ABB automation increases capacity 10x for Tate & Lyle food additive plant

When Tate & Lyle acquired Biovelop, a Swedish manufacturer of oat based food ingredients in 2013, the factory in Kimstad, Sweden was modernized and expanded by installing automation systems, variable speed drives, motors, motor control cabinets  and valve positioners from ABB Automation. In 2016 the remodeled plant celebrated the first anniversary of operations with the new systems and significantly increased production capacity.

The global market for specialty food ingredients, including health and wellness products, is growing, with annual sales of $51 billion and annual growth rate of 4-5%. Oat ingredients have been actively involved with this trend as they offer some key nutritional and functional benefits. In particular, oat contains beta glucan, a soluble fiber that has been shown to lower cholesterol and reduce post prandial glycaemic response – claims that have been approved by the European Food Safety Authority (EFSA). In fact, it was these properties of the grain that made the sector an attractive one to Tate & Lyle, and triggered the decision to diversify its portfolio into this sector.

“We have seen a more than tenfold increase in capacity with the same number of shift operators compared to four years ago,” said Annika Werneman, Tate & Lyle plant manager. “It’s a huge change in such a short time, and it means that we’ve gone from a low-level facility to one that can deliver high quality product to our customers globally.”

Advanced automation technologies in the plant run critical food processing equipment -including pumps and decanters: material handling machinery is also used to transport the dry food products. ABB delivered automation equipment that included 85 variable speed drives (VSDs), with power ratings ranging from 0.37 kW to 55 kW, as well as ABB MNS 3.0 motor control cabinets and low voltage motors. ABB also delivered 44 Digital Electro pneumatic positioners (TZID-C) , which use the Hart protocol to communicate with the control valves.

“We needed a process that was highly automated and could run 24 hours, seven days a week, all year long,” Werneman continued. This meant building a system that enabled Tate & Lyle engineers to digitally interact with the system, commission (start) devices, and diagnose performance deviations or failures from anywhere in the world. This not only helps ensure operational consistency, but also reduce the total cost of ownership by enabling staff to manage the processes without being physically present at each site.

Such interactivity was enabled by the ABB fieldbus automation for the drive controls, providing flexibility as well as remote monitoring of the plant performance. “I like that ABB designed the system so that the fieldbus responsible for device control is split from the fieldbus used for asset management,” explained Leo Dijkstra, power & controls team leader Europe at Tate & Lyle. “This ensures that I can make any changes to the configuration of the devices without the risk of the whole network going down.”

At Tate & Lyle, they place great importance not just on what they do, but how they do it. “We are working continuously wherever we can to reduce the environmental footprint of our operations,” said Dijkstra. ABB was well placed to help as it has developed a portfolio of products and solutions that improve industrial energy efficiency.

“In our pump applications alone, we are using up to 50 percent less energy thanks to the variable speed drives, and these have been running non-stop for the last two years without a single failure,” Dijkstra continued. “What’s more, ABB was so quick to deliver products that we even had the first VSD delivered in just a few days.”

Although the nearest ABB support is only a ten-minute drive away from the Kimstad factory, the fieldbus flexibilities in the drives enable Tate & Lyle to rely on its own staff to handle the ABB equipment remotely. “Our work with Tate & Lyle illustrates the benefits of digitization, which can yield immense productivity and output gains from existing facilities,” said Petter Hollertz, area sales manager at ABB. “The improvements at this plant also show what great teamwork between the equipment supplier and the user can accomplish, as we worked together as true partners on this project.”

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Diabetes plant for Novo Nordisk chooses Emerson

Another Novo Nordisk greenfield pharmaceutical project has chosen Emerson Automation Solutions to achieve a fast project start-up: this Emerson release gives the following information.

Emerson advises: “Global healthcare company Novo Nordisk has awarded Emerson a $40 million automation systems and services contract for a new US-based drug manufacturing facility to help battle the global diabetes epidemic. The largest project in its history, Novo Nordisk’s new $2 billion plant in Clayton, North Carolina, will leverage Emerson Project Certainty methodologies and automation technologies to help ensure the plant achieves a tight project construction schedule to meet a construction target of 2020.

The new 825,000-square-foot production facility will help the Danish drug company increase manufacturing capacity and meet its goal of doubling production of diabetes drugs over the next decade. According to the Centres for Disease Control and Prevention, more than 29 million Americans are living with diabetes, with another 86 million living with prediabetes.

“Our extensive experience in the life sciences industry and integrated offering for capital projects and automation perfectly positions us to help Novo Nordisk deliver its largest project in history,” said Mike Train, executive president, Emerson Automation Solutions. “Together we can design and deliver this world-class manufacturing facility to be ready on time, and to quickly deliver these important diabetes medicines.”

Novo Nordisk will implement elements of the Emerson Project Certainty approach to help reduce project complexity and achieve the tight project schedule. This transformational approach leverages automation technology, which serves as a central nervous system in a plant, and new methodologies, to reduce costs and complexity and accommodate late-stage project changes.

Novo Nordisk selected Emerson’s integrated portfolio of automation technologies and services, including its DeltaV distributed control system (DCS) and Syncade manufacturing execution system (MES). Emerson will also provide smart automation technologies including valves and measurement instrumentation.”

E+H acquires Blue Ocean Nova

A new Endress+Hauser press release says the company is further expanding its portfolio of products, solutions and services in the field of process analytical measurement, by  acquiring Blue Ocean Nova AG, a manufacturer of innovative inline spectrometers for monitoring quality-relevant process parameters. 

Blue Ocean Nova will operate under the umbrella of the Endress+Hauser centre of competence for liquid analysis headquartered in Gerlingen, Germany: the 15 employees currently located in Aalen, Germany will be retained. “The intelligent process sensors developed by Blue Ocean Nova will enhance our offering in the field of process analytical measurement, adding a strategic building block,” said Dr Manfred Jagiella, Managing Director of Endress+Hauser Conducta GmbH+Co. KG. As a member of the Group’s Executive Board he is also responsible for the analytics business. 

Innovative concept

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The process sensors developed by Blue Ocean Nova cover the relevant optical spectroscopy regions of UV-VIS, NIR and MIR to analyze liquids, gases and solids inline. The innovative technology allows the spectrometer to be directly integrated into the measurement probe, even in explosion-hazardous areas. The sensors can furthermore be automatically cleaned and easily integrated into process control systems.

The systems from Blue Ocean Nova are utilized in the food & beverage, oil & gas, chemicals and life sciences industries for applications such as concentration and moisture measurements and for measuring relevant quality parameters. The technology enhances the Group’s portfolio, which already encompasses Raman spectroscopy, tunable diode laser absorption spectroscopy (TDLAS) and process photometers.

Extensive experience

Blue Ocean Nova was founded by Joachim Mannhardt and Stefan Beck in 2015, bringing extensive product development experience in the field of industrial spectroscopy and process analytical measurements to the company. “Endress+Hauser opens the door to international markets and customers for us,” explains Stefan Beck. Joachim Mannhardt adds: “We’re convinced that our technology will be an ideal enhancement to Endress+Hauser’s optical portfolio.”

Endress+Hauser acquired Blue Ocean Nova effective 31 October 2017. Both parties agreed not to disclose the details of the transaction. Joachim Mannhardt and Stefan Beck will remain on the management team of the innovative company. “With this acquisition, we are continuing to pursue our strategy of strengthening the process analytical measurement portfolio and in the future supporting our customers from the lab to process,” says Manfred Jagiella.

 

600,000 flowmeters measure beer and lager flow

Titan Enterprises has established a long-standing working relationship with Vianet plc (formerly Brulines) for the supply of beer flowmeters for pub and bar automation projects. Over the last 20 year period Titan have delivered, and Vianet has installed, over 600,000 of these meters for beer and other bar flow measurement and automation applications.

Brulines, was formed in 1993 with the intention of providing pub chain owners with data on their bar activity via an electronic point of sale (EPOS) system. After trialling several other flowmeters, the company sought a solution to resolve flowmeter bearing lifespan problems and to overcome the unreliability of the optical detection method in beer.

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The beer flowmeter

Following a collaborative approach to developing the solutions needed for the Vianet customer base, Titan Enterprises proposed an adapted version of its 800-series turbine flowmeter as the design included durable sapphire bearings proven reliable for many thousand hours operation, and a Hall effect detector which was not subject to problems with discolouration inside the pipe. After successful tests, a trial order for 400 units was placed in 1997, which after the subsequent field trials, was followed by an order for >5000 meters which were all delivered to the clients required timescales.

To ensure the flowmeter was ‘fit for purpose’, Titan additionally adapted the cable type as well as the body and increased the length to 10 metres. These adaptions enabled Brulines installations to be maintained in beer cellars with differing wire runs to the control panel without any junction boxes.

Twenty Years of Collaboration

With the widespread reliability of this product, Vianet turned again to Titan Enterprises in 1999 to develop for them an “intelligent” flowmeter (IFM) for their enhanced iDraught retail product. The specification for the IFM required that it should additionally measure temperature as well as determining the type of fluid in the line to detect line cleaning cycles which are essential for the dispensing of a good pint.

At the time, Titan did not have the technology to provide sensing electronics at a reasonable price so we produced a revised version of the beer flowmeter with the capability of being matched to a PCB designed, manufactured and installed by a third party.

After trialling and testing, this new IFM was introduced in June 2000 and supplied to Vianet at the rate of up to 3500 units a week. Mark Fewster, product manager at Vianet commented “Titan’s supply chain has always delivered to our quality and timescale needs”.

IoT Developments

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An intelligent flowmeter design

Since this first IFM introduction, close collaboration between the two parties has resulted in 5 iterations of the product with revised features as end user requirements have developed and evolved with the growth of the IOT (Internet of Things). Drawing upon this close working relationship, over a long period of time, Titan continue to work with Vianet on new solutions and offerings as the Vianet customer offering further develops.

This Titan Enterprises application story is based on a report in the Autumn issue of Flowdown, the regular news bulletin published by Trevor Forster, MD of Titan, from their Dorset, UK base.

Roxtec transits ensure safety on “Mein Schiff 6”

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On cruise liner Mein Schiff 6 of TUI Cruises, thousands of Roxtec transits provide certified protection against fire, gas, water and electromagnetic disturbance. Co-owner Royal Caribbean and shipyard Meyer Turku in Finland continue to cooperate with Roxtec to enable the use of more plastic and composite pipes.   “Roxtec transits make it cost-efficient to install light-weight and long-lasting plastic pipes,” says Berth Strömborg, senior superintendent of Royal Caribbean.

One sealing system

Over 6000 openings for cables and pipes in decks, bulkheads and cabinets are sealed with Roxtec transits. The seals are used in the engine room as well as in passenger areas, and many of them include spare capacity for additional cables and pipes.  “It is good to have one supplier for all pipe systems,” says Antti Laaksonen, system responsible for HVAC and catering design at Meyer Turku.

Optimizing logistics

Mika Tuokko, head of electrical outfitting at Meyer Turku, says one hundred installers have been working with Roxtec cable seals on the new cruise liner:  “The most important thing is to keep up the speed by handling fewer items. By using Roxtec instead of other systems we avoid 50 items in stock for each transit.”

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Roxtec Mulltidiameter bulkhead seals in-situ

About Roxtec and Multidiameter

The Swedish Roxtec Group is the world-leading provider of modular-based cable and pipe seals. The company’s invention for adaptability to cables and pipes of different sizes, the Roxtec Multidiameter, is based on sealing modules with removable rubber layers and allows for a perfect sealing, regardless of the outside dimension of the cable or pipe.  The technology simplifies design, speeds up installation and reduces the need for stock, material and logistics. It also provides spare capacity for upgrades. Roxtec serves and supports customers in more than 80 markets through subsidiaries and distributors.

Wireless gas detection total system

Yokogawa has announced that the ProSafe-RS SIL2 Wireless Gas Detection System will be released in September 2017. This will offer a total flammable gas detection system solution, using ISA100 wireless communications, and Yokogawa will include the necessary  consulting and engineering.

The ProSafe-RS SIL2 wireless gas detection system will consist of a newly enhanced version of the Yokogawa ProSafe-RS SIL3 safety instrumented system (R4.03.10), Yokogawa field wireless network devices, annunciator panels, and GasSecure (a subsidiary of Drägerwerk AG) wireless gas detectors GS01 or the GS01-EA (this model is equipped with an extension antenna).

For this system, Yokogawa will establish a total solution that will include both consulting and engineering.

Development Background

In energy and basic materials industries such as oil & gas, petrochemicals and chemicals, a safety instrumented system is employed to safely initiate an emergency plant shutdown when a critical failure is detected, and to initiate the operation of facilities that can extinguish or prevent the spread of a fire.

A field wireless system consists of field devices that are able to communicate wirelessly with a monitoring and control system. Wireless devices have a number of advantages such as allowing installation in difficult-to-access locations and the reduction of installation costs, and they are increasingly seen as essential elements in plant safety solutions. This is a particularly important consideration with gas detection systems, as operation can easily be impacted by factors such as installation location and ambient conditions. And even after system installation, ongoing efforts to optimise its overall configuration may necessitate occasional changes in the location and number of detection devices. The use of wireless technology eliminates the need to worry about wiring and thus greatly facilitates the process of moving and/or installing additional detection devices.

To achieve SIL2 level risk reduction when using wireless gas detectors with a safety instrumented system, communication protocols that comply with the functional safety requirements specified in the IEC 61508 international standard are required. A standard for the functional safety of electrical/electronic/programmable safety-related systems. To meet this need, Yokogawa will provide a SIL2 wireless gas detection system based on a new version of the ProSafe-RS safety instrumented system that will link to field devices using an IEC 61508 compliant communication protocol.

Features of the System

The ProSafe-RS SIL2 wireless gas detection system will consist of a new version of the ProSafe-RS safety instrumented system, R4.03.10, that will be enhanced to add support for an IEC 61508 compliant safety communication technology used in distributed automation; annunciator panels; ISA100 Wireless compliant field wireless devices; and GasSecure GS01 or GS01-EA wireless gas detectors, which are the only devices of this type in the industry that achieve SIL2 risk reduction. The ISA100 Wireless network protocol is based on the ISA100.11a wireless communication standard for industrial automation that was developed by the International Society of Automation (ISA), and the applications necessary for its implementation. This was approved as the IEC 62734 international standard in October 2014.

Total system solution including both consulting and engineering

Through the use of wireless technology, the ProSafe-RS SIL2 wireless gas detection system will allow increased flexibility with the configuration of detection devices, and will be suitable for use as a fire & gas system and emergency shutdown system thanks to its achievement of SIL2 risk reduction. Based on its knowledge of each of this system’s components and its expertise in production control, safety instrumentation, and field wireless engineering and consulting, Yokogawa will be able to offer a total system solution that includes customer support.

Enhanced operating efficiency

On their Yokogawa CENTUM VP integrated production control system screens, operators will be able to easily monitor the operation of the ProSafe-RS SIL2 wireless gas detection system as well as that of any conventional wired gas detection system. Since the GasSecure GS01 or GS01-EA wireless gas detector uses the same faceplate as a wired gas detector, operators will have no trouble identifying any changes in the detector’s status, thus helping to prevent errors that can result from the misinterpretation of information.

 Improved maintenance

With CENTUM VP, operators will have on-screen access to information on the status of all network devices, the charge remaining on the gas detector batteries, and the status of wireless communications, and thus will be able to quickly detect and respond to any abnormality. Thanks to this functionality, more efficient maintenance plans can be drawn up that, for example, will require fewer periodic checks.

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About ProSafe-RS

Released in February 2005, the ProSafe-RS safety instrumented system helps prevent accidents by detecting abnormal conditions in plant operations and initiating emergency actions such as a plant shutdown. An independent certification body has certified that ProSafe-RS can be used in SIL3 applications. Unlike conventional safety instrumented systems and distributed control systems, which are regarded as having different roles and functions and operate separately, the operation of ProSafe-RS and the CENTUM integrated control system can be fully integrated. ProSafe-RS is highly regarded by users and has been installed in more than 2,100 projects worldwide (as of June 2017).

Yokogawa’s Commitment to the Field Wireless Business

Yokogawa developed wireless communication technologies for continuous processes that necessitate advanced control and released the world’s first ISA100 Wireless system devices in July 2010, thereby offering its customers a wider range of products to choose from. Currently, Yokogawa offers its customers in the oil & gas, and other industries a wide range of field wireless management stations, field wireless access points, wireless field devices, and wireless adapters for conventional wired devices.

Major Target Markets and Applications

For use in fire and gas systems (FGS) and emergency shutdown systems (ESD) in process industries such as oil, natural gas, petrochemicals, chemicals, pharmaceuticals, electric power, and iron and steel.

Dräger GasSecure

GasSecure AS is a subsidiary of Dräger, and has been a long term partner with Yokogawa in developing the market for wireless gas detectors using ISA100. GasSecure developed, markets and sells the world’s first truly wireless optical gas detector for demanding industrial applications. Representing an evolution in gas detection, the detector is based on innovative ultra-low power MEMS optical technology and has introduced a new level of reliability and flexibility for the detection of gas leaks. The totally wireless detectors increase safety and dramatically reduce costs for the oil & gas, petrochemical, marine, and other process industries. For more information, please visit www.gassecure.com.

UV keeps bottled water safe

Hanovia UV has supplied Cott Beverages UK, based in Derby, with a PureLine intelligent UV system to keep its production process water pure.

PureLine range

In an increasingly regulated and safety-conscious market, legislation such as the EU Directive for Bottled Water 98/88/EC (1998) drives the beverage industry to meet ever more stringent standards of quality. Microbial growth due to contaminated water or ingredients can cause discolouration, off flavours and shortened shelf-life. The threat of contamination is further increased as manufacturers respond to demands for less chemical additives and preservatives. Effective microbial disinfection of the whole process is therefore essential.

To meet this requirement, Cott Beverages has been using Hanovia UV disinfection technology to treat process water used in the production process. The company decided to use UV technology to ensure final product security prior to mixing and bottling and has been very satisfied with the performance of the UV systems.

“The Hanovia UV systems have been easy to integrate, maintain and operate,” said Chris Prentice, site service engineer at Cott Beverages. “They provide us with absolute insurance before bottling by making sure that we are producing and maintaining a high-quality product, which is essential for our brand.”

PureLine UV from Hanovia is an intelligent system that is optimised for the beverage industry to simplify the treatment of water, sugar syrup, brine and even reducing chlorine and ozone. Critically, there are no microorganisms known to be resistant to UV – this includes pathogenic bacteria such as listeria, legionella and cryptosporidium (and its spores, which are resistant to chlorination). Unlike chemical treatment, UV does not introduce toxins or residues into process water and does not alter the chemical composition, taste, odour or pH of the fluid being disinfected.

UV is used for both primary disinfection or as a back-up for other purification methods such as carbon filtration, reverse osmosis or pasteurisation. Because UV has no residual effect, the best position for a treatment system is immediately prior to the point of use. This ensures incoming microbiological contaminants are destroyed and there is a minimal chance of post-treatment contamination.

UV disinfection systems are easy to install, with minimum disruption to the plant. They need very little maintenance, the only requirement being the replacement of the UV lamps every 9-12 months, depending on use. This is a simple operation that takes only a few minutes and can be carried out by trained general maintenance staff. The Hanovia UVCare training programme supports businesses like Cott Beverages to make sure servicing is carried out by certified engineers at all UK production sites.