The pressure transmitters in the multi-purpose 

plant are calibrated on site with the 

CPH7000: the measuring instruments are 

integrated in the process by means of 

Wika‘s CPH7000 portable process calibrator with Atex approval provides highly flexible 

on-site calibration for process transmitters and pressure gauges. Due to its equipment, 

the CPH7000 also fulfils test tasks for the measurement parameters of temperature, 

voltage and current. 

monoflanges with an Ermeto coupling as 

the test connection. An external CPT7000 

reference sensor is mounted to the coupling 

for the duration of the test. It is supplied 

with the same pressure as the transmitter 

and transfers the value to the calibrator as a 

digital signal. The result of the calibration is 

instantly recognisable: it appears in a green 

frame if the test item meets the class accuracy 

or in a red frame if it does not. 

Other testing tasks 

Although calibrating pressure measuring instruments 

is the most important of the 

CPH7000’s functions, this portable device 

can also carry out other testing tasks in a 

single step, for example those linked to 

voltage and current with the electrical module. 

Switch tests and sensor simulations are 

just two possibilities here. Temperature 

measuring points can also be checked with 

the help of an Atex approved Pt100 sensor. 

An external atmospheric module and an integrated 

barometer moreover provide information 

on atmospheric pressure, relative 

humidity and ambient temperature. Due to 

its small surface, this module in miniature 

format does not require an intrinsically safe 

design. A data logger stores all measured 

values and parameters for documentation 

purposes. The logger also shows pressure 

and temperature cycles on a live graph in 

real time, so that any deviations are detected 

immediately. The CPH7000 is thus equally 

suited for leak-testing. 

The data recorded by the calibrator can be 

transmitted wirelessly to a host computer or 

a notebook for further processing. In the 

opposite direction, calibration routines can 

be uploaded in this way, so that testing processes 

in sensitive areas are even safer. If the 

CPH7000’s “partner” device is within the 

range for Bluetooth, operators can transmit 

all relevant information without even leaving 

the hazardous area. 


Online search: Wika 

AUTHOR: 

JENS ROLLMANN 

Product Manager Calibration 

Technology, 

Wika 

Picture: Wika 


cpp FOCUS INSTRUMENTATION, CONTROL, AUTOMATION 

With enhanced connectivity for smart production 

Making the wealth of data 

usable at last 

The chemical industry is preparing to tap further optimisation potential for its production 

processes by implementing various concepts from Industry 4.0. This is based 

on (diagnostic) data which, for example, intelligent field devices supply in addition 

to the primary measured variables. A NOA-compliant, open architecture and 

methods of enhanced connectivity make this data usable with manageable effort. 

All too often on the journey to Industry 

4.0, the second step is taken before the first. 

For some time now, promising scenarios 

have shown the type of potential that can be 

achieved if industrial companies were to use 

cyber-physical systems. The basis for this is 

selected automation data, especially from the 

field level. A considerable amount of this data 

is already being generated, but only a small 

proportion is actually evaluated and processed 

into information. Before this data can 

be fully utilised to create added value for 

digitalisation, it needs to be properly exported 

from the field or process control level 

(via a side channel) to higher levels, such as 

a cloud. Concepts like NOA (Namur Open 

Architecture) illustrate how this can be done 

in large plants without compromising system 

availability and the safety of core processes. 

Another prerequisite on the journey to 

smart production is that it should be as 

straightforward as possible to read this data. 

Only then will it be possible for this data to 

be widely used, for example, for monitoring 

and optimisation systems in process 

automation. These and other challenges associated 

with the contextualisation of data 

have not yet been adequately addressed. 

Reduction of complexity 

Using the NOA interface, based on OPC UA, 

data such as diagnostic data from existing 

field devices and data from any other lowcost 

sensors and controllers should be made 

accessible, so that it can then be utilised by 

various applications through read-only ac- 

Picture: Travel mania – shutterstock.com 

Existing plant data can be read in an easy, secure, and impact-free way and utilised for 

additional services, such as predictive maintenance, or for sustainable process optimisation 


Every child 

is one of a kind and unique. Each child needs individual support 

according to their needs. Please help us by donating. Thank you! 

Tel.: 0800/50 30 300 (gebührenfrei) 

IBAN DE22 4306 0967 2222 2000 00 

BIC GENO DE M1 GLS 

www.sos-kinderdoerfer.de 

cpp 01-2020 17 

2016/1


new plants is no small matter. But above all, 

as Namur states in its Guiding Principles for 

NOA: “Usability, reduction of complexity, 

and economic efficiency are the main success 

factors”. 

Principle of the enhanced connectivity system (Ecosystem) in 

combination with cloud solutions and the PLCnext Store 

The field data read via a process interface is 

contextualised using an open architecture 

Picture: Phoenix Contact 


No unstructured collection of data 

The aim must be to ensure connectivity as 

easily and inexpensively as possible, and to 

implement all general conditions such as IT/ 

OT security within this context. Despite the 

wide range of transmission protocols involved, 

the integration effort should be near 

non-existent. In view of these requirements, 

one thing must be avoided: the unstructured 

collection of data. Phoenix Contact 

therefore recommends an architecture in 

which data read via a process interface is 

contextualised first. This means that it is 

made available in an aggregated and structured 

format before it is used in the actual 

information processing level. All this is ensured 

by the “enhanced connectivity system” 

(Ecosystem). Without a system of this 

type, the integration effort largely depends 

on process interfaces and protocols. 

At the process interface level, this integration 

is largely handled by the Ecosystem, 

for example, through the impact-free automated 

reading of Hart data. At present, this 

is only possible with significant engineering 

effort, as the Hart information is available as 

raw data and makes little sense without 

context. Initial solutions are available in the 

form of Hart IP gateways or Hart IO cards, 

which can be used to read the raw data collected 

from field devices. 

Even in existing plants, it is possible to tap Hart data with no ill effects; 

the field data required for this is available in OPC UA format 

cess to not impact the actual core process. 

Although they may appear relatively 

straightforward at first glance, the NOA core 

requirements formulated by Namur only 

hint at the complexity involved. The most 

important requirement concerns consistently 

high system availability and system 

safety. In addition, open system interfaces 

are required, as is the use of existing stand - 

ards. However, those familiar with the gradually 

evolved and therefore heterogeneous 

landscape of process plants in Germany 

alone will know that finding solutions that 

work in equal measure for both existing and 

Picture: wavebreakmedia – shutterstock.com 

Download of functionality 

To reduce the engineering effort for users, 

the Ecosystem provides support at the contextualisation 

level, as it carries out the preprocessing 

via a gateway on the edge, for 

example. Data mapping with the aid of device-specific 

description (EDD, FDI) transforms 

raw data, process data or diagnostic 

data into valuable, usable information. 

PA-DIM (Process Automation – Device 

Information Model) will be the standard 

used for this. Users will no longer have to 

deal with the complex process of data 

mapping; in future, they will be able to 

download the functionality in the form of 

an app from the Phoenix Contact app store. 

The app makes the data available in context 

for further evaluation or aggregation of 

information. At this level, it is also possible 

for an open runtime system, such as the 

PLCnext Ecosystem, to analyse the information 

“on the edge” and, using com- 


® 

Unlock the wealth of data available in existing 

plants (brownfield) with relatively little 

effort: read Hart data in an impact-free way 

using Hart IP gateways and make it available 

for further processing via OPC UA in compliance 

with NOA 

plex algorithms (high-level languages via 

Matlab or C++), utilise this information 

for predictive maintenance or to optimise 

processes. 

Connectivity with other systems is supported 

at the information processing level with 

cloud connectors, various cloud applications, 

and software as a service (SaaS), which can 

be accessed via an online platform. 


Hart data to be stored in a cloud 

As mentioned, the data diode model 

requires the Hart protocol to be used solely 

as a one-way street, i.e., write access is prevented. 

In addition, secure routes, e.g., 

using a security router, are recommended 

for reading Hart signals. The Hart signals 

that are obtained can be collected in a local 

database or a cloud. 

In principle, it is easier to use a cloud: data 

cannot be lost, accessibility is optimised by 

the provider, and cloud services are convient. 

In practice, a Hart gateway with OPC 

UA interface acts as the link between the 

field and the higher-level system. OPC UA 

supports various security measures. The data 

stored on the OPC UA server can be used 

for suitable and authorised higher-level systems, 

where each system can select the data 

it requires. 

Up to 40 sensors can be connected to the 

Phoenix Contact Hart gateway extended 

with the OPC UA server. The information 

(such as identifiers or diagnostic values) is 

read cyclically – without any configuration 

effort. This opens up various possible applications 

for the operator, such as plausibility 

checks, predictive maintenance or use by 

external specialists. 

Optimised connectivity 

As explained, data can be made usable with 

manageable effort. IoT gateways direct diagnostic 

information and other information to 

a cloud or server where it can be evaluated, 

for example, by web services – better than 

in standard maintenance tools. In future, device 

manufacturers will support this with 

big data analysis based on a huge amount of 

data from their worldwide database. The 

NOA concept in conjunction with various 

web services opens up significant potential 

for increasing the efficiency of plants. The 

effort involved on the part of the operator 

will decrease further. Those who want to 

ensure (enhanced) connectivity will be able 

to benefit from Industry 4.0 and artificial 

intelligence in future without having to invest 

excessive resources. 

New technologies like 5G and Ethernet to 

the Field, in process automation specifically 

APL (Advanced Physical Layer), will play an 

important role. With its higher bandwidth 

and availability, 5G communication enables 

new wireless applications. APL, as a prerequisite 

for using Ethernet (Profinet) in the 

Ex area, makes it easier to implement big 

data applications, as large volumes of diagnostic 

data can be transmitted from the field 

at high speed. The restrictions imposed by 

previous fieldbuses no longer apply and the 

handling of promises is also easier. All in all, 

both 5G communication and APL will provide 

optimised connectivity that supports 

the specific requirements of Industry 4.0 

and smart production more effectively than 

current solutions. 


Online search: Phoenix Contact 

AUTHOR: 

WILFRIED GROTE 

Director Industry 

Management Chemicals 

and Pharmaceuticals, 

Phoenix Contact 

Innovations for heating 

Flexible 

 

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 



How to improve industrial security in large brownfield plants 

Update management 

for the plant network 

In industrial plants, PLCs run the show. The chemical giant, BASF, has a large number 

of PLCs that needed to be automatically updated. But with multiple firewalls to navigate 

and many third-party devices involved, integrating them into a single network 

would be a challenge. Until the solution Sinema Remote Control from Siemens was 

brought to the table. 

An industrial network is a production 

plant’s backbone. As long as it’s strong, secure, 

and reliable, productivity can run at 

full steam. But should a network error 

occur, devices may become inaccessible or 

stop communicating. In a worst case sce - 

nario, production may halt altogether. 

At its Antwerp site, BASF had 350 devices 

controlled by Simatic PLCs from Siemens. 

This included PLCs running compressors, 

energy meters, charging stations, and other 

mission critical devices. So keeping all PLCs 

updated with the latest security updates was 

vital to protect them from malware, unau - 

thorized access, and other threats. But the 

PLCs had yet to be connected to a single 

network. This meant Siemens’ on-site automation 

team had to update every device 

manually. With the site spanning 6 km 2 and 

updates taking several hours, this was a process 

that could take a full year to complete. 

Picture: BASF 

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


BASF knew it needed an automation network. 

But installing one hadn’t been feasible 

for two key reasons. Firstly, the site housed 

16 plant clusters with their own firewalls 

and third-party devices. Secondly, the site’s 

vast size meant installing a new fiber optic 

network, which was not financially viable. 

BASF approached Siemens for new ideas. 

Experts in complexity 

With its track record of successfully implementing 

networks in complex industrial environments 

all over the world, BASF was 

confident Siemens could devise an effective 

solution. And upon receiving their request, 

Siemens jumped into action, bringing in 

network specialists to assist its on-site automation 

team. 

This BASF Antwerp team says, “We are familiar 

with networks, Siemens and PCS 7, but 

our team was short on technical know-how 

for developing a concept that could meet 

the stringent requirements imposed by the 

IT department. So, we joined forces with 

product and service specialists from 

Siemens to create the concept.” 

In addition to improving security and reliability, 

BASF wanted a network that would be 

easy to manage and master. They also 

wanted to be able to create user groups, so 

every plant cluster could manage their own 

devices. After assessing all the requirements, 

Siemens’ team planned the rollout of a secure, 

dedicated network with Sinema Remote 

Connect at its core. 

Connections via VPN tunnels 

The first challenge was devising a network 

that could securely connect technicians and 

devices across 16 plant clusters. A challenge 

Sinema Remote Connect easily solved. 

Using Sinema Remote Connect, Siemens 

created VPN tunnels, connecting every PLC 

and user through the Sinema Remote Connect 

server. An inventory of the security certificates 

for every device and user was also 

created in the server. This meant that whenever 

a connection was requested, the certificates 

would be checked and verified before 

the connection was approved. Sinema Remote 

Connect further improved security by encrypting 

all communications using OpenVPN. 

Another advantage of Sinema Remote Connect 

is that it can provide remote access to 

Scalance M-800 as well as Scalance S-600 

Industrial Security Appliances and dedicated 

CPs and RTUs. This allows each device to be 

configured and integrated automatically, 

eliminating an otherwise complex and 

time-consuming task. 

Providing technicians with central access to 

the PLCs in all parts of the BASF plant was 

realised by Sinema RC Client. Once all 

groups and rights in the Sinema Remote 

Connect server were configured, Sinema RC 

Client’s address book function enabled every 

technician to see the parts of the network 

they have access to. 

Transparent processes 

To fulfill BASF’s requirements for central 

network monitoring, the Sinema server was 

Sinema Remote Connect and Simatic Rack 

PCs enable a secure and centrally managed 

VPN connection 

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

Picture: Siemens 

implemented. Siemens’ team created one 

user group for each plant cluster so they 

could access their own devices and monitor 

their performance in private. In addition, 

the Sinema server’s network monitoring 

software would provide BASF with around 

the clock monitoring, and diagnostics, including 

diagnostics for SNMP, Profinet, and 

Simatic. 

Putting it to the test 

Before rolling out the network, Siemens ran 

a proof of concept project in the lab. This 

project was to verify how devices would re- 





AT A GLANCE: 


Scalance S615 Industrial Security Appliances 

made controllers accessible from the central 

Sinema Remote Connect server 

• BASF’s Antwerp site had PLCs 

spread across 6 km², which 

had to be manually updated 

• The PLCs belonged to 16 plant 

clusters with different network 

infrastructure 

• The Sinema server enabled the 

creation of user groups for 

each plant cluster and provided 

desktop access to devices 

and diagnostics 

• Scalance S615 Industrial Security 

Appliances made both 

PROJECT BASF ANTWERP 

spond when added to the network and 

whether firewall rules needed to be 

modified. 

“We wanted to ensure we developed a network 

that would meet the stringent requirements 

for security, seamless implementation, 

and ease of use,” says BASF Antwerp. 

“The proof of concept project translated 

into significant time savings, while for the 

businesses on-site, it meant better service.” 

Along with saving time and lowering risk, 

the proof of concept project enabled 

Siemens to develop workflows for installing 

and managing devices. Siemens trained 

BASF’s technicians these workflows through 

a workshop, so they could manage the network 

independently. 

“Good preparation is the key to success,‘‘ 

says Bert Vanstraelen, Service Engineer at 

Siemens Customer Services in Belgium. 

“Giving BASF’s technicians training in the 

new system will ensure they can perform 

The automation solution from Siemens 

integrates 16 plant clusters with different 

network infrastructures 

Siemens and third-party controllers 

accessible from central 

Sinema Remote Connect server 

• Sinema Remote Connect enabled 

the creation of secure 

and centrally managed VPN 

tunnels 

• A proof of concept project was 

completed before rolling the 

entire system out 

• A task that would have taken a 

year to complete, can now be 

done automatically 

their own maintenance in the future without 

IT support.” 

Rolling out 

Following the successful test project, 

Siemens built out the network in stages. 

Close cooperation between BASF and 

Siemens’ team ensured the network’s central 

elements were completed within one 

month. The PLCs were then linked to the 

system step-by-step, allowing the network 

to grow organically. With the successful implementation 

of Sinema Remote Connect, 

BASF now has the reassurance knowing all 

PLCs across 16 plant clusters can be monitored 

and updated around the clock by their 

central maintenance team using the TIA 

Portal – the engineering platform for automation 

from Siemens. 

At a ground level, desktop access through 

Sinema Remote Connect means Siemens’ 

automation team no longer has to travel 

around to the different plants. This has freed 

Siemens’ technicians to focus on providing 

high quality services across BASF’s site. 

Future upgrades planned 

There are now plans to further improve the 

network monitoring with Siemens’ Network 

Management System, Sinec NMS. This will 

further enhance transparency and ease of 

use by providing BASF’s technicians with 

desktop access to devices for prompt fault 

resolution, security monitoring, and device 

configuration with hardening. 

The project’s success also reinforced the value 

that BASF has for both Siemens’ technology 

and its expertise, especially when overcoming 

complex challenges. In fact, the project 

has been such a success that the company is 

now planning to upgrade their logistics systems. 

The new system will be completely integrated 

into the Sinema Remote Connect 

architecture. Siemens’ team will be there to 

support them on every step of the way. 


Online search: Siemens 

AUTHOR: 

MAXIMILIAN KORFF 

Product Sales Development, 

Digital Industries, 

Process Automation, 

Siemens 


Explosion proof thermostat 

Pluggable power distributors 

Picture: Larson 

Larson Electronics, released an 

explosion proof thermostat 

rated for use in Class I, Divisions 

1 and 2 hazardous locations. 

This thermostat is ideal for temperature 

control in industrial facilities 

where flammable gases, 

vapours and dust may be present. 

The EXP-TSTAT-250V-86F- 

20M-CE16 explosion proof 

thermostat is rated for use in 

Class I, Divisions 1 and 2, 

Groups C and D; Class I, Zones 1 

and 2, Groups IIA and IIB; Class 

II, Division 1, Groups E, F and 

G; Class II, Division 2, Groups F 

and G; and Class III hazardous 

locations. This unit features an 

SPDT snap action switch and is 

rated at 250 V(AC). It can be adjusted 

via a set point knob to set 

the thermostat within a range of 

2 to 28 ˚C. 

The explosion proof thermostat 

is made of precision die-cast 

and corrosion resistant components 

and does not contain any 

exposed copper, brass or mercury. 

To improve the accuracy of 

the temperature readings, this 

unit must be secured five feet 

above the floor and can be 

mounted to walls or compatible 

surfaces via four cover bolts. 


Online search: Larson 

Phoenix Contact has expanded the application range of 

its PRC plastic circular connectors with pre-assembled 

power distributors. The distributor boxes are weatherproof 

and designed with an IP 69 degree of protection. 

This makes the product series particularly suitable for 

supplying power to devices used indoors or outdoors. 

The single-phase designs have a 3-pos. input and two 

3-pos. outputs. Three-phase distributors provide one 

5-pos. input and three 5-pos. outputs. A phase splitter, 

which enables a three-phase input to be split into three 

single-phase outputs is also supplied. The entire series 

is designed for rated currents up to 32 A and rated 

voltages up to 400 V(AC). 


Online search: Phoenix Contact 


Paving the way for modular production 

Level switches for all silo types 

Picture: Wago 

To meet growing demands for 

modular systems, Wago added 

the “Module Type Package” 

(MTP) to its range of automation 

solutions. Similar to 

printer drivers from the Office 

ecosystem, MTP works as a 

standardised interface and functional 

image of entire system 

modules. The MTP creates the 

basis for the automation of 

versatile production systems. 

MTP is based on the 2658 Directive 

adopted jointly by 

Namur, ZVEI and VDMA. It can 

be used with both Wago Controllers 

PFC200/PFC200 XTR 

and Wago Touch Panels (600). 

For module engineering, the 

Wago e!Cockpit Engineering 

Software provides a library with 

many preparatory functions. It 

also contains a control image 

description, which can be used 

to easily build a library of reusable 

modules. Once the module 

has been created, the MTP is 

automatically generated with 

one click and can be read into 

a wide variety of process visualisation 

and control systems 

(Process Orchestration Layer, 

POL). 


Online search: Wago 

Emerson has introduced a range 

of Rosemount solids level 

switches designed to optimise 

operations, increase safety and 

reduce waste. The vibrating fork, 

paddle, capacitance and vibrating 

rod switches within the range 

ensure reliable monitoring of 

solid materials such as powders, 

grains and pellets in all silo types 

across industries. The switches 

can be used to provide standalone 

point level monitoring to 

help optimise filling and emptying 

cycles. They can also be deployed 

within an overfill prevention 

system. In applications involving 

light, fine-grained and 

powdered materials where high 

measurement sensitivity is 

required, Rosemount 2511 and 

2521 vibrating fork switches 

provide a cost-effective solution. 

Atex certification permits installation 

in explosive areas, and all 

wetted parts are made from corrosion-resistant 

stainless steel. 

The 2501 rotary paddle switch 

for example can be used as a 

full, demand or empty detector 

in storage silos or process vessels 

and the 2555 capacitance switch 

can be installed in pipes. 


Online search: Emerson 

Picture: Emerson 

T +49 2961 7405-0 | info@rembe.de 

Gallbergweg 21 | 59929 Brilon, Germany 

F +49 2961 50714 | www.rembe.de 

Your Specialist for 

EXPLOSION SAFETY 

and PRESSURE RELIEF 

Consulting. Engineering. Products. Service. 

© REMBE® | All rights reserved 



Intrinsically safe pressure transmitters 

The Keller D-line boasts a combination of highly robust 

industrial pressure transducers and the I 2 C interface. 

This series has undergone further development and an 

intrinsically safe version is now available too. The D Ei 

series is approved for gas group II applications and can 

be used to measure absolute and relative pressures in 

zone 0. With its modular structure, the series permits 

numerous combinations, making it the ideal component 

for customisations using an I 2 C interface: 

• OEM pressure transmitters for fitting directly into a 

system’s existing drilled holes 

• OEM pressure transmitters with ultra-flexible pressure 

connection for screwing into existing pressure systems 

• Pressure transmitters with a pressure connection and 

cable gland 

• Level sensor for measuring the contents of a tank up 

to a maximum fill level of 3 m 


Online search: Keller 

Updates for frequency converter portfolio 

Glass-free pH sensors 

The Isfet sensors made of unbreakable 

Peek from Endress+Hauser 

offer high product 

safety, accuracy and improved 

CIP stability. The sensors made 

of unbreakable Peek are available 

with three different reference 

systems. The Isfet sensors 

Memosens CPS47D and CPS77D 

are perfectly equipped to meet 

the strict demands of hygienic 

applications. Thanks to their design 

with an increased chip surface, 

they are even easier to 

clean than their predecessors. 

They deliver stable and reproducible 

measured values, even 

after sterilisation and autoclaving 

up to temperatures of 

135 °C, come with USP, EHEDG 

Picture: Endress+Hauser 

and 3A ap proval, and are TSE-/ 

BSE-free. They can outlast at 

least 25 CIP cycles and have 

therefore significantly improved 

CIP stability . In addition, the 

Memosens CPS77D offers maximum 

bacteria tightness thanks 

to its microporous ceramic diaphragm. 

Even at low temperatures, Isfet 

sensors such as the Memosens 

CPS97D have a fast response 

time and are chemically stable 

thanks to their Peek stem. Also, 

their open diaphragm means 

that they do not become 

clogged even in the case of high 

solids concentrations. 


Online search: Endress+Hauser 


With numerous innovations, 

Siemens is extending its drive 

portfolio, improving userfriendliness 

and offering spacesaving 

installation options. The 

Sinamics G120X converter, designed 

specifically for use in 

water/waste water applications 

and in HVAC systems, is now 

also available in a three-phase 

3AC 200V voltage variant in the 

power range up to 55 kW. This 

means that the converters can 

now be integrated seamlessly 

into applications in the USA and 

in Latin America. Due to its robust 

construction and the coating 

of the PCBs according to 

3C3 standard the converter is 

suitable for harsh environments. 

The module for extending the 

digital and analogue inputs and 

outputs increases the flexibility 

and the optimal control of converter-guided 

applications. The 

Sinamics G120X now also supports 

the communication protocols 

Profibus, Modbus RTU, USS 

and BACnet MS/TP. It is 

equipped with extensive interfaces 

and can be easily integrated 

into existing or new systems. 

The Sinamics G120 modular 

frequency converter combines 

with the Sinamics control 

unit adapter kit CUA20 to provide 

an option for simple and 

flexible cabinet design. Power 

modules and the control unit 

can be separated physically and 

thermally, making the converter 

even more flexible and customisable. 

A new Sinamics V20 converter 

size has been added in 

the 2.2 to 3 kW power range. 


Online search: Siemens 

Central processing unit with high scalability 

Picture: Jumo 

A new hardware and software 

platform is being used in the 

Jumo Varitron 500 central processing 

unit. During its development, 

scalability had the highest 

priority. The result is modular, 

flexible, and, above all, sustainable. 

The basis of the Varitron 

500 is a hardware platform 

with an 800 MHz processor 

which can be used as a single, 

dual, or quad core variant depending 

on the application. 

The software has a modular 

structure based on a Linux platform 

and enables scalability for 

performance, memory, and interfaces. 

Another special feature 

is a customer-specific configuration 

and process data editor. 

Several operator stations can be 

integrated into the system via 

Codesys Targetvisu or Codesys 

Webvisu as well as up to 64 intelligent 

connection modules. 

In the future, Jumo will provide 

visualisation libraries for individual 

customer-specific operation 

via Codesys Targetvisu or 

Codesys Webvisu. Flexibility is 

also made possible by the integration 

of all important fieldbus 

systems via Codesys, such as 

Modbus RTU or TCP master and 

slave, Profinet IO controller, 

Ethercat master, and OPC UA 

server. A Profinet IO device interface 

will allow an alternative 

connection to higher-level control 

systems via Modbus TCP. 


Online search: Jumo 


Pressure switch with IO-Link and display 

Wika's PSD-4-ECO program - 

mable pressure switch enables 

pressure monitoring in machines 

which is as uncomplicated 

as it is reliable. With IO- 

Link version 1.1, the instrument 

− in a space-saving design and 

with a two-colour display − is a 

flexible automation solution. 

The plug-and-play principle enables 

the pressure switch to be 

commissioned quickly, either 

through individual factory preconfiguration 

or via IO-Link. Its 

display can be set so that the operator 

receives on-site information 

without any prior 

knowledge about the status of 

the current pressure or the condition 

of the instrument. For 

example, a measured value within 

the defined pressure range is 

displayed in green, a measured 

value outside the limit in red. 

For the best possible view of the 

Picture: Wika 

display, the case head can be rotated 

and the display tilted electronically 

through 180°. 

The PSD-4-ECO has been designed 

for installation in tight 

spaces. With a diameter of only 

29 mm and a vertical orientation 

of the electrical output, it can be 

fitted almost anywhere. The 

pressure switch is also suitable 

for harsh environments: it is designed 

for medium temperatures 

between -40 and +125 °C and 

shock resistant up to 50 g. 


Online search: Wika 

Fluently digitized. 

Precise measurement with long-term stability 

Suitable for fresh and salt water 

Immediately ready for use due to 

factory calibration 

No minimum inflow 

Easy connection to field devices and 

process control systems due to analog 

and digital interface 

Extremely easy to maintain due to robust 

and easily replaceable sensor 

JUMO digiLine O-DO S10 

Digital optical sensor for dissolved oxygen 

in aqueous solutions 

Welcome to JUMO. 

www.jumo.net 

Visit us 

Hall 11, Booth C28 

Enclosures for Zones 1 and 21 

Picture: Pepperl+Fuchs 

Delivering advertisement 

data simply and safely 

PDF 

Pepperl+Fuchs is now offering more and more customised 

solutions for zones 1 and 21 that feature sensor technology 

from factory automation and can be used in a huge 

range of applications. Sensors from Pepperl+Fuchs are 

housed in pressure-resistant enclosures, allowing processes 

to be further automated even under harsh conditions. 

The GR series of GRP enclosures caters perfectly to the 

needs of electrical installation in process plants. The products 

are designed to offer maximum flexibility for a wide 

range of applications. The mounting grid makes the additional 

mounting base obsolete, while also enabling terminals 

and switching elements to be planned and installed 

quickly and easily. It also means that any DIN mounting 

rails can be mounted using self-tapping screws. An innovative 

spacer system allows components to be installed at 

different levels within the enclosure. Different enclosure 

sizes and depths ensure that the enclosure series with IP 66 

expanded silicone seal offers high flexibility. The series can 

be used in environments up to -60 °C in zones 1/21 and 

zones 2/22. 


Online search: Pepperl+Fuchs 

Upload 

Send 

www.konradin-ad.de 

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Correct 



Valve islands as electro-pneumatic all-rounders 

Step by step into 

the future 

Valve islands in process automation have, step by step, become an integral part of 

process engineering plants. Now Bürkert is taking the next step: Seamless integration 

into distributed peripheral systems has created a future-proof platform that 

offers users maximum security, including redundant Profinet topologies. 

More than 20 years ago, the initial combination 

of a valve island and a powerful 

distributed I/O system paved the way for 

the success of valve islands in the process 

engineering environment. The Bürkert valve 

island Airline Type 8644, for example, has 

long since become the industry standard 

and can still be found in many applications 

to this day. Thanks to these devices, it was 

now possible for the first time ever to control 

electrical and pneumatic signals via just 

one bus line and to transmit the information 

to a higher control level. Users 

were able to integrate pneumatics and electrics 

into a single control cabinet and the 

number of bus participants within networks 

was reduced significantly. 

Valve islands for Ex atmospheres 

Since many users, particularly in the pharmaceutical 

and chemical industries, also 

have potentially explosive atmospheres 

within their plants, an intrinsically safe 

valve island variant was subsequently developed 

that can be seamlessly integrated into 

the Siemens ET 200 iSP distributed I/O system. 

Thanks to the valve island Airline Ex 

Type 8650, it was possible to use a uniform 

concept in both potentially explosive and 

non-hazardous atmospheres and also to 

carry out maintenance and diagnostics in 

potentially explosive environments. The integrated 

pneumatic hot-swap function 

allows the valve to be changed during operation 

under pressure and – thanks to the intrinsic 

safety in potentially explosive atmo - 

spheres – even when energised. Fail-safe 

signals can also be processed in potentially 

explosive atmospheres and correspondingly 

safe shutdown can be implemented for the 

pneumatics. 

Pictures: Bürkert 

Growing requirements 

Although the principles of valve islands 

have not changed drastically over the years, 

they still have to perform an increasing 

number of functions within a production 

line and meet high demands in terms of 

safety and operability. For example, safety 

functions must be easy to integrate. Additionally, 

integration into higher-level control 

systems or process control systems is 

required, as are diagnostic options, both onsite 

and remotely. Components must be 

quick and easy to replace or add on, and 

compact dimensions are also an issue. 

More than 20 years ago, the initial combination of a valve island and a powerful 

distributed I/O system paved the way for the success of valve islands in the process 

engi neering environment 

Distributed integration 

Thanks to experience and close cooperation 

with customers and users, these requirements 

have been implemented in the current 

valve island Airline SP Type 8647. Its in- 


The valve islands can be used in combination with 

Siemens modules and stainless steel control cabinets in the 

immediate process environment 

Valve island Airline SP Type 8647: users can now read the status of the 

valve island, faults or process parameters directly on a locally installed LC 

display without the need for additional peripheral devices 

tegration into the distributed peripheral system 

ET 200SP from Siemens also offers users 

the added advantage of working within the 

familiar Siemens programming environment. 

For the first time, they can now read 

the status of the valve island, faults or process 

parameters directly on a locally installed 

LC display without the need for additional 

peripheral devices. In addition, the switching 

position of the pilot valves and the associated 

process actuators can be displayed 

graphically directly at the valve island. This 

mapping of digital input and output signals 

facilitates start-up, maintenance and troubleshooting. 

All the information generated at 

the valve island can also be processed in the 

controller, for example diagnostic data such 

as defective coils, open outputs or pressure 

fluctuations in the intake air. Two independent 

switching cycle counters generate 

messages that enable preventive maintenance. 

The new valve island also has a lot to 

offer when it comes to safe pneumatic shutdown. 

The valve modules can be de-energised 

via the optional EVS function. In this 

case, the supply circuit for the load voltage 

of the valves is interrupted by a potentialfree 

contact. As soon as the safety function is 

active and the valve supply circuit has been 

interrupted, this informa tion is shown on 

the local LC display and, if required, sent to 

the controller. Since internal communication 

is not affected by this emergency stop function, 

there is no loss of control in the plant 

at any time and users are always aware of 

what is happening in the field. 

Saving space in the control cabinet 

This simple but robust and safe solution 

offers users the option of emergency stop 

circuits directly at the valve island. If, for 

process-related reasons, it is not possible to 

implement block-by-block shutdown, i.e. 

simultaneous shutdown of several valve 

functions, users can utilise safety valves 

with a second electrical connection which 

can be retrofitted at any time, and shut 

them down individually via potential-free 

contacts. Safety functions can thus be retrofitted 

at all Bürkert valve islands without too 

much effort. A valve change under pressure 

during operation is enabled by the integrated 

P-channel shut-off. The built-in 

check valves protect the downstream process 

actuators against unintentional switching 

in the event of pressure surges or exhaust 

air build-up. To meet the demand for 

smaller sizes and more compact systems, 

the valve islands combined with the 

Siemens modules can be installed directly 

on the control cabinet wall or floor thanks 

to the universal Airline Quick floor installation 

plate. Up to 48 valve functions can 

thus be accommodated in a particularly 

space-saving fashion, and small distributed 

units with high signal density can be implemented 

directly on-site. 

Maximum availability 

Although valve islands have previously also 

been operated in redundant Profinet topologies, 

the current generation of the valve island 

Airline SP Type 8647 now goes one 

step further. It is seamlessly integrated into 

the Simatic ET 200SP HA (High Availability) 

distributed I/O system, i.e. combined in a 

compact yet powerful automation system. 

Compared to its predecessor, this new level 

of integration further enhances plant availability. 

Now, for the first time, valve islands 

Fit for the future: now, for the first time, 

valve islands in highly available and up to 

R1 redundant Profinet environments can be 

operated directly in a distributed peripheral 

system 

in highly available and up to R1 redundant 

Profinet environments can be operated directly 

in a distributed peripheral system. In 

addition, thanks to complete software integration 

in the Siemens process control system 

PCS7, all diagnostic information and 

process parameters of the valve island can 

be monitored. This allows preventive and 

wear-oriented plant maintenance to be initiated 

and downtime to be minimised. 


Online search: Bürkert 

AUTHOR: 

HEIKO KURTZ 

Field Segment Manager 

Hygienic, 

Bürkert 



Control loop analysis reduces energy use 

Distillation column 

trimmed for efficiency 

The energy efficiency target presented by the German government in December 2019 

provides for a 30 % reduction in primary energy consumption compared to 2008. Companies 

are therefore obliged to make further energy savings. The example presented 

below shows how energy consumption can be reduced and the process improved at 

the same time by means of a precise control loop analysis of a distillation column. 

Distillation columns are one area within a 

chemical plant that offer considerable potential 

in terms of improving energy efficiency. 

In the United States, there are more 

than 40,000 distillation columns within the 

refining and bulk chemical industries, and 

according to the US Department of Energy 

they consume approximately 40 % of the 

total energy used to operate these plants. 

Because they are very high users of energy 

they are obvious candidates for closer inspection 

with a view to making performance 

improvements that lead to greater 

energy efficiency. 

However, reducing the amount of energy 

that distillation columns consume is not always 

straightforward. Columns will have 

different operating objectives and different 

configurations which will produce different 

behaviours. The operation of these processes 

typically involves a trade-off between energy 

usage and product recovery, and setting 

the appropriate operational targets involves 

careful evaluation of the relative economic 

value of these two factors. Another factor is 

the complexity of the distillation process, 

with multiple process parameters interact - 

ing strongly, making straightforward control 

difficult. An example of this occurred with a 

distillation column operated by Clariant at 

one of its sites in Germany. 

Not content to limit itself to compliance 

with current directives, Clariant aims to 

minimise the environmental impact of its 

operations. The company has developed an 

extensive energy efficiency programme 

By means of a precise control loop analysis energy consumption of a ditillation column 

can be reduced and the process can be improved 

Bild: Sittinan – Adobe Stock 

called eWatch, which uses analysis to identify 

potential savings in energy consumption, via 

the optimisation of machines and processes 

across all its global production sites. This is 

supplemented by training programmes for 

employees, to sharpen their awareness regarding 

energy-saving possibilities. 

Reducing steam usage 

As part of its eWatch programme, Clariant 

wanted to improve energy efficiency at its 

chemical facility in Frankfurt, Germany. The 

facility produces azo pigments, highly 

specialised high-performance pigments and 

polyolefin waxes, which are further processed 

into automotive and industrial 

paints, inks and plastics. Clariant wanted to 

reduce the amount of steam used by a distillation 

column which separates water from 

acetic acid, before returning the acetic acid 

back to the process. Key to achieving this 

was to optimise the performance of the column. 

One major obstacle to achieving this 

was that many of the column’s PID controllers 

were not able to run in automatic 

mode. This meant that they were being 

manually controlled by operators, which 

was not only a labour-intensive and timeconsuming 

process, but also made it extremely 

difficult to optimise activities. 

Clariant turned to Emerson, who is a major 

supplier of instrumentation at the plant and 

had worked with the company on other 

energy reduction projects. Members of 

Emerson’s lifecycle support team, specialising 

in process optimisation, were invited to 

investigate the distillation column to see if 

they could reduce energy usage. The initial 

approach to the problem was to conduct an 



energy saving study, including analysis of 

historical process data. This identified that 

the column had not been performing at optimum 

levels, leading to higher steam usage 

than necessary, loss of product due to too 

much acidic content in the reflux water, and 

subsequently higher water treatment costs 

due to the removal of that acid trace. 

Investigation of the control loops 

Emerson provided its Advanced Loop Service, 

during which a process optimisation 

team investigated the layout of all the column’s 

PID control loops to check that they 

were working properly and being controlled 

in the best way possible. PID control loops 

present an excellent opportunity for optimisation. 

There can be several hundred active 

in some chemical plants and it’s not uncommon 

for as many as two-thirds of these 

to be underperforming, due to deficiencies 

in design and tuning. This is a recipe for 

chronic process inefficiency and places a 

heavy burden on experienced operators 

who must continually control major aspects 

of the process manually, adjusting set-points 

locally and reacting to changes. A loop tuning 

sequence was performed as well as 

manual output step tests to detect problems 

and measure process dynamics. 

In addition to this, all measurements and 

control valves were evaluated, to ascertain 

whether they were correctly designed and 

performing as they should. Distillation columns 

feature several critical control valves, 

such as a feed valve to control the rate of 

feed flowing into the column, a reflux valve 

to adjust the purity of the overhead product, 

bottom and overhead product valves 

that regulate the level in the bottom of the 

column and in the overhead receiver, pres - 

sure control valves, and a re-boil valve that 

controls the amount of heat put into the 

column by the re-boiler. The sizing and performance 

of these valves are crucial, as any 

discrepancies can affect both product purity 

and energy usage. 

Finally, a complete appraisal of all installed 

instrumentation was performed, checking 

to ensure that the right measurement 

methodology was being used, every device 

was working correctly and installed in the 

correct position as well as identifying where 

additional measurements would help provide 

a greater understanding of the process 

leading to greater process optimisation. 

Revised control strategy 

After completing testing, Emerson’s team 

produced a comprehensive report with details 

about which control loops, valves and 

equipment were performing sub-optimally 

and therefore affecting process performance, 

process optimisation and subsequently 

increasing the energy use of the distillation 

column. The report highlighted various opportunities 

for improvement and a complete 

revised control strategy was provided which 

would contribute directly to reduced energy 

usage. Clariant implemented all the recommendations, 

with Emerson providing support 

by tuning all the PID loop controllers, 

enabling them to run in automatic mode. 

Critically, the changes implemented meant 

that set-points could be controlled with an 

accuracy of ±0.5 % compared with ±2.5 % 

previously. Greater control helped to make 

significant improvements in terms of energy 

usage. 

The target of Emerson’s performance-related 

contract had been to achieve a 2 % reduction 

in steam usage resulting from its Advanced 

Loop Service. The actual result was a 

6 % saving, which was an outstanding success, 

especially considering how previous 

attempts had failed to generate any significant 

reductions. 

Fast return on investment 

Previously, the distillation column used approximately 

6,1 GWh/a, amounting to approximately 

1 million euros per year in 

energy costs. The 6 % steam usage reduction 

achieved amounts to 5,7 GWh/a and therefore 

a saving of 80,000 euros per year. 

Based on the target figure of 2 % steam 

usage reduction, Clariant had expected that 

it would take approximately one year to 

achieve a return on investment (ROI), but 

the actual 6 % saving meant that ROI was 

achieved in less than four months. 

Picture: Clariant 

At the Clariant site in Frankfurt, 

Germany, the steam 

consumption of distillation 

columns could be reduced by 

6 % using the Advanced Loop 

Service 

The improvements made to the distillation 

column also produced other significant 

benefits. Greater control and a more optimised 

distillation process enabled a reduction 

in product loss in the form of acetic 

acid content in water removed from the distillation 

column. Subsequently there was 

also a reduction in water treatment costs to 

remove the acid, which further improves 

profitability. 

Switch to automatic mode 

Following Emerson’s work, operators are 

now able to run all the distillation column’s 

control loops on automatic mode, rather 

than relying on manual control as before. 

This means that operators who previously 

had to watch and control the steam input 

and make manual adjustments every 30 to 

60 min are now freed up to concentrate on 

other roles, therefore improving both 

worker and plant efficiency. Clariant was so 

satisfied with the increased energy reduction 

and process optimisation achieved on this 

two-month project that it is now looking to 

review the performance of other distillation 

columns at its other production sites. 


Online search: Emerson 

AUTOR: 

JÖRG WIERZ 

Advanced Process Control 

Consultant, 

Emerson 



PROCESS ENGINEERING 

Pictures: Julabo 

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

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

Constant temperature in 

all processes 

Julabo circulators are renowned for their reliable technology. Now, the new Magio 

series complements the product range with bridge mounted circulators, refrigerated 

circulators and circulators for most demanding temperature applications and 

maximum flexibility in the laboratory and industry. 

As a supplier to almost all manufacturing 

companies, the chemical industry relies on 

efficient and safe processes to meet its production 

requirements. Since most chemical 

reactions are either exothermic and release 

heat, or endothermic and absorb heat, a reliable 

temperature control application plays 

a central role in the chemical industry. 

Julabo has developed the high-end circulators 

of the new Magio series with new future-oriented 

technologies, especially for 

such requirements. They are manufactured 

in Germany to the highest quality standards. 

Especially the refrigerated circulators of the 

Magio series offer the ideal conditions for 

precise external temperature control as 

required by the chemical industry, for 

example, in reactor temperature control. 

Reactor temperature control 

In both chemical and biological processes, 

the conversion of substances often takes 

place in reactors, which make it possible to 

create consistent conditions and a safe space 

for the reactions. This requires temperature 

control systems with fast and precise compensation 

and a wide temperature range. 

This is why temperature control systems 

such as the Magio circulators are used, 

which react dynamically to temperature 

changes inside the reactor and compensate 

for them quickly and reliably. The reactor 

type, its size and the material (e.g. glass or 

metal) as well as the wall thickness, and the 

thermal conductivity associated with the 

material are, among other things, decisive 

parameters. In addition to the process having 

to be temperature-controlled, these pa - 

rameters also influence the choice of the 


The Magio circulators are ideal for flexible temperature 

control of reactors in the laboratory and industry 

The Magio circulators have no side ventilation slots and can 

therefore be placed directly against a wall or next to other 

circulators like Corio or Dyneo 

temperature control system. Pump capacity, 

pressure build-up, heat exchange rates, and 

the efficiency of the components in the 

temperature control system must precisely 

cover the individual requirements to guarantee 

process reliability and effective material 

conversion. For special requirements 

outside the standard temperature control, 

specially-developed temperature control 

solutions are also considered. In most cases, 

however, this is not necessary because temperature 

control systems available on the 

market can be easily and efficiently adapted 

to individual requirements. 

For temperatures from -50 to +300 °C 

With the Magio series, Julabo offers products 

of the highest performance class with a 

working temperature range from -50 to 

+300 °C and a heating capacity of up to 

3 kW. Due to the high heating and cooling 

capacity, the models guarantee short heatup 

and cool-down times. In combination 

with the high-performance power pressure/ 

suction pump with output values of up to 

31 l/min or 0.92 bar (pressure) and 

-0.4 bar (suction), the Magio units are ideal 

for the most demanding external applications. 

The pump is not only powerful, but 

it is also continuously adjustable, making it 

easy to adapt to pressure or volume sensitive 

external applications. Furthermore, 

samples can also be temperature-controlled 

in the internal bath. To ensure maximum resistance 

to chemical substances, all parts in 

contact with the medium are made of stainless 

steel. The high-quality insulation of all 

relevant components supports energy efficiency 

during operation. 

Functional operation 

The high-resolution TFT touch display 

offers a multilingual user interface and 

stands for simple, intuitive operation and 

optimum visibility of relevant functions. 

The modern display shows all important information 

at a glance. Three pre-defined, 

generous main screens clearly show data 

and graphics with different application focuses. 

The menu navigation is self-explanatory 

and arranged according to relevance in 

the daily work. All display functions can be 

operated at the touch of a finger. This allows 

even complex applications to be controlled 

easily and safely. The support function assists 

with further detailed questions at any time. 

The sophisticated operating concept of the 

Magio series allows quick and convenient 

access to the most frequently used functions. 

All operating elements, as well as 

safety functions, can be easily operated 

from the front. The main switch on the top 

of the circulator simultaneously switches 

the circulator and refrigeration unit on and 

off. With the bright and extremely robust 

touch display, it is visible from afar and can 

be read easily even from a distance. The circulator 

fully controls the connected cooling 

unit during operation. Inclined pump connections 

on the back of the model facilitate 

the connection of external applications. 

Modern interfaces such as USB, RS 232, and 

Ethernet support a simple remote control. 

Safety through automatic shut-off 

For optimum process reliability, critical 

states are indicated visually and acoustically 

at an early stage. The automatic shut-off in 

the event of high temperature or low liquid 

level additionally provides maximum safety. 

Classification III according to DIN 12876-1 

enables safe operation, even with flammable 

fluids. The fill level of the temperature 

control medium can be read at any 

time on the display. 

The bath fluid is drained without special 

tools, comfortably and cleanly via the drain 

tap. The magnetic front grid of the refrigerated 

circulators can be removed easily for 

time-saving care and maintenance of the 

model. 

As usual with Julabo, all Magio models do 

not have vent slots on the sides of the system. 

Thus, they can be placed directly next 

to other devices and applications or against 

walls to save space. Depending on the 

model, the refrigerated circulators from the 

Magio series have handles or castors for 

easy transport. In combination with the 

ergonomic handles, the models can be 

easily and comfortably moved to a different 

location. 

Individual solutions 

In chemical reaction and process engineering, 

a precise temperature control application 

has a decisive influence on production 

output, product quality, and process reliability. 

The requirements placed on temperature 

control systems are strongly application-related. 

Due to the extensive range of 

accessories, the wide temperature range, 

and the extraordinary dynamics, the circulators 

of the Magio series can be adapted 

modularly and individually to almost any 

application. Modern interfaces and an integrated 

programmer complete the intelligent 

design. 


Online search: Julabo 

AUTHOR: 

SILJA MOSER- 

SALOMON 

Marketing & PR, 

Julabo 



PRODUCTS 

Modular orbital cleaner 

Quick couplings according to ADR/RID 

The modular OC200 orbital cleaner from GEA offers 

distinctive advantages in terms of cleaning performance 

and efficiency. The orbital cleaner’s normal operating 

pressures are 4 to 10 bar and can easily deliver high impact 

liquids for tanks with a diameter of up to 35 m. The 

OC200 is particularly suitable for large process tanks 

and storage vessels for industries. It can be individually 

configured. The modular system allows interchangeability 

of key components – rotors, nozzle carriers and 

nozzles – in various standard options whilst the main 

cleaner assembly simply remains in place. This modularity 

offers flexible adjustments of impact values, cleaning 

diameter, dwell time and insertion size, as well as reduced 

consumption of cleaning media, according to the 

application requirements and customers’ priorities. 


Online search: GEA 

Picture: GEA 

The quick couplings of the 

Clean-Break CN series from 

Walther Präzision meet the 

requirements of the directive 

RL 2010/35/EU on transportable 

pressure equipment in conjunction 

with ADR/RID 2017 

and DIN EN 14432:2014 for 

hazardous goods. This approval 

permits the use of CN quick 

couplings for transfer processes 

of liquid chemical products 

classified as hazardous into/ 

from ADR/RID-approved containers 

as a secondary product 

shut-off valve downstream of 

the bottom valve and as a primary 

shut-off valve for peak use 

in road and rail vehicle tanks. In 

the case of tanks intended for 

the transport of these dangerous 

goods, the fittings can thus be 

used for filling and removal operations. 

The locking device is 

not placed in the flow coupling 

for hygienic and cleaning reasons. 

The CN couplings therefore 

have excellent hygienic 

properties, are easy to clean and 

SIP-compatible. All these quick 

coupling systems can be 

coupled against high differential 

pressures and are insensitive to 

transverse loads (forces acting at 

90° to the axial direction). 


Online search: Walther 

Picture: Walther Präzision 

Stationary acid dosing unit 

Graphical analysis of mixer and process data 

Proview process data visualisation 

from Eirich is a universal 

tool that is not tied to any specific 

platform, enabling efficient 

analysis of operating data. It can 

be used on a PC in the office or 

on a tablet or smartphone while 

on the move. In many industries, 

monitoring the mixing 

process is necessary for reasons 

of quality assurance, particularly 

if plants are working automatically, 

without direct control by a 

designated member of staff. 

Proview enables simple and 

quick analysis of the process 

values in such situations. 

As browser-based software Proview 

works with any controllers, 

whether from Siemens, 

Rockwell or Mitsubishi. Installation 

on the company network 

is easy. The programme is preconfigured 

for each machine or 

plant, but can also be adjusted 

by the user at any time. 


Online search: Eirich 

Picture: Eirich 

Picture: Bühler 

For the extractive analysis of 

process and emission gases the 

reliable and constant reduction 

of the sample gas moisture is 

indispensable. The solution for 

moisture reduction by cooling 

leads to the problem of loss of 

concentration of the water-soluble 

sample gas component 

(e. g. SO 2 ). This effect is also 

called the leaching effect. 

In order to minimise this leaching 

effect, Bühler Technologies 

developed the stationary acid 

dosing unit. A premixed acid is 

metered into the heat exchanger 

at a constant flow rate to saturate 

the precipitated water content. 

A plate holder allows the 

complete unit to be mounted on 

the wall. The modified cover facilitates 

the connection to the 

acid tank. The specifically designed 

connection adapters on 

the metering pump and the heat 

exchangers ensure a short lead 

time of the acid feed in the metering 

line. A capacitive sensor 

for level monitoring of the acid 

is also available. 


Online search: Bühler 


Intelligent liquid ring vacuum pump 

Edwards Vacuums developed the 

Elri series of liquid ring pumps 

for applications which are wet, 

humid as well as corrosive. The 

stainless steel impeller, endplates, 

liquid reservoir and heat 

exchanger makes this pump 

highly resilient against corrosion 

and harsh process gases. 

The internal injection channels 

reduce the risk of leakage while 

the horizontal motor flange arrangement 

saves time on maintenance. 

The use of mechanical 

seals also ensures reliable operation 

by preventing leaks as well 

as extending service intervals. 

The Elri is equipped with two 

VSD. While the main VSD 

matches the speed of the pump 

to vacuum level by adjusting its 

Tare-compensated feeder 

speed, the second VSD regulates 

the water flow through the centrifugal 

pump according to the 

operating conditions to avoid 

risks of cavitation. A special algorithm 

always maintains a perfect 

harmony between the two VSD’s. 

The Air logic control ler not only 

enables the monitoring of important 

features and parameters 

of the pump, but also offers the 

option of set-point control. 

While the Econtrol box even 

allows to connect and control 

multiple Elri pumps, the Icon 

Box enables smart monitoring 

and remote controlling ensures 

optimal servicing to get maximum 

uptime with the pumps. 


Online search: Edwards 

Picture: Edwards Vacuum 

Sanitary filter housings 

WS Sanitary housings from Wolftechnik are designed for 

use in sterile production. Depending on the product 

requirements, depth filter types can be used in the cartridge 

filter housings for clarification, as can pleated elements 

and membrane filter cartridges for sterilisation. 

The housings are made of stainless steel AISI 316L 

(1.4404) and have a mirror polished surface inside and 

outside. The surface roughness (Ra) is


PRODUCTS 

Visualisation app for pumps 

Metering and drainage station for IBC 

Lewa has developed an app that presents a virtual, freely 

scalable ecoflow process diaphragm pump on an iPad 

and allows malfunctions to be simulated. This makes it 

unnecessary to provide a demo model at trade shows, 

for example, and technicians at the customer’s facility 

can be trained more effectively. Also augmented reality 

smart glasses are available from Lewa for remote maintenance 

and initial diagnostics of malfunctions in operation. 

With the smart glasses, a connection to a service 

technician can be established to support the on-site employee 

with their repair and maintenance work. 


Online search: Lewa 

Picture: Lewa 

The Dulcodos Safe-IBC from 

Prominent is a special metering 

and drainage station for Intermediate 

Bulk Containers (IBC) 

with almost complete residual 

drainage. The customer positions 

and fixes the IBC on the slightly 

forward-tilted installation surface 

of the collecting pan. Using 

leak-proof safety couplings and 

hoses, the IBC is connected to an 

interim tank of approximately 

200 l fitted to the left side of the 

collecting pan. Optionally, the 

station can be equipped with a 

standpipe and a tank volume of 

approximately 60 l. 

This buffer volume ensures an 

uninterrupted process when 

changing the IBC. The visual 

level indicator and a level 

measurement function with 

alarm message also allow more 

efficient planning of IBC 

changes. The station is equipped 

with an inspection opening for 

Picture: Prominent 

maintenance purposes. 

To ensure reliable metering, a 

compact metering station can be 

integrated in the front of the interim 

tank according to process 

requirements. This is equipped 

either with one or two solenoid 

metering pumps or with one 

motor-driven metering pump. 

Larger metering stations can be 

configured as required and designed 

for side mounting on the 

wall or installation on the floor. 


Online search: Prominent 

Facelift for IE3 asynchronous motors 

Mixer for continuous processes 

The facelift of the IE3 asynchronous 

motors from Nord 

Drivesystems involves no 

change of electrical data and 

outer dimensions. They can be 

seamlessly used without adjustments 

in any existing application 

with Nord IE3 motors. 

The optimised cooling fin 

shape, an assembly-optimised 

fan and a modern fan cowl enable 

a better heat dissipation 

and assembly. The fan cowl can 

be simply assembled in case a 

motor-mounted frequency inverter 

is used. The special cooling 

fins design enables an unhindered 

airflow around the terminal 

box. The revised terminal 

box is without sharp edges and 

corners and has reinforced feet 

for a better motor stability. Another 

important detail is the optimised 

incremental encoder 

mounting. Due to the fan cowl, 

the encoder is fully shock-resistant 

and not within the airflow, 

which further improves the 

cooling power. Retrofit mounting 

is also possible due to a 

plug-on shaft. 


Online search: Nord 

Picture: Nord Drivesystems 

The continuous Ploughshare 

mixers of the KM series are 

particularly suitable for environmental 

engineering applications. 

This low-maintenance 

mixer model is intended for 

processing powders, fibrous 

or granular solids, but also 

fluids and pastes. The continuous 

mixer even performs gran - 

ulating processes with minimum 

retention times. It is characterised 

by excellent repeatability, 

maximum homogeneity 

of the final product, short retention 

times and great econo - 

mic efficiency. 

The sophisticated mixer concept 

also includes universal applicability 

of the machine. Beyond 

Picture: Lödige 

processing of dry, powdered, 

granular or fibrous solids, it can 

also be equipped for numerous 

other mixing tasks. Adding 

fluids to moisten product components 

is just as possible as 

processing pastes and fluids. A 

broad range of different mixer 

sizes allows for even more versatility. 

The smallest model with 

a drum volume of 5 l boasts a 

feed rate of 0.25 m 3 /h based on 

retention time and degree of 

filling. The feed rate of the larg - 

est model to date with a 

57,000 l drum volume is 

1300 t/h. 


Online search: Lödige 


Valves with electric drives 

Gemü has expanded its selection 

of motorised valves with the 

launch of the Gemü Esystep and 

Esydrive valves.The Gemü Esy - 

step valves are designed for 

standard open/close and simple 

control applications. With regard 

to the actuator, this is a compact 

spindle actuator with step 

motor. Via the interface in the 

Picture: Gemü 

housing cover, the valve can be 

extended with additional accessories 

such as diverse electrical 

position indicators or travel sensors 

to provide extra functions. 

The Gemü Esydrive valves are 

available for variable and complex 

open/close and control applications 

in conjunction with 

high requirements on perfor - 

mance and service life. The actuator 

is based on the hollow 

shaft principle. Both the Ethernet-based 

Esy-web interface, in 

conjunction with an integrated 

web server, and the Modbus-TCP 

communication interface, enable 

the exchange of parametrisation 

and diagnostics data and the 

networking of several devices. 


Online search: Gemü 

Jacket-cooled submersible motor pumps 

The Amarex KRT range of submersible motor pumps are 

available with drive ratings of 10 to 30 kW and are suitable 

for vertical or horizontal dry installation. Since the pump 

motors remain fully operational when not submerged, the 

pump sets can also be used in pump sumps when water 

lev els have dropped. Thanks to IP 68 enclosures, the pumps 

also offer trouble-free continuous operation when flooded. 

The pump sets meet all explosion protection requirements 

set out in the Atex, FM and CSA standards. 

The motor is cooled via a closed circuit which avoids contact 

between the circulating water-glycol mixture and the 

fluid handled. This also rules out any risk of contaminants 

in the fluid handled impairing the cooling of the motor. 

The cooling liquid is circulated by a special impeller 

which the pump’s design engineers have integrated into 

the cartridge seal. 

The pumps are able to transport fluids with a temperature 

of up to 40 and operate in environments with a temperature 

of up to 55 °C. 


Online search: KSB 

Picture: KSB 

Smart actuator in protection class IP 67 

The Profox from Auma is not 

only cunning and adaptable but 

also extremely hardy. The smart 

actuators are suitable for process 

and water applications. Adjustable 

speed ensures fast and precise 

positioning. Operating costs 

are low, thanks to high mechanical 

efficiency and low standby 

consumption. Special diagnostics 

ensure long-term availability 

and future-proof Profox 

for IIoT applications. 

Auma Profox actuators work 

with gate, butterfly, ball and 

globe valves. There are multiturn 

versions for torques of 10 

to 100 Nm and part-turn versions 

delivering 32 to 600 Nm. 

A linear actuator will follow 

soon. Modular design ensures 

flexible configuration, rapid delivery 

and consistent operation. 

Host system integration is 

equally flexible, the most common 

communication protocols 

are supported. IP 67 protection 

Ultrasonic clamp-on flow and energy meter 

The ultrasonic clamp-on flowmeters 

and energy meters 

TFX-5000 are available in two 

versions: 

• a flowmeter for water delivery, 

raw sewage, cooling water, sea 

water, deionised water, waterglycol 

mixtures, alcohols, 

chemicals and many caustic 

fluids 

• a heating/cooling energy 

flowmeter used in conjunction 

with dual clamp-on Resistance 

Temperature Detectors (RTDs) 

for temperature measurement 

in hydronic processes and 

HVAC systems 

Picture: Auma 

(IP 68 optional) and Auma’s 

corrosion protection ensure that 

Profox actuators have a long life 

even under the toughest process 

conditions, at temperatures 

from -30 to +70 °C. 

Profox actuators are simple and 

easy to use, with rapid installation 

and commissioning via 

pushbuttons or an app. Actuator 

status is always clearly visible, 

even from a distance. 


Online search: Auma 

Picture: Badger Meter 

Users can select up to eight pa - 

rameters to log, including flow 

rate and total, signal strength, 

and alarms to an 8 GB microSD 

card. Users are alerted to out-ofspecification 

flow conditions 

and can access a history with 

the most recent alarm, error and 

event codes. 

The TFX-5000 meter features a 

large, easy-to-read graphical 

display and provides Modbus 

RTU, Modbus TCP/IP, Bacnet 

MS/TP, and Bacnet/IP connectivity. 


Online search: Badger Meter 




Compact level measurement in the waste water industry 

Radar as real alternative 

to ultrasonic 

Radar technology has established itself as a real problem solver in the field of level 

measurement. So far, however, the price of the devices has prevented their general 

use in standard applications. Now, the compact radar sensor Vegapuls is also gaining 

the upper hand in price-sensitive applications in the waste water industry. 

In sewage treatment plants, one treatment 

stage immediately follows the next. Each of 

these processes must be perfectly coordinated 

with the previous and the subsequent 

one so that the overall system can work optimally. 

To control the various process stages 

automatically, precise measurement data are 

required. But accuracy is not everything. 

Smooth, trouble-free operation is only pos - 

sible with robust, durable sensors that can 

withstand wind, weather and the challenges 

posed by dirt and contamination. 

Compact and highly accurate 

For decades, the Schiltach-based company 

Vega has been supplying a wide variety of 

level and pressure sensors to sewage treatment 

plants all over the world. At the beginning 

of this year, a new compact series of 

radar level sensors was introduced to the 

market. The beating heart of these new sensors 

is a radar chip newly developed by Vega 

and specially optimised for the requirements 

of level measurement. And thanks to its small 

size, very compact sensors are now possible. 

Moreover, these new instruments are so inexpensive 

that they can replace previouslyused 

ultrasonic sensors in almost all applications. 

Vegapuls series C 11, C 21 and C 22 

sensors have a fixed cable connection and 

are designed in protection class IP 66/IP 68. 

In accordance with the requirements in the 

waste water sector, the sensors are also suitable 

for use in Ex hazardous areas up to 

zone 0. And for the typical zone 1 in the 

wastewater industry, Vega has come up with 

something special. By means of a special encapsulation, 

which is new for radar sensors, 

operation in Zone 1 is possible even without 

an intrinsically safe power supply – making 

installation much easier for the user. 

In addition to being unaffected by temperature 

fluctuations, vacuum or changing gas 

overlay, radar sensors are, most importantly, 

non-insensitive to soiling. These are all factors 

that often lead to malfunctions in ultrasonic 

level measuring devices. The Vegapuls 

series measures with a frequency of 80 GHz, 

which enables very good signal focusing. 

With this advanced technology, measurement 

signals can be better separated from 

interference signals − the measuring process 

itself thus becomes much easier and more 

precise than other measuring methods. Before 

its official market launch, the new sensor 

series was tested in over 400 applications 

in 30 countries. Several application examples 

in the wastewater industry show where the 

new sensor can really unleash its strengths. 

The basis for calculations 

Waste water and rainwater are transported 

to the waste water treatment plant via 

The compact radar level sensors 

Vegapuls and the control 

unit Vegamet offer a real alternative 

to the ultrasonic 

sensors commonly used in 

sewage treatment plants 

Pictures: Vega 


widely branched sewer networks and 

measured in open channels on the way to 

the plant inlet. An important job, since 

measuring the amount of water flowing in 

and out of the plant provides the basis for 

calculating service rates and fees as well as 

operating costs. The Vegapuls C 21 delivers 

these measured values reliably with an accuracy 

of ±2 mm, regardless of the ambient 

temperature and the type of medium. 

The sensors are also used at another point 

on the way to the waste water treatment 

plant – in pumping stations. If the natural 

gradient from the households to the plant is 

not steep enough, various pumping stations 

are required to create sufficient height differences 

along the way. Level measurement 

with Vegapuls C 11 in the inlet shaft of the 

pumping station, together with a controller, 

ensures economical operation of the pumps. 

The rain overflow basins, which protect 

waste water treatment plants from overload 

during heavy rainfall, are also an ideal location 

for the new sensor series. The precipitation 

is stored there temporarily and then 

released to the plant at a slower rate. If the 

basin cannot hold the accumulating quantities 

of water, part of the water is discharged. 

Due to legal requirements, such impounding 

events and discharged water quantities 

have to be measured and documented. 

Vegapuls C 22 stands out here due to its 

compact design and simple ceiling mounting, 

delivering the required measured values 

reliably – even in the event of flooding. 

Controlling the cleaning processes 

In the precleaning stage, floating materials 

are mechanically removed with rakes or 

sieves. This protects later process steps from 

buildup, clogging, and abrasion. Solids with 

diameters greater than 25 mm are trapped 

in the coarse screens, compressed in the 

screenings press, and then disposed. 

The fine screen removes smaller residual 

materials from the waste water. Measurement 

of the water level difference between 

the front and the back of the screen is used 

to determine the degree of contamination 

and initiate the cleaning of the screen. This 

is where things get particularly rough and 

dirty. An ideal task for the fully encapsulated 

Vegapuls C 11. Reliable level measurement is 

also required in the containers where the 

solids, sand and sludge sorted out through 

coarse and fine raking are collected. Here, 

the measured values, which are also supplied 

by a Vegapuls C 11, give the signal to 

start the automatic exchange of the containers. 

Through the addition of chemicals, phosphates 

in the wastewater are precipitated 

out in primary sedimentation, in aeration 

systems or in special precipitation and postclarification 

pools. Precipitants like ferric 

chloride bind the phosphate chemically and 

deposit it in the sludge. In each chemical 

storage tank, a level measuring system as 

well as a limit level detector are deployed 

for continuous inventory monitoring and 

optimal dosing. Vegapuls C 21 is also used 

here. The sensors are approved as overfill 

protection systems according to WHG 

(Water Resources Act in Germany) and thus 

reliably protect the environment from an 

overfilling of the tanks. 

Displaying the essential readings 

The sensors are supplemented by Vegamet 

controllers. These supply the connected 

4...20 mA sensors, process the measured 

values and display them, all without complicated 

programming. A large display for 

data visualisation is integrated in the housing 

designed for harsh field conditions. 

Vegamet enables simple implementation of 

pump controls, flow measurement in open 

channels/weirs and totalising counters as 

well as the calculation of difference, total 

and average values. Limit values can be 

monitored and relays switched, e.g. for 

overfill protection according to WHG. 

The compact Vegapuls series is ideally suited 

for a wide range of applications in the 

waste water industry. It is a real alternative 

to ultrasonic sensors not only because of its 

low price, but also because of its high reliability 

and long service life. All sensors and 

controllers can also be adjusted via a smartphone 

or tablet with Bluetooth functionality. 

This makes everyday work easier in the 

harsh environments of the industry – especially 

since many sensors are often located 

in virtually inaccessible places. 


Online search: Vega 

AUTHOR: 

JÜRGEN SKOWAISA 

Product Management Radar, 

Vega 

With the Vegapuls C 21 a flow measurement 

in open channels can be carried out at the 

inlet of the waste water treatment plant 

The level measurement with the Vegapuls C 

11 in the inlet shaft of the pumping station 

ensures economical operation of the pump 

The new Vegapuls series is also well suited 

for level measurement in rainwater overflow 

basins 




Future-proof drying in compressed air treatment 

F-Gas Regulation 

forces action 

For businesses that rely on refrigeration dryers for their compressed air treatment, 

there will be no getting around the new F-Gas Regulation. This new standard will be 

the end of many dryers in use today – operators should be wary. 

Compressed air drying and production go 

together hand in hand. Virtually every compressed 

air station uses refrigeration dryers, 

for the simple reason that virtually every 

compressed air application requires dry 

compressed air. The F-Gas Regulation EU 

517/2014 aims to minimise emissions of 

fluorinated greenhouse gases (F-gases) in 

order to mitigate the effects of global warming. 

Set in place since 2015, this regulation 

is now only just beginning to cause ripples 

in the industrial sector. Operators of compressed 

air stations count amongst those 

now feeling the effects, owing to the fact 

that F-gases are used as a refrigerant in many 

refrigeration dryers. Any company wishing 

to service or repair their existing refrigeration 

dryer, or to purchase a new one, must 

do so within the confines of the regulation. 

Refrigerants that have until now been freely 

available will henceforth gradually be withdrawn 

from the market – partially by means 

of outright bans, but also by a deliberate 

tightening of the supply of refrigerants with 

high global warming potential (GWP). 

The hitherto ubiquitous refrigerant R404A 

now finds itself firmly in the regulation’s 

sights. As of this year, the release to market 

of new refrigeration dryers that use R404A 

are prohibited. Existing stocks of this refrigerant 

are only permitted for maintenance 

purposes in larger systems until 2030, 

whereupon it will become banned from service 

altogether. The result is clear to see: 

R404A will henceforth be difficult to source 

in large quantities, and will only be available 

at great cost. And it does not end there … 

Future-proof refrigeration dryers not only save operators both energy and space, 

they also use a climate-friendly refrigerant 

Pictures: Kaeser 

Shortages ahead 

Other commonly used refrigerants with 

high global warming potential are also 

being targeted, such as R407C and R410A. 

Quotas have been assigned to the individual 

manufacturers and distributors of these refrigerants, 

limiting the volumes which they 

are legally allowed to produce and sell. The 

quotas will gradually be reduced to just 

21 % of their initial volumes. The lower the 

global warming potential of a refrigerant, 

the higher the volumes that may be produced 

and sold; as a result, manufacturers 

are rushing to switch their product ranges 

over to refrigerants with the lowest possible 

global warming potential values. Access to 

refrigerants with high global warming potential 

will consequently become much 

more difficult. Many such products currently 

on the market will no longer be available 

for maintenance and servicing work, or 

if they are, only at very high prices. 

Operators of compressed air stations would 

be well advised to check up on which re- 


REFRIGERATION DRYERS: 

TG-SERIES 

The new refrigerant R-513A offers the most 

future-proof solution currently available on 

the market 

frigerant their system currently uses and, if 

necessary, seek advice on possible alternatives. 

Stockpiling large quantities of refrigerant 

for later use is not an option for 

most; operator certification is a prerequisite 

for purchasing new stocks and the only alternative 

– sourcing unofficial supplies on 

the black market – is fraught with danger 

from a technical point of view, not to mention 

highly illegal. As a starting point, all 

operators of refrigeration dryers – particularly 

older units – should have them serviced 

by a certified technician as soon as 

possible, to ensure there are no leaks in the 

refrigerant circuit that could waste precious 

supplies. There are also new regulations regarding 

mandatory leak testing that must be 

adhered to. 

Not a feasible alternative 

Unfortunately, in many cases, simply converting 

an existing dryer to use a new refrigerant 

is not a feasible alternative. It is 

not always technically possible to do so and 

even when it is, it can be prohibitively expensive. 

In such cases a better option in the 

long run would be to invest in a new dryer 

altogether. 

The enormous strides recently taken in the 

development of dryer technology mean that 

there are several advantages to this option. 

The latest generation of dryers are designed 

for the highest levels of efficiency and energy-saving, 

and frequently take up much less 

space than their older counterparts. On top 

of securing their future supplies of refrigerant, 

operators will also benefit from reduced 

energy and servicing costs. 

Think about the future 

Any operator planning to invest in a new refrigeration 

dryer should first ensure not 

High-performance TG-series refrigeration 

dryers from Kaeser 

not only impress with their 

latent heat storage system, future-proof 

use of climatefriendly 

R-513A refrigerant and 

relatively small footprint – they 

now also benefit from a new exhaust 

air system, which elevates 

these high performers to an entirely 

new level of cost efficiency 

when it comes to compressed 

air treatment. 

Designed for large-scale industrial 

operations, these compact 

powerhouses are capable of delivering 

flow rates of up to 

98 m 3 /min and ensure stable 

pressure dew points, even under 

the most challenging conditions 

Thanks to a frequency-controlled radial 

fan, Secotec TG refrigeration dryers can 

be connected directly to the central 

exhaust air ducting 

– all whilst guaranteeing maximum 

reliability and minimal 

lifecycle costs. 

When installed in a location that 

is less than ideal, energy consumption 

can increase due to a 

build-up of heat inside the 

dryer. The frequency-controlled 

radial fan fitted to TG-series 

dryers is designed to allow the 

dryer to be connected directly 

to a facility’s central exhaust air 

ducting – making this potential 

issue a thing of the past. Furthermore, 

thanks to space-saving 

component layout, the new 

units are smaller than their predecessors, 

meaning operators 

save on space as well as operating 

costs. 

only that refrigerant supplies for it are currently 

available, but that they will continue 

to be available for service purposes over the 

entire lifecycle of the machine. By far, the 

safest choice is to go with a refrigeration 

dryer that already operates using a refrigerant 

with the lowest possible global warming 

potential, or at the very least, one that is capable 

of being converted inexpensively for 

use with it at a later date. 

Some manufacturers continue to use refrigerants 

that, whilst currently unrestricted, are 

bound to be either banned completely or 

gradually withdrawn from the market in the 

near future. Inevitably, operators using these 

systems will find themselves in trouble 

sooner or later. 

The most proactive manufacturers of re - 

frigeration dryers are already offering products 

using a new generation of refrigerants 

such as R-513A, which has the lowest 

GWP value of all refrigerants on the market 

today, thereby ensuring the most futureproof 

and climate-friendly solution currently 

available. 


Online search: Kaeser 

AUTHOR: 

DANIELA KOEHLER 

Press Officer, 

Kaeser Kompressoren 




Pictures: Auma 

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

How digital services improve plant availability 

Off to the cloud 

Asset management and predictive maintenance on the basis of data stored in the 

Auma Cloud. This is Auma‘s way to increase actuator availability. Thomas Knecht 

and Kevin Nietupski, both staff members of Auma at Service Center Cologne, 

explain the advantages for the users and how classical and digital services are 

further merged. 

Mr Knecht, which are the milestones Auma has achieved in terms 

of digitisation? 

Thomas Knecht: The topic of digitisation is not new to us. In 2002, 

we had introduced the first generation of our software-based actuator 

controls. This was the AC.1. The actuator controls made it considerably 

easier to integrate our actuators into digital fieldbus protocols. 

One year later, COM-AC software for AC.1 configuration was 

launched. In 2005, data matrix codes were introduced on the actuator 

name plates. At first, this was purely for production reasons. Later, 

this code was used to store device data which can be read out 

today using the Auma Assistant App. 

The year 2009 was also a very important milestone. 

Knecht: That is correct. It was the time when AC.1 actuator controls 

were replaced by the new AC.2 actuator controls, which are still integral 

part of our product portfolio. The Commissioning and Diagnostic 

Tool, in short CDT, is used for device configuration, replacing 

the previously used COM-AC software. In 2014, we launched our 

first App, the Auma Support App, enabling quick and easy access to 

the device documentation by means of mobile end devices. This 

App was then integrated into the Auma Assistant App which was introduced 

to the market in 2017. 

If I remember correctly, Auma showed a first idea of the Auma 

Cloud on the Achema in 2015? 

Knecht: At that time, it was just an idea. We needed more than three 

years to turn a mere idea into a complete solution. In September 

2018, the Auma Cloud went online. A few weeks later, we presented 

our new service scheme with the Auma Cloud as central “hub”. 

Moreover, the latest version of the Auma Assistant App was 

launched. The App enables to download data from AC.2 actuator 

controls to the Auma Cloud. 


Mr Knecht has mentioned several products which we will explore 

in detail. Mr Nietupski, let us start with the AC.2 actuator controls. 

Kevin Nietupski: The AC.2 can be considered as the brain of the 

MOV package, i. e. the system consisting of valve, actuator and 

actuator controls. Actuator controls collect a large quantity of data 

such as operating and status data allowing statements on the actuator 

status. At the same time, critical operating states are recorded 

and archived. Thus, our service technicians can quickly provide the 

user with straight-to-the-point solutions in case of failures. 

You mentioned the CDT software. What do you need this software 

for? 

Nietupski: As referred to by its name, the Commissioning Diagnostic 

Tool, the software is both used by our service as well as by our 

customers for commissioning, configuration and diagnostics of the 

actuators. The diagnostic function is extremely useful since it ena - 

bles a sound analysis of data packages and event reports, which can 

be downloaded directly from the AC.2 actuator controls to a mobile 

end device, e. g. a laptop. 

And what is the function of the Auma Assistant App? 

Nietupski: The App is the light version of the CDT software. In its 

initial version, the complete device documentation could be 

downloaded by scanning the data matrix code on the actuator name 

plate. With the latest version of the app, you can also modify the 

device settings. Furthermore, the intuitive app can also be used to 

take snapshots. 

What is a snapshot? 

Nietupski: Snapshots are documents containing all relevant device 

data including serial number and operating data, which can be 

uploaded to the Auma Cloud. 

„Cloud-based Auma services cater for 

intelligent asset management and the launch 

of predictive maintenance.“ 

Which operating system do you need? 

Nietupski: The app runs on both Apple and Android devices. 

Mr Nietupski, let us talk about the Auma Cloud. What does it do? 

Nietupski: All the systems that my colleague just presented were 

not initially connected within a network. And this is exactly what 

we did with the introduction of the Auma Cloud. It links both de - 

vice and operating data as well as information on the respective 

applications, enabling centralised management of all Auma devices 

within one site, applying the same system which complies with the 

site setup. Both users and our service personnel may access the 

Auma Cloud. In fact, it is a platform on which the users can 

manage, edit and analyse the operating and device data. 

This means the plant layout is stored in the Auma Cloud. 

How does this work? 

Nietupski: You use the „Create a serial number list“ function of the 

Assistant App. The user scans the data matrix code of all Auma 

actuators on their tour throughout the plant. Thus, a complete list 

AUMA: 

FACTS AND FIGURES 

The company Auma Riester GmbH & Co. KG with headquarters 

in Muellheim, south of Germany, can look back 

on 50 years of active business. Founded in 1964, the company 

counts among the worldwide leading manufacturers 

of electric actuators for industrial valves, actuator controls 

as well as gearbox combinations. The prime customers for 

their products are traditionally water and waste water 

companies as well as power plants of any kind. A further 

important market segment is the oil and gas industry starting 

with oil production and refinery. Not to forget applications 

in the chemical industry and concrete production. 

As a medium-sized company, operating at 30 locations, 

Auma employs approximately 2,600 people, whereby 

around 1,200 of the employees are working in Germany 

(as of 2018). More than 15 % of the Auma staff work in 

the service sector. This figure shows the substantial customer 

orientation of Auma. In 2018, the company turnover 

was 420 million Euros. 

of all actuators and actuator controls is created. The data is stored in 

a structure which has been previously defined by the user. They may 

also be concentrated into subgroups and therefore appear in a hier - 

archical structure. Once complete, the list is transferred to the Auma 

Cloud by simply pressing a button. 

If I understand you correctly, the plant structure includes a list of 

all actuators and actuator controls within the plant? 

Nietupski: That’s perfectly right. It is a structured serial number list 

to which short notes can be added. 

This sounds very straightforward. Still, I believe that filling the 

Auma Cloud with data is quite time-consuming. Do you offer any 

support? 

Nietupski: Only recently, we have been offering to load data to the 

Auma Cloud as an actual customer service. Once our service engineers 

are on-site at the customer’s premises, they scan the data 

matrix codes within the plant and set up the plant structure for the 

Auma Cloud. 

Can you please explain by means of an example how the AC.2. 

actuator controls and the Auma Cloud work together? 

Knecht: The AC.2 actuator controls provide the event reports. They 

list all relevant events and faults or failures within the MOV with a 

time stamp. The data is continuously stored within the Auma Cloud 

and analysed by means of an algorithm. This way, we obtain valid 

figures allowing qualified statements on plant availability. 

When talking about cloud applications, we are actually talking 

about data security. How do your customers deal with this issue? 

Knecht: Indeed, data security is always a focus during discussions 

with customers, even if the advantages of our new service scheme 

has been described in detail beforehand. To ensure maximum security 

to our customers, we have decided in favour of Azure, the 

cloud computing platform of MS Microsoft. A renowned name, proven 

technology and a leading product – this creates trust among 

our customers. 




With the intuitive Auma Assistant App, complete 

device documentation can be downloaded 

from the Internet, device settings 

can be changed and snapshots can be taken 

Plant structure: the user walks through the plant with his mobile phone and scans 

the data matrix codes on each Auma actuator. In this way, a list of all actuators and 

controls is generated 

And has Azure met your expectations? 

Knecht: More than initially expected. 

obtains the complete device-specific documentation, i. e. device 

data, documentation, wiring diagrams, etc. 

How do you protect the data stored within the Auma Cloud 

against unauthorised access? 

Knecht: On the one hand, we have uncompromisingly implement - 

ed the security specifications of our customers. On the other hand, 

we apply a special user management. It includes registration via 

two-factor authentication and multi-stage validation process. After 

this initial step, access rights for the individual users are defined. 

User management enables the respective functions for the individ - 

ual users. 

Is the use of the Auma Cloud free of charge for your customers? 

Knecht: Basic services are free of charge while additional functions 

have to be purchased. 

Can you give an example? 

Knecht: Among others, we charge for continuous live data transmission 

directly from the field level via OPC UA to the Auma Cloud. 

I would like to take this opportunity to emphasise that our maintenance 

services will also work for discontinuous data transmission 

to the Auma Cloud. However, continuous transmission will result in 

more accurate data analysis. Once defined escalation levels are exceeded, 

the Auma service will automatically be notified. Or even device 

monitoring can completely be assigned to our service staff. 

Mr Nietupski, which advantages do the cloud-based Auma services 

provide for the user? 

Nietupski: They cater for intelligent asset management and the 

launch of predictive maintenance. Eventually, plant availability is 

considerably improved. In addition, business processes are 

accelerat ed, transparency reigns on all levels and information is 

quickly available: Without any research on our website, the user 

Will the cloud-based services replace on-site service staff in the 

future? 

Nietupski: Definitely not. But we would like to make full use of the 

cloud-based services. At the same time, face-to-face contact for continuous 

customer care is indispensable, especially when it is used as 

a source of information which is later included in our algorithms. 

What is the outlook for the Auma Cloud and the adapted services? 

Knecht: We have different approaches. One major keyword is connectivity. 

Our actuators shall become IIoT ready for automated data 

transfer to the Auma Cloud. The Auma Cloud as such will undergo 

enhanced development based on the feedback we receive from our 

users. Furthermore, our R&D is working on expanding our digital 

services portfolio while combining them with our standard maintenance 

options. 


Online search: Auma 

THE INTERVIEW WAS CONDUCTED BY: 

LUKAS LEHMANN 

Assistant Editor-in-Chief 


High-speed turbocompressors 

Picture: Sulzer 

The HST 30 high-speed turbocompressor 

from Sulzer offers 

more flow and pressure at a 

higher efficiency than its predecessors. 

This translates into savings 

in the energy consumed by 

low-pressure air compression, 

both in waste water treatment 

and industrial processes. 

HST 30 introduces updated versions 

of the active magnetic 

bearings. It also includes a permanent 

magnet motor design, 

built specifically for this duty. 

Almost unique for this size of a 

machine is that it is cooled with 

air only. 

All cooling air filters are well 

protected by the front door, but 

can easily be exchanged in seconds. 

Thanks to the horizontal 

shaft and inlet direction, the 

replacement of integrally-geared 

turbos and multistage centrifugal 

machines is also straight - 

forward. The flexible pipework 

configuration is helpful for the 

designer and builder as well. 

With filter boxes for wall or 

floor mounting as well as silencers 

and valves for all relevant 

flange sizes, HST 30 is one 

of the most flexible machines of 

its kind. The HST 30 has a maximum 

input power of 300 kW 

and a maximum flow of 

12,000 Nm 3 /h. 


Online search: Sulzer 

Seventh model for screw compressor series 

Easy to install pail filling station 

The pail filling station type 14 from Feige Filling uses 

the Feige weighing technology to fill cans, pails or canisters 

with liquid or pasty products in a highly accurate, 

rapid and cost-effective way. And all that for filling volumes 

ranging from 1 to 30 kg or 3 to 60 kg, depending 

on the customer or market requirements. Further benefits: 

The pre-configured station is easy to install. Control 

and operating elements are located directly at the filling 

station, easing the operation of the filling station. The 

optional LID Roller closes the pails with lids. 


Online search: Feige Filling 

Picture: Feige Filling 

Filling system for the chemical industry 

The screw compressor VM 100 

from Aerzen is designed for a 

volume flow range from 1500 

to 7620 m 3 /h and covers a 

maximum differential pressure 

of 3.5 bar. Aerzen is thus responding 

to specific practical 

requirements in the low-pres - 

sure range and the constantly 

growing demands for high-performance 

and efficient technology. 

All in all, the product range 

of E compressors includes sizes 

in the volume flow range from 

330 to 7620 m 3 /h and drive capacities 

from 30 to 630 kW. 

Picture: Aerzener Maschinenfabrik 

A special feature of the VM 100 

is the already integrated acoustic 

hood fan. Oil-free operation is 

certified according to ISO 

8573-1/Class 0. The principle 

of the built-in reflection silencer 

protects against contamination 

and ensures process reliability 

over the entire service life of the 

system. Various equipment options 

and a comprehensive 

range of accessories complete 

the VM 100’s operational capability. 


Online search: Aerzen 

The form fill seal system Fillpac 

FFS forms bags from a prefabricated 

tubular PE film and fills 

them with the product. The customers 

can select the optimal 

machine performance class 

from the Beumer product family 

depending on their requirements. 

To palletise the bags, barrels, 

canisters, cartons or 

buckets, the Beumer Robotpac is 

used. Depending on the packaged 

items, it is equipped with 

the appropriate gripping tool 

which can be easily and automatically 

changed, if the packaged 

items change. The fork 

gripper for example was designed 

specifically for palletising 

cardboard boxes, the finger 

gripper for bagged goods. For 

maximum performance, a 

double gripper for both types is 

offered. Moreover, there are parallel 

grippers for dimensionally 

stable packed items. 


Online search: Beumer 

Picture: Beumer 




Pictures: Samson 

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

Optimised cryogenic valve 

Keeping cool when 

controlling cryogenic media 

The Type 3598 cryogenic valve by Samson was carefully tailor-made for use at cryogenic 

temperatures, high operating pressures and high pressure drops: optimised 

features include the materials used for the valve bodies and trims, the design engineered 

to master cavitation and flashing as well as the well-thought-out temperature 

distribution across the insulating section. Together with the top-entry design and 

standard pressure balancing, these benefits add up to lower cost of operation and 

quicker maintenance. 

Cryogenic liquefied gases are stored and 

transported at very low (cryogenic) temperatures 

and, if necessary, high pressures. To 

maintain these conditions, the employed 

valves must have a special design. The materials 

used to manufacture wetted components, 

such as the valve body and trim, must 

be capable of withstanding the extreme temperatures 

of the process medium, which may 

drop to near absolute zero. Even after longer 

periods in service, the materials must show 

no signs of embrittlement. 

In terms of appearance, cryogenic valves 

stand out from other valves due to their long 

insulating section or extension bonnet, 

which creates the necessary distance between 

the valve body that carries the process medium 

and the valve bonnet. This cryogenic extension 

bonnet ensures that the cryogenic 

process medium does not damage sensitive 

components. To prevent an exchange of energy 

between the inside of the cryogenic valve 

and the warm environment, cryogenic valves 

are often insulated (e.g. in offshore installations) 

or mounted in a so-called ‘cold box’. 

These installation specifications make it difficult 

to access the valves. As a result, working 

on them is time consuming and complicated, 

which calls for low-mainte nance designs 

with a long service life. 

Even stricter requirements apply to cryogenic 

valves used as throttle valves in gas 

liquefaction. If gases are liquefied using turbines 

and/or valves, the process takes advantage 

of the Joule-Thomson effect. This 

means that the gases are depressurised 

below their inversion temperature, which 

causes them to liquefy – contrary to their 

behaviour above the pressure-dependent inversion 

temperature. Joule-Thomson valves 

are expected to handle high pressure drops 

between the compressed medium at the 


valve inlet and the relieved medium at the 

valve outlet. Severe pressure differences 

across the valve favour the occurrence of 

cavitation and flashing. This results in high 

noise levels, severe vibrations and erosion 

on valve components. 

For larger volume flow rates 

For many decades, Samson has been developing 

and manufacturing cryogenic valves in 

compliance with applicable specifications. 

Different valve versions in small and medium 

sizes for moderate pressure drops at 

cryogenic temperatures were added to the 

product range long ago. With the newly developed 

Type 3598 valve, Samson responds 

to the trend that has also taken hold of the 

industrial processes to produce and distribute 

cryogenic gases: plants are becoming 

ever larger while constantly higher flow rates 

and differential pressures need to be 

handled. During the development process, 

Samson brought together the thorough onsite 

experience gained over many years by 

plant operators with the corporate knowhow 

acquired through CFD (computational 

fluid dynamics) simulations and experiments 

conducted at Rolf Sandvoss Innovation 

Center. The product management and R&D 

departments focused on reducing the total 

cost of ownership by achieving greater reliability, 

ease of service and energy efficiency. 

More reliability 

The Type 3598 valve for cryogenic process 

media is capable of handling high pressure 

drops and also available in large valve sizes. 

This makes the valves suitable for operation 

in up-scaled process plants with high flow 

rates as well as for use as Joule-Thomson 

valves in applications with high pressure 

drops and, consequently, a risk of cavitation. 

In larger valve sizes, there is enough space 

downstream for the flow to continue without 

disturbances despite cavitation and 

flashing. To minimise undesired vibration 

and imminent cavitation damage on the 

sealing surfaces inside the valve, the pres - 

sure is let down in the clamped-in cage and 

not at the seating surface, as is the case in 

valves with seat-plug design. 

Ease of service 

The cryogenic valve has a top-entry design. 

This design comes with a single-piece valve 

body including a large-diameter cryogenic 

extension bonnet. As a result, service and 

maintenance work on the trim parts can be 

performed without having to remove the 

valve from the pipeline, cold box or insulation. 

After the actuator has been disassembled, 

there is free access to the valve seat, 

piston and circulation inhibitor through the 

cryogenic extension bonnet. The pressure 

balancing assembly fitted as standard guarantees 

that even large control valves are easy 

to service and disassemble. This is because 

relatively little force is required to move the 

piston, even in large control valves and at 

high pressure drops. As a result, smaller actuators 

having a lower weight can be 

mounted on the valves. As a positive side effect, 

it is also possible – depending on the 

valve size – to fit actuators suitable for the 

direct attachment of positioners or limit 

switches. This considerably reduces the piping 

and hosing required for installation. 

Higher energy efficiency 

A circulation inhibitor is installed in the 

lower part of the cryogenic extension bonnet, 

which influences the process medium’s 

temperature distribution across the insulating 

section. This offers several advantages: 

no icing up of the packing chamber, which 

is located in the valve bonnet outside the 

cold box or insulation. And no heat energy 

from the outside can heat up the process 

medium, which has been cooled down with 

great effort. The interface between the cold 

box and the environment can additionally 

be insulated by attaching an optional cover 

plate to the valve. So, the control valves’ 

total energy balance is influenced by the 

optimised temperature conditions as well as 

the required air capacity. On top, the thrust 

needed by the actuator plays an important 

role, which means that the included pres - 

sure balancing has a positive effect as well. 

Lower actuator thrust 

Due to the engineered design, the cost of 

purchasing a Type 3598 cryogenic valve is 

higher than a standard valve with screw-on 

insulating section. This is counterbalanced 

by the lower cost resulting from the lower 

actuator thrust and smaller actuator size 

required. Realistically, it would be possible 

to use an actuator with 1000 cm² diaphragm 

area on a pressure-balanced valve 

instead of a 2 x 2800 cm² actuator on an unbalanced 

valve of the same size. A comparison 

of the two actuators shows a reduction 

of roughly 90 % concerning travel volume 

and weight and of around 80 % when it 

comes to the actual cost of the actuator. 

Outlook 

Further versions of the cryogenic valves 

with enhanced features are already in the 

pipeline. This includes modular additions – 

such as larger valve sizes and higher pres - 

sure ratings – as well as angle-style valve 

bodies. Currently, the valves are available according 

to Ansi standards only, but DIN versions 

will follow. 


Online search: Samson 

AUTHORS: 

The Type 3598 cryogenic 

valve comes with some 

extras integrated as standard: 

pressure balancing (bottom 

right) and circulation inhibitor 

(top right) 

MARTIN KNAACK 

Product Management & Technical Sales, 

Control Valves Solutions, 

Samson 

TIMO MAUS 

Product Management & Technical Sales, 

Control Valves Solutions, 

Samson 

ANDREAS SANDER 

Research & Development, 

Modular Systems & Severe Service Applications, 

Samson 




Positive displacement pump transfers viscous suppository masses 

Pump and product 

are a perfect match 

Manufacturing of suppositories requires reliable transfer of the viscous mass from 

the preparation tank to the moulding plant and back in a low pulsation environment. 

The slightest temperature or pressure fluctuation could cause the mass to harden 

and product quality to suffer. At Dr. Pfleger Arzneimittel in Bamberg, Germany, a 

Certa sine positive displacement pump is tasked with handling this critical process. 

Pharmaceutical manufacturer Dr. Pfleger 

Arzneimittel is behind well-known OTC 

brands such as Bio-H-Tin, Ipalat Neuralgin 

and Mykosert, and also manufactures and 

markets numerous prescription medicines 

in the fields of urology, dermatology and 

pain-relief. What’s less known: In the modern 

production facility in Bamberg, the 

company manufactures the products of 

many well-known domestic and foreign 

pharmaceutical companies on a contract 

basis and in accordance with current GMP 

requirements. Dr. Pfleger Arzneimittel offers 

services from product development, manufacturing 

and packaging through to distribution. 

In addition to tablets, film-coated 

tablets, capsules, ointments and creams, 

the company manufactures and packages 

suppositories. „We are one of the leading 

contract manufacturers in this field in 

Germany,“ said Martin Schaller, Technical 

Services Project Manager. 

The suppositories are manufactured in a modern moulding process 

Pictures: Watson Marlow 

Suppository manufacturing 

The suppositories are manufactured in a 

modern moulding process. A 500 l process 

plant is used for this purpose, in which the 

suppository mass, consisting of the active 

ingredient and a fatty base, is melted and 

transferred via hose bridges to the suppository 

moulding plant. In the moulding plant, 

the primary packaging is formed in either 

plastic or aluminium foil, and the suppository 

mass is then moulded directly into the 

cavities. The suppositories are then hard - 

ened and sealed in a 105 m long cooling 

tunnel before being mechanically packaged 

into cartons. 

Production capacity is approximately 

20,000 suppositories per hour. As part of 

this process, a 14 m long ring pipe is used. 

„The mass is pumped directly from the 

preparation tank with agitator through 

heated hose bridges to the suppository filling 

station,“ explains Martin Schaller. There 

is no need for an additional moulding 

vessel, intermediate tank or product funnel. 

Once at the filling station however, only a 

small amount is moulded into the cavities; 

the remainder is pumped back into the 

preparation tank to repeat the process. 

Given the repetitive nature of the process, it 

is particularly important that the tempera- 


The Certa sine pump delivers the viscous suppository mass 

reliably and with low pulsation from the preparation tank 

to the moulding plant and back 

The sine pump is designed with only one rotor, one shaft and one seal. 

Pump disassembly and cleaning therefore is quick and easy. 

ture is kept constant at 35 to 38 °C. At just 

two degrees below this value, the mass 

would harden and settle, and the entire production 

process could come to a standstill. 

The homogeneity of the suppository mass 

and thus the even distribution of the active 

ingredient could also be affected. 

Transferring without pulsation peaks 

A positive displacement pump is used to 

circulate the suppository mass in the ring 

pipeline. To avoid hardening, the pump 

must not only be sanitary and efficient 

enough to process the mass at a viscosity of 

approximately 4000 to 6000 mPas, but it 

must be stable and reliable. Of upmost importance 

is that the pump transfers constantly 

and without pulsation peaks. High 

pressure peaks in the volumetric dosing 

pumps at the filling station could lead to 

problems with the dosing accuracy. In extreme 

cases, the uniformity of the suppositories 

and thus the product quality would 

suffer. Another criterion: Easy pump maintenance 

and cleaning. „The pump is rinsed 

with purified water every night and at the 

end of a production cycle the pump is disassembled 

and thoroughly cleaned by a machine. 

As a result, we require the effort for 

disassembly and reassembly to be as low as 

possible,“ says Martin Schaller. 

Initially, a rotary lobe pump was used for 

the important task of recirculating the suppository 

mass during production. “Not only 

did the rotary lobe pump have an annoyingly 

high noise level, but over time its 

maintenance costs also increased,“ reports 

Martin Schaller. Recurring leakages led the 

team at Dr. Pfleger Arzneimittel to look for a 

more modern alternative. They found what 

they were looking for at Masosine process 

pumps, a brand of Watson-Marlow Fluid 

Technology Group. The requirements for 

sanitary, reliable low-pulsation pumping at 

high viscosity, alongside easy and quick 

manual cleaning meant a sine pump was the 

optimum solution. 

Gentle conveying 

In this type of positive displacement pump, 

a sinusoidal rotor revolves. This results in 

four chambers of the same size that shift as 

a whole – their volume remains unchanged 

during the process. Inside these chambers, 

the medium is gently conveyed from the 

inlet to the discharge port. The seal between 

the pressure side and the suction side is 

made by a gate located on the rotor. This 

simple but effective design makes sine 

pumps particularly suitable for use at high 

viscosities of up to 8,000,000 mPas. Certa 

sine pumps are available in various sizes 

with a flow rate of up to 99,000 l/h at a 

maximum pressure of up to 15 bar. Some 

Certa pump models are self-draining and 

self-priming. The pump can be used in aseptic 

processes as it is bacteria-proof and 

requires no additional steam connections. 

EHEDG and 3A certified 

Thanks to extensive EHEDG EL Class I Aseptic 

and 3A certification as well as quick and 

easy cleaning through CIP and SIP, the Certa 

sine pump sets the benchmark for hygiene 

among positive displacement pumps. The 

pump also offers advantages over other 

pump types such as rotary lobe pumps, 

when it comes to manual disassembly and 

cleaning: Designed with only one rotor, one 

shaft and one seal, the number of parts in 

contact with the product is reduced to a 

minimum. Disassembly and cleaning are 

therefore much easier and quicker. In addition, 

this design offers significantly lower 

energy consumption than comparable positive 

displacement pumps. 

„Compared to our previous rotary lobe 

pump, the mechanical seal of the sine pump 

is much easier to access. Unlike the rotary 

lobe pump, manual cleaning of the mechanical 

seal can be done with minimal effort. In 

addition, the static flushing of the seal is 

much easier to carry out and the seal is also 

easier to control visually,“ says Martin Schaller. 

During comprehensive preliminary tests, 

the Certa sine pump proved its suitability 

for use in the production of suppositories at 

Dr. Pfleger Arzneimittel. During a period of 

nine months, not a single pump failure occurred. 

Furthermore, the use of the sine 

pump has led to a reduction in the noise 

level in the preparation area. Most impor - 

tantly: Thanks to the virtually pulsation-free 

pumping of the viscous mass, the dosing 

pumps at the filling station work precisely 

and the suppositories are uniform. 


Online search: Watson Marlow 

AUTHOR: 

CHRISTIAN PASCHEN 

Commercial Manager, 

Watson-Marlow 




Mobile pipe cleaning system for BASF 

Nothing but air and water 

Pipe systems require cleaning at regular intervals, especially multi-purpose product 

pipelines. Existing processes such as the use of pigs require complex additional 

installations. Intensive water rinsing results in large quantities of waste water and 

therefore in high costs for discharge. By contrast, the Comprex process needs only 

a small amount of water and can be integrated into existing pipe systems easily. 

Finally the compressed air is used to dry the system after cleaning process. 

Product changes are inevitably associated 

with significant effort and interrupted production. 

The requirements vary according to 

the plant and the products. In any case, the 

pipe system has to be cleaned carefully before 

it is used for another product. If the 

product is water-based (e. g. aqueous solutions, 

emulsions and dispersions), the 

pipeline is usually rinsed with pure water. 

Depending on the desired level of cleanliness, 

more or less waste water has to be 

discharged. Another possible cleaning process 

involves the use of pigs. Pig gates must 

allow the pig to be inserted into the pipeline 

and removed again after cleaning. 

Changes of geometry (e. g. changes to the 

pipe diameter and fittings) are highly problematic 

for this process. Pumps, valves and 

backflow preventers cannot be cleaned at all 

using pigs and have to be removed from the 

piping system before cleaning. 

Cleaning with air and water 

The Comprex pipe cleaning system developed 

by Hammann is based on the controlled 

injection of compressed air into a 

pipeline that is partially filled with water. 

These compressed air impulses lead to the 

formation of water blocks that are accelerated 

to high velocities of up to 20 m/s. As a 

result, impurities, product residues and 

fouling material are mobilised and removed. 

Production plants in the chemical industry 

often contain hazardous material. For this 

reason, the waste water resulting from the 

cleaning process is also hazardous and has 

to be discharged into containers prior to 

further cost-intensive treatments. Compared 

Pictures: Hammann 

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


Scheme of the Comprex process: The compressed air pulses lead to the formation 

of water blocks that remove impurities, product residues and fouling material. 

The Comprex sytem is operated 

by touch-screen 

to conventional water rinsing, the Comprex 

process needs only about one tenth of the 

quantity of water. Moreover, Comprex units 

can be adjusted to individual needs. 

Development and testing period 

BASF’s agricultural production plant in Ludwigshafen 

has high requirements as regards 

the cleanliness of piping systems after product 

changes. Special measures are in place to 

prevent cross contamination by product 

residues or microbial growth. The piping 

system was traditionally rinsed using large 

quantities of de-ionised water. BASF therefore 

decided to test the Comprex process, 

which promised lower water consumption. 

The following basic conditions had to be 

considered: 

• Numerous product changes per year 

• Different product pipelines of various 

lengths 

• Minimal construction work on existing 

plants 

• Mobile solution for the whole factory 

• Simple process workflow with intuitive 

handling by operators 

• Cleaning using compressed air and water 

from existing supply networks 

• Piping system to be dried after cleaning 

• Lower operating costs due to less waste 

water and downtime 

In 2017, several tests were successfully performed 

using Comprex units. Compared to 

water rinsing, water consumption was reduced 

by between 50 and 75 % – an enormous 

potential saving due to the thermal 

disposal of the waste water. Following the 

test period, Hammann developed and constructed 

a customised prototype of the 

Comprex system. 

Adapted to the customer’s needs 

The customised unit – internally named 

A8700 – uses electricity, water and compressed 

air from the respective BASF supply 

systems. The machine’s control system is 

based on software developed by Hammann 

and adapted to the customer’s needs. Cleaning 

tests verified the potential for added 

value and enabled refinements to the 

requirements for the final Comprex unit. 

These included: 

• Mobile design for different injection 

points 

• Components and materials according to 

BASF’s specifications 

• Special encoded couplings to prevent connection 

errors 

• Vessel size suitable for 1000 l of compressed 

air 

• Internal control of compressed air and 

water 

• Specific cleaning programmes for every 

pipe section at the factory 

• Easy touch-screen operation based on 

icons and visualisation of all relevant information 

• Automatic cleaning with documentation 

of each cleaning procedure, including air 

and water consumption 

• Option of adding cleaning agents 

The development of the specific software 

for the agricultural production plant as well 

as the engineering and construction of the 

components according to BASF’s requirements 

were completed at the beginning of 

2018, so that delivery was possible in 

spring the same year. A few minor software 

adjustments were performed together with 

the customer following an initial period of 

operation in the summer. The system has 

been operating reliably and successfully 

since the end of 2018. 

The operating staff were highly satisfied 

after the first few weeks of operation. 

Thanks to Comprex cleaning, the quantity 

of contaminated waste water was reduced 

by 70 % on average – an important step towards 

sustainability. The costs for disposing 

of waste water were significantly reduced, 

as were CO 2 emissions resulting from the 

thermal treatment of waste water. A comparison 

of the cleaning results with laboratory 

samples showed them to be consistently 

below the threshold. Further potential 

was identified for optimising water consumption 

and more fine adjustments to the 

cleaning process are therefore planned in 

the near future. 


Online search: Hammann 

AUTHOR: 

DR. TILL 

SCHMIDBERGER 

Process Manager, 

BASF 

AUTHOR: 

HANS-GERD 

HAMMANN 

Managing Partner, 

Hammann 



CONTACT THE EDITORS 

GÜNTER ECKHARDT 

Editor-in-Chief 

Phone +49 711 7594-291 

guenter.eckhardt@konradin.de 

LUKAS LEHMANN 

Assistant Editor-in-Chief 

Phone +49 711 7594-290 

lukas.lehmann@konradin.de 

CLAUDIA BÄR 

Editor 

Phone +49 711 7594-287 

claudia.baer@konradin.de 

URSULA FISELY-BUSTORFF 

Editor 

Phone +49 711 7594-373 

ursula.fisely@konradin.de 

DANIELA HELD 

Editor 

Phone +49 711 7594-284 

daniela.held@konradin.de 

DR. BERND RADEMACHER 

Editor 

Phone +49 711 7594-263 

bernd.rademacher@konradin.de 

ANGELIKA STOLL 

Editor 

Phone +49 711 7594-300 

angelika.stoll@konradin.de 

BARBARA DIVIGGIANO 

Editorial Assistant 

Phone +49 711 7594-415 

barbara.diviggiano@konradin.de 

ISSN 0724–1054 

Publisher: 

Katja Kohlhammer 

Publishing House: 

Konradin-Verlag Robert Kohlhammer GmbH 

Ernst-Mey-Straße 8, 70771 Leinfelden Echterdingen, 

Germany 

General Manager: 

Peter Dilger 

Publishing Director: 

Peter Dilger 

Editor-in-Chief: 

Günter Eckhardt (ec), Phone +49 711 7594-291 

Assist. Editor-in-Chief: 

Lukas Lehmann (le), Phone +49 711 7594-290 

Editorial Staff: 

Ursula Fisely-Bustorff (fi), 

Phone +49 711 7594-373 

Dipl.-Ing. Daniela Held (dh), 

Phone +49 711 7594-284 

Dr. Bernd Rademacher (br), 

Phone +49 711 7594-263 

Angelika Stoll (st), 

Phone +49 711 7594-300 

Editorial Assistant 

Barbara Diviggiano, 

Phone +49 711 7594-415, -1415 

e-mail: barbara.diviggiano@konradin.de 

Desktop Publishing: 

Jennifer Martins, Phone +49 711 7594-262 

Ana Turina, Phone +49 711 7594-273 

Birgit Ender (freelancer) 

Sales Director: 

Andreas Hugel, Phone +49 711 7594-472 

e-mail: andreas.hugel@konradin.de 

Order Processing: 

Andrea Haab, Phone +49 711 7594-320 

e-mail: andrea.haab@konradin.de 

Rate card No. 53, effective October 1, 2019. 

Reader Service: 

Ute Krämer, Phone +49 711 7594-5850 

Fax +49 711 7594-15850 

e-mail: ute.kraemer@konradin.de 

Subscription price: 

Inland 20,70 €, VAT and distribution included; 

Foreign countries 20,85 €, VAT and distribution 

included 

Retail price 5,30 €, VAT included, plus distribution 

International Sales Offices: 

Great Britain, Jens Smith Partnership, The Court, 

Long Sutton, GB-Hook, Hampshire RG29 1TA, 

Phone 01256 862589, Fax 01256 862182, 

e-mail: media@jens.demon.co.uk, 

Japan, Mediahouse Inc., Kudankita 2-Chome 

Building, 2–3–6, Kudankita, Chiyoda-ku, Tokyo 102, 

Phone 03 32342161, Fax 03 32341140; 

USA, Kanada, D.A. Fox Advertising Sales, 

Inc. Detlef Fox, 5 Penn Plaza, 19th Floor, New York, 

NY10001, Phone 212 8963881, Fax 212 6293988, 

e-mail: detleffox@comcast.net. 

Articles published under the name of an author do 

not necessarily constitute the Editor`s opinion. 

The Editor cannot be held responsible for unsolicited 

reports from industry. Please note that brands 

or trade names that are not specifically trademarked 

may nevertheless be pro tected. 

The Editor reserves the right to condense or enlarge 

manuscripts submitted to him. Proofs can regrettably 

not be sent. 

Place of performance and jurisdiction: Stuttgart 

Printed by Konradin Druck GmbH, 

Leinfelden-Echterdingen 

Printed in Germany 

© 2020 by Konradin-Verlag 

Robert Kohlhammer GmbH, 

Leinfelden-Echterdingen 


LIST OF ADVERTISERS 

Fette Compacting GmbH, Schwarzenbek 2 

GATHER INDUSTRIE GmbH, Wülfrath 3 

Hillesheim GmbH, Waghäusel 19 

JUMO GmbH & Co. KG, Fulda 25 

REMBE GmbH Safety + Control, Brilon 23 

VEGA Grieshaber KG, Schiltach 52 


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