www.hpmag.co.uk March 2024 p22 p16 Retrofitting pumps for a new role Seven reasons to monitor hydraulic flow on mobile machines The shifting vision of a smart factory p40 Harnessing the power of pneumatic control
Premier global manufacturer of components for fluid power applications SCAN ME TO REGISTER Have you registered for our Digital Platform yet? Search and order the right product for your application... and so much more! • Product Information • Technical Details • CAD Models • Product Videos • Account Specific Pricing • Invoices • Delivery Notes • Live Order Tracking Sheffield Tel: 0114 251 8518 Email: uk.sales@stauff.com Aberdeen Tel: 01224 786166 Email: uk.absales@stauff.com Ireland Tel: 02892 606900 Email: uk.irsales@stauff.com
Spring Budget 2024: Future workforce concerns unaddressed EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2024 3 While the Budget hinted at progress in other sectors, its failure to address the fundamental need for workforce development risks stifling long-term economic growth and innovation. ‘ ’ The Spring Budget 2024 presented a mixed bag of promises and omissions, leaving critical areas of concern unaddressed. While EngineeringUK applauded the Government’s pledge to invest in key sectors like engineering and technology, and its recognition of the importance of Small to Medium Sized Enterprises (SMEs) through initiatives such as the Green Industries Growth Accelerator (GIGA), there’s a glaring absence in the narrative – the future workforce. Without a concerted effort to nurture skilled young individuals, the growth and competitiveness of UK businesses in vital sectors could be compromised. The disappointment stems from the lack of emphasis on skilling the next generation. Without a concerted effort to nurture skilled young individuals, the growth and competitiveness of UK businesses in vital sectors could be compromised. The acute shortage of STEM teachers remains a pressing issue, hindering students’ access to quality education and potential career paths. Surprisingly, the Budget neglected to address this shortfall or outline plans for supporting educators. In addition, the oversight extends to the crucial role of apprenticeships and training routes in shaping tomorrow’s workforce. Investment in these areas is imperative for sustainable growth and innovation, yet specifics on funding and development were notably absent from the Budget. As such, EngineeringUK reiterated its call for the Government to devise a comprehensive and adequately funded STEM skills plan. This should encompass initiatives ranging from career outreach and education to apprenticeship programmes tailored for young people. Sustaining existing funding levels for STEM teacher professional development must also be prioritised to ensure a robust foundation for future generations. While the Budget hinted at progress in other sectors, its failure to address the fundamental need for workforce development risks stifling long-term economic growth and innovation. Investing in the talent pipeline is not just a necessity but a strategic imperative for securing the UK’s position as a leader in technology and innovation. Neglecting to prioritise the skilling of the future workforce could have far-reaching consequences, hampering the nation’s ability to adapt to rapidly evolving technological landscapes and compete effectively on a global scale. Without adequate investment in education, training, and apprenticeship programmes, the UK risks falling behind other nations in cultivating the skilled workforce necessary to drive innovation and sustain economic growth. Therefore, it is imperative for the Government to recognise the critical role of workforce development in shaping the country’s future prosperity and take decisive action to address this pressing issue in subsequent budgetary initiatives. Aaron Blutstein Editor
Standards AISI 316 ti Maximum precision Approvals & Norms High availability PH Industrie-Hydraulik GmbH & Co. KG Wuppermannshof 8, 58256 Ennepetal, Germany Tel. +49 (0) 2339 6021, Fax +49 (0) 2339 4501 info@ph-hydraulik.de, www.ph-hydraulik.de Application Hydraulic engineering and shipbuilding Railway technology Offshore technology Machine construction SAFETY FIRST. STAINLESS STEEL CONNECTORS FROM PH. PH catalogue available as app for Android and iPad
www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2024 5 CONTENTS EDITORIAL Editor: Aaron Blutstein t| 01732 370340 e| editorial@dfamedia.co.uk Content Sub Editor: Leslah Garland t| 01732 370340 e| leslah.garland@dfamedia.co.uk SALES Sales Manager, UK & Overseas: Andrew Jell t| 01732 370347 e| andrew.jell@dfamedia.co.uk Italian Sales Office: Oliver & Diego Casiraghi t| 031 261407 f| 031 261380 e| info@casiraghi.info Turkey: Intersmart Media meltem@intersmartmedia.co.uk Managing Director: Ryan Fuller t| 01732 370344 e| ryan.fuller@dfamedia.co.uk Production Manager & Designer: Chris Davis t| 01732 370340 e| chris.davis@dfamedia.co.uk Reader/Circulation Enquiries: Perception t| +44 (0) 1825 701520. e| dfamedia@dmags.co.uk Marketing Manager Hope Jepson e| hope.jepson@dfamedia.co.uk Operations Manager: Emma Godden-Wood e| emma.godden-wood@dfamedia.co.uk Financial: Finance Department e| accounts@dfamedia.co.uk Chief Executive Officer: Ian Atkinson e| ian.atkinson@dfamedia.co.uk Published by: DFA Media Group 192 The High Street, Tonbridge, Kent TN9 1BE t| 01732 370340 e| info@dfamedia.co.uk w| www.hpmag.co.uk In co-operation with Printer: Warners, UK © Copyright 2024, DFA Manufacturing Media Ltd ISSN 1366-1981 H&P is a controlled circulation magazine, published 8 times a year. Please contact DFA Media with any subscription enquiries. Paid subscriptions are also available on an annual basis at £110.00 (UK), £145.00 (Europe) or £180.00 (Rest of the World) P+P included. The content of this magazine, website and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. 14 30 6 NEWS 14 SMART MANUFACTURING & ENGINEERING WEEK 16 KNOWLEDGE BASE Floating production storage and offloading (FPSO) vessels are used for processing oil and transferring it to tankers or pipelines. Positioned close to an oilfield, they remain there until the field is exhausted. Originally designed with a service life of over 20 years, FPSOs represent a huge investment for international oil companies (IOCs) and to maximise their potential, they are refitted and relocated once a project is completed. H&P reports. 18 APPLICATIONS 20 HYDRAULICS 28 PNEUMATICS Once relegated to niche applications, pneumatic control has emerged as a pivotal technology powering efficiency, safety, and precision in manufacturing processes. H&P reports. 30 INTEGRATED SYSTEMS Kieran Bennett discusses the importance of bioreactor controls for scaling-up cultivated meat production. 34 COMPRESSED AIR David De Pril examines ways to consume less energy, produce more, and bring lasting benefits in terms of sustainability, profitability, and effectiveness to your compressed air applications. 38 BCAS Our regular news and events update on the British Compressed Air Society. 40 SPECIAL FOCUS Digital Transformation Focus 42 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 44 NEW FACES 46 PRODUCTS & SERVICES DIRECTORY 40 Subscribe for your FREE copy now
NEWS 6 HYDRAULICS & PNEUMATICS March 2024 www.hpmag.co.uk Hannover Messe 2024: Empowering a Green Industrial Revolution In a bid to propel industries toward sustainability, Hannover Messe 2024 is set to showcase cutting-edge innovations in automation, artificial intelligence, and renewable energies. The global trade fair, held under the theme “Energising a Sustainable Industry,” aims to address the pressing challenges of enhancing competitiveness, climate protection, and economic prosperity. Basilios Triantafillos, Global Director of Hannover Messe at Deutsche Messe AG, emphasised the pivotal role of innovative technologies showcased at the event in fostering a climate-neutral and high-performance industry. Triantafillos acknowledged the hurdles faced by companies, including the need for guidance in implementing automation, artificial intelligence, and energy management concepts, as well as the obstacles posed by bureaucracy and a shortage of skilled workers. Hannover Messe 2024 seeks to provide solutions to these challenges through a mix of new technologies, cross-industry collaboration, and a clear political framework. More than 4000 companies, representing a unified industrial ecosystem, will demonstrate how automation, digitalisation, and electrification can lead to climate neutrality. Key industry trends highlighted at the fair include artificial intelligence, carbon-neutral production, energy systems, Industry 4.0 and Manufacturing-X, and hydrogen and fuel cells. Large global technology companies such as Amazon Web Services, Bosch Rexroth, Google Cloud, Microsoft, SAP, and Siemens, alongside numerous small and medium-sized businesses, will present their contributions to a greener future. Leading research organisations, including Bavaria Innovative, various Fraunhofer institutes, the Karlsruhe Institute for Technology (KIT), and Germany’s Ministry of Education and Research, will showcase the current state of research and technology transfer. Additionally, over 300 industrial start-ups will boost the focus on entrepreneurship and innovation. A significant focus of Hannover Messe 2024 is on green hydrogen, with approximately 500 companies from the hydrogen and fuel cell industry, including more than 300 at the group exhibit Hydrogen + Fuel Cells Europe. Norway, as the Partner Country at Hannover Messe 2024 under the theme “Norway 2024: Pioneering the Green Industrial Transition,” will highlight its plans for a low-carbon society and its role in developing solutions for renewable energy, carbonneutral production, and green and digital applications. The European Union, showcasing itself as an economic alliance, presents a programme featuring Ursula von der Leyen, President of the European Commission, at the opening ceremony. The EU’s programme includes the conference “EU as Home of Decarbonised Industry” and the European Commission Pavilion. Addressing the persistent challenge of a skilled workforce shortage, Hannover Messe introduces “YOUR FUTURE,” a young talent initiative encouraging high school graduates, college students, and young professionals to pursue careers in AI, engineering, and robotics. The programme includes meetings with potential employers, guided tours, information on apprenticeship and trainee programmes, and networking opportunities. Hannover Messe 2024, the world’s leading trade fair for industrial technology, promises to be a key event shaping the future of manufacturing and energy supply. The exhibition runs from April 22 to 26 in Hannover, Germany, with Norway taking centre stage as the Partner Country.
AP - MODULAR PIPING SYSTEM Innovative system inspired by the mechanical dovetail joint: durable and easy to install. HBS - HOLLOW BAR SYSTEM In 1988 Teseo Srl invented a market by developing and bringing to market worldwide innovative modular aluminium piping systems for compressed air and technical fluids distribution. Revolutionary systems, carefully designed and manufactured in Italy, designed to be quick to install, durable and efficient over time: all this with a view to economic, energy and environmental sustainability. Since then, Teseo has never stopped inventing and designing products and services tailored to each customer’s needs, also enhancing its range of solutions for the distribution of compressed air and technical fluids, in order to be a solid and reliable partner from the compressor room to the machine or workbench. With the experience and expertise that only the Company that invented the product can provide. , , , ERGONOMIC CUSTOMISED SOLUTIONS TESEO DROP COLUMNS AM DISTRIBUTION MANIFOLD ATS TRACK AND TROLLEY SYSTEM WBA PRESSURISED WORKBENCHES SAB SWINGING ARMS Reliable and environmentally friendly, it’s the world’s first extruded aluminium hollow bar modular system. Thanks to its easy-to-assemble modules, the whole piping installation can be easily and safely modified or extended at any time. OPTIMISED COST ASME B31.1-B31.3 UNI EN ISO 9001 2014/68/UE EN 13501-1:2007 COME TO VISIT US 22 - 26 APRIL 24 MADE IN ITALY
8 HYDRAULICS & PNEUMATICS March 2024 www.hpmag.co.uk NEWS The UK Automation Forum has recently been launched to invigorate the industry’s embrace of automation. This initiative aims to unite industry experts, end-users, policymakers, and technology suppliers under one banner. At its core, the UK Automation Forum seeks to elevate the nation’s manufacturing sector to global prominence by advocating for widespread adoption of automation technologies. With a view to rectifying the comparatively low uptake of robotics in the UK, the Forum aspires to position the country as a leader in automation. Backed by prominent trade associations, including Automate UK (formerly the PPMA Group), the Manufacturing Technologies Association (MTA), Make UK, and GAMBICA, the Forum pledges to foster collaboration, emphasise the advantages of automation, dismantle barriers to adoption, and influence decision-making processes. Mike Wilson, Chief Automation Officer at the Manufacturing Technology Centre (MTC) and Chairman of the UK Automation Forum, emphasises the importance of creating a unified voice within the industry: “We are establishing a community of leading experts and businesses to ensure that every stakeholder has a platform. “Through this collective voice, we aim to drive advancements that benefit all.” Automate UK launched to champion the uptake of automation across manufacturing Tom Parker Ltd, an authorised distributor of CEJN products to the UK fluid power market for over 50 years, has announced the release of the 208 Detect FDA-approved blow gun. This latest addition to its product line is designed to address concerns surrounding accidental contamination, product rejections, recalls, and waste, particularly within the food and beverage industry. Recognising the evolving landscape of food safety standards, CEJN’s introduction of the 208 Detect aims to tackle the prevalent issue of foreign body contamination during production processes. Metal and plastic, commonly found in food products, pose significant risks, prompting the need for innovative solutions. The 208 Detect blow gun stands out as the first X-raydetectable plastic blow gun on the global market. Constructed from 100% food-grade plastic and compliant with relevant regulations, including Reg. (EC) No. 1935/2004 and FDA CFR 21.170-199, it offers enhanced detectability by metal detectors and X-ray systems, thus bolstering contamination prevention efforts. With its food-grade seals on valves, the 208 Detect ensures minimal risk of contamination even in accidental encounters with food. Its detectable plastic composition allows for the identification of tiny plastic fragments as small as 2x2 mm*, aligning with various global food regulations and standards, including HACCP, IFS, BRC, and GFSI standards like FSSC 22000. By incorporating metal and X-ray detection capabilities, the 208 Detect significantly reduces the risk of product contamination and waste in production processes. This feature, combined with its resilience to frequent cleaning and disinfection chemicals, underscores its potential as a valuable asset in maintaining stringent hygiene standards within food processing facilities. The CEJN 208 Detect blow gun features stainless steel AISI 303 (1.4305) valves that resist corrosion, high temperatures, and chemicals. In the food and beverage industry, cleaning production equipment several times a day is crucial to maintaining stringent levels of hygiene. CEJN has designed the 208 Detect blow gun with plastic that can withstand frequent cleaning and disinfection chemicals typically used in food processing and manufacturing plants. In addition to being detectable, the 208 Detect blow gun boasts the same features as the standard CEJN 208 blow gun, including high blowing force, precise flow control and a lightweight and ergonomic design. In addition, the CEJN detect blow gun includes a maximum working pressure of 232 psi, a minimum burst pressure of 928 psi, a temperature range of -20°C to 60°C, a flow capacity measured at 87 psi inlet pressure, and a pressure drop of 7 psi. To showcase these advancements, Tom Parker Ltd will present its latest products at the Fluid Power & Systems exhibition in Birmingham from June 5–6, 2024. As Premier Partners, the company aims to highlight its commitment to promoting innovation and best practices within the industry. The release of the 208 Detect blow gun marks a significant development in addressing food safety challenges, presenting a balanced blend of technological innovation and regulatory compliance to safeguard food integrity. *Dependent on the metal detector itself and how the sensor is calibrated. New food-safe compressed air blow gun offers potential breakthrough in industry standards
NEWS 10 HYDRAULICS & PNEUMATICS March 2024 www.hpmag.co.uk The Forum’s agenda includes hosting live events and roundtable discussions to exchange insights on various topics. These discussions will cover crucial areas such as education, skills development, career promotion in automation, and overcoming adoption challenges for users, employees, and manufacturers. Moreover, the Forum is committed to amplifying the voices of end-users, from multinational corporations to small and medium-sized enterprises (SMEs), to ensure that automation equipment providers align with their evolving needs. Influence on policymaking stands as a key objective for the Forum. Peter Williamson, CEO of Automate UK, highlights the intent to leverage collective influence to shape government policies and engage with academia and funding bodies: “Our goal is to advocate for a strategic focus on automation. We will collaborate with education providers to equip the workforce with relevant skills for the future.” The Forum’s inaugural roundtable event, titled “Automation – how will greater adoption benefit UK PLC?”, will convene experts from various sectors to explore this critical question. By offering diverse perspectives, the panel aims to provide attendees with a comprehensive understanding of automation’s potential impact on the UK’s economic landscape. The recent Talking Industry panel discussion, sponsored by the Drives & Controls Exhibition, delved into the intricacies of network connectivity in the industrial sector. The discussion, which featured seasoned experts David Bradley-Foley, Managing Director of HMS Networks, UK and Ireland, and John Browett, General Manager of CC-Link Partner Association Europe, highlighted several key trends shaping the landscape of industrial communications. Networking trends HMS Networks’ annual survey of industrial networking technologies for 2023 revealed a notable 7% growth in the number of installed nodes, with a rising prevalence of multiple networks being operated by users. Industrial Ethernet emerged as the frontrunner, now constituting 68% of total network usage, while Fieldbus technologies maintained a stable presence. Wireless solutions, although still modest in market share, experienced accelerated growth, signalling a shift towards wireless industrial networking solutions in factory automation. David Bradley-Foley underscored the challenges posed by existing wireless infrastructures predominantly based on 2G or 3G technologies, citing bandwidth limitations and maintenance issues. He emphasised the significance of fast-reacting networks, particularly in ensuring safety amidst the operation of machinery and Automated Guided Vehicles (AGVs). With the advent of 5G, industries are increasingly gravitating towards deploying private 5G networks, previously perceived as cost-prohibitive but now more feasible with reduced costs, enabling real-time communication and connectivity even for legacy machines. Time-Sensitive Networking (TSN) John Browett shed light on the evolution of Time-Sensitive Networking (TSN) as a pivotal component in facilitating deterministic and convergent communications, essential for Industrial networking experts discuss trends in network connectivity Industry 4.0 applications. TSN, which integrates seamlessly with Industrial Ethernet, emerged from the realm of professional broadcast and media, leveraging standards established by the IEEE to synchronise devices across networks. Browett drew parallels between TSN and the operation of a railway network, elucidating its role in ensuring precise timing and prioritisation of network traffic through mechanisms like the “QBV” standard. The QBV standard allows the same network to be used for many different functions, whereas in the past, you may have had one network for safety, one for motion control, another one for your cameras, etc. But with TSN, you can now just put all this together on one network. In turn, this ensures that machines are simpler, less expensive, and faster to develop. The launch of CC-Link IE TSN in 2018 marked a significant milestone, offering gigabit bandwidth coupled with TSN capabilities in an open industrial Ethernet platform. Browett highlighted the versatility of TSN in consolidating various network functions onto a single infrastructure, resulting in simpler, more cost-effective, and expedited development of industrial machines. The insights shared by industry veterans David BradleyFoley and John Browett underscore the evolving landscape of industrial communications, driven by the adoption of advanced networking technologies such as 5G and TSN. As industries continue to embrace digitalisation and automation, the importance of robust, high-speed, and deterministic networks cannot be overstated. The convergence of these trends heralds a new era of connectivity, enabling unprecedented levels of efficiency, safety, and innovation in industrial operations. For those interested in revisiting the engaging panel discussion, the on-demand video is available at: https://talkingindustry.org Make UK has partnered with Peoplesafe, a personal safety technology leader, to protect the manufacturing industry’s workers. Make UK says the new partnership with Peoplesafe will build on its existing health and safety expertise to provide its members with direct access to cuttingedge personal safety technology, whilst offering the highest-level expertise and guidance around establishing in-house employee safety programmes Representing manufacturers throughout the United Kingdom, Make UK says it works at every level to ensure Make UK partners with Peoplesafe to enhance worker safety in manufacturing
12 HYDRAULICS & PNEUMATICS March 2024 www.hpmag.co.uk NEWS the UK manufacturing sector performs and grows. Focussed on creating a supportive environment for UK manufacturers to thrive, it invites and enables manufacturers to connect, share, solve problems and create opportunities together, through regional and national meetings, groups, events, and advisory boards. As it stands, manufacturing currently accounts for almost one in five employee injuries and fatalities in the workplace. Figures from 2021 show that the HSE fined UK-based manufacturing firms more than £8 million for health and safety breaches. There were 10,382 non-fatal injuries and 15 fatalities in the manufacturing industry in 2022/23, with slips, trips, and falls accounting for 24% of non-fatal injuries. Make UK says it sees lone working as a significant concern as it can increase the risk and severity of any accidents at work. According to recent estimates, there are around eight million lone workers in the UK, making up a significant 22% of the country’s total working population. Despite this, a recent survey of lone workers and occupational safety executives uncovered a significant communication problem around what safety measures are in place for these workers. 97% of companies have formal policies in place to protect lone workers but one in five lone workers are unaware of these policies. This suggests more needs to be done to provide lone workers with the equipment and comprehensive training they need to work safely. Make UK says its partnership with Peoplesafe aims to support manufacturing and engineering, businesses in fulfilling the obligation to better protect workers. Chris Newson, Environment, Health and Safety Director at Make UK says: “The partnership brings together the best of both organisations in one accessible package. Employee safety must be top priority in any manufacturing business and our partnership with Peoplesafe will provide all Make UK members with access to the most up-to-date guidance on lone worker safety best practice, alongside the most cutting-edge personal safety technology.” Naz Dossa, Peoplesafe CEO and BSIA Chair of the Lone Worker Group, comments: “Peoplesafe is not just about providing tech solutions. We want to help tackle the problem at source and it is our continuing aim to amplify the issue of lone worker personal safety in the manufacturing sector. Many employers still underestimate the impact that providing 24/7 safety and peace of mind brings, and by working with Make UK to improve levels of lone worker safety across the manufacturing industry, we hope to set a standard that eventually becomes the basic requirement for any employer.” The partnership was launched at the Manufacturing Conference, which took place on the 27 February at the QEII Conference Centre, Westminster. ERIKS & Festo celebrate partnership 25th Anniversary Andy Parker-Bates, Relationship Development Manager at Festo highlighted other initiatives where the two businesses are combining their strengths: “We recently had 12 of ERIKS’ sales team take part in their P111 Fundamentals in Pneumatics training course at our Northampton facility which enables them to provide a first line of support to the customers and we also train many of ERIKS’ end users either at our HQ on at their own site.” Over the years there have been a number of firsts achieved as a result of the partnership. ERIKS was Festo’s first £1 million annual spend account in the UK and the first distributor to spend £1 million pounds annually. It was also the first EDI (Electronic Data Interchange) Distributor for Festo and there has been a “Logistics revolution” according to Paul Lynch, which in the early years saw Festo products transported daily from Northampton to Halesowen and then out to the local branch network. “That was seen as cutting edge back in the day” says Paul “but now we are not reliant on a local branch network to deliver products. We have removed that obstacle from our system, and we now ship directly overnight from the FCE which is the Amazon-type experience people now expect. ERIKS Industrial Services and Festo UK & Ireland are celebrating the 25th anniversary of their partnership with a host of activities that will develop the relationship further and continue to grow business for their mutual benefit. The two businesses started working with each other in the 1990s, firstly at a local level but as Paul Lynch, Chief Commercial Officer for UK & Ireland at ERIKS commented: “We wanted to become a national presence in the UK with a pneumatics offering and we wanted that brand to be Festo due to the quality of their products. Festo were looking, for the first time, at what they could achieve by embracing distribution, which wasn’t part of their DNA, and so both businesses took a leap of faith on each other and here we are 25 years later celebrating our silver wedding anniversary.” The full catalogue of Festo’s standard products is available via ERIKS with the fast-moving products stocked at their FCE (Fulfilment Centre of Expertise) in Oldbury as well as the range of configurable products. A recent area of development has been the addition of energy saving services such as compressed air audits that the two businesses are working closely on.
www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2024 13 “Rather than unpacking boxes our local teams are now focused on helping customers solve supply chain and technical challenges. They have the time and the knowledge to understand their customers’ businesses and to solve their problems practically and quickly”. Of the future relationship, Swapnil Khedekar, Head of operations at Festo UK and Ireland said: “Distribution is a big part of our global strategy going forward, but we have some big topics ahead of us in relation to both technology change, the move away from pneumatics to electrical systems and the shift in terms of knowledge, not just for specifying the parts but also how to maintain them in the future. The work we are doing with ERIKS helps us address these topics.” Andy Parker-Bates, Relationship Development Manager added: “In pneumatics our future direction is more around intelligence, capability and the monitoring and control of compressed air. To be able to benefit from that end users need to be able to work with partners that have got those skills. Last year we had an ‘automation day’ which ERIKS attended, and this enabled them to assist customers in those areas. It’s an area we are developing together.” There are innumerable ideas as to how the relationship can progress with business not only taking place between the two in the UK and Ireland but also across Europe. ERIKS has just added a further £35,000 of Festo stock at their FCE and now holds all the commonly required parts for next day delivery. The partners are also exploring sharing industry specific learnings, the sharing of best practice across companies and sectors to help create better solutions faster. ERIKS are also further improving the product knowledge of its front-line teams around the country so that customers get the best advice on both specifying the right product and stock availability. In addition, they are exploring how to speed up the development of engineered solutions through the partnership. Paul Lynch concluded: “After 25 years, some start to take partners for granted, ERIKS and Festo are very much renewing our vows and setting off on a series of exciting adventures together.” This blow gun is made with food-grade metal & X-ray-detectable plastic, making it the 昀rst of its kind in the global market. Its exceptional features are designed to enhance food safety during the production process. The 208 Detect blow gun comes loaded with a host of impressive features: www.tom-parker.co.uk sales@tom-parker.co.uk 01772 255109 ! Metal & X-ray detectable Food grade plastic Detectable & food approved seals Metal-detectable blow gun for food industry Metal & X-ray detectable Food grade plastic Stainless steel valves with food grade grease Detectable & food approved seals High chemical resistance Compliant with Reg. (EC) No. 1935/2004 & FDA CFR 21.170-199 The lightweight, robust, ergonomic 208 Detect blow gun features the same high blowing force & precision 昀ow as the standard CEJN 208 blow gun range.
SMART MANUFACTURING & ENGINEERING WEEK Across its two halls, six exhibitions, two summits and eight education theatres Smart Manufacturing & Engineering Week 2024 (https://www.mandeweek.co.uk/) will address the key issues that concern manufacturing businesses currently, irrespective of the market sector they serve. The main themes that the wideranging event covers are innovation, the supply chain, sustainability, digital transformation and people and skills. People and skills The British Fluid Power Association is a Strategic Partner of Smart Manufacturing & Engineering Week and on the key topic of people and skills Chris Butcher, Managing Director of the BFPA recently said: “The skills gap isn’t just a fluid power sector 14 HYDRAULICS & PNEUMATICS March 2024 www.hpmag.co.uk issue, it is impacting the whole manufacturing industry. All sectors are fishing in the same talent pool to secure new people into their business. To help our members start the process of engaging with learning centres, the BFPA has provided a significant amount of information to its membership advising them of local technical colleges, STEM Ambassadors and University Technical Colleges in their area. Over the coming months we will be providing a resource pack to help our members engage with their local education centres. This will enable companies to introduce their business, the products they sell or manufacture, and how young people can have a role within the fluid power industry.” As well as seeking advice from the The live events for Smart Manufacturing & Engineering Week 2024 take place at the NEC, Birmingham on the 5th and 6th June. Of central interest to readers of Hydraulics & Pneumatics are the Fluid Power & Systems and Air-Tech events and in this article, we dig a little deeper into what visitors can expect at that event and some other significant activities taking place. BFPA there are presentations focused on the people and skills topic at the Fluid Power & Systems and Air-Tech education theatres. One such presentation is from Colin Guttridge, Principal Manufacturing Engineer at Baker Hughes. Colin will be presenting on the topic of Navigating the People and Skills Landscape in Manufacturing and Engineering on the 5th June. His presentation will cover skill shortages in advanced areas such as automation, robotics, data analytics and digital technologies and the imperative of diversity and inclusion. Colin will also address technological advancements, exploring the necessity for continuous Fluid Power & compressed air innovations set to shine at Smart Manufacturing & Engineering Week Colin Guttridge, Principal Manufacturing Engineer at Baker Hughes
www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2024 15 upskilling and reskilling of the workforce in response to rapid technological advancements, including IoT devices, AI systems, and advanced machinery. He will also address the aging workforce discussing the implications and the importance of knowledge transfer and succession planning to ensure continuity and innovation. Discussed as part of a ‘fireside chat’ on Day 2, Ioana Hera, Head of Improvement, Rolls Royce will also look at the topic in a session entitled Harmonising People, Skills, and Technology: The Path to Manufacturing Innovation and Efficiency. The sessions will address how, in the dynamic landscape of modern manufacturing, the convergence of people, skills, lean improvement methodologies, digital technologies, and efficiency is crucial for sustainable growth and competitiveness. This discussion aims to explore how organisations can effectively bring these elements together to drive innovation, optimise processes, and empower their workforce. Summits Taking place alongside Fluid Power & Systems and Air-Tech are the Smart Factory Expo, Drives & Controls, Maintec and Design & Engineering Expo exhibitions. A notable element of Smart Factory Expo are the summits that run alongside it namely the Industrial Data and AI Summit and the Manufacturing Digitalisation Summit. Now in its 7th year the Industrial Data & AI Summit takes place on the 5th of June and focuses on Data Management and Data Insights. The structure of the summit includes four keynote presentations, a panel discussion and two 60-minute roundtable discussion sessions. The summit allows senior leaders to hear from the sector’s most respected experts, such as the Head of Digital and Data at BAE Systems and the Senior Director of Data and Analytics at Mars, as well as to share their knowledge and experiences with their peers. The roundtable sessions offer a unique opportunity for in-depth discussions on topics ranging from Data Integration and Management to Developing a Data Driven Business to Generative AI. Taking place on both the 5th and 6th June is The Manufacturing Digitalisation Summit. This summit includes eight keynote presentations, two panel discussions and four 60-minute roundtable discussion sessions. The Summit focuses on how digitalisation is changing how products are designed, produced, used and maintained as well as transforming the operations, processes and energy footprints of factories and supply chains. This summit is broken down into two distinct streams, the Enterprise stream is for those working within businesses with revenues in excess of £100 million while the Growth stream is for those less than £100 million (theoretically classed as SMEs) While the summits charge an entry fee there is also a great amount of freeto-access education taking place during the event with no less than 144 presentations taking place across the eight educational theatres. The theatres cover: Drives & Controls, Digital Transformation, IIoT & Connectivity, Industrial Data & AI, Innovation, Maintenance and, as mentioned above, Air-Tech Solutions and Fluid Power & Systems. Allocating time away from the workplace to visit events at the NEC is a challenge and this is appreciated by Nineteen Group, the organisers of Smart Manufacturing & Engineering Week which is why they are doing everything they can to ensure there is a huge amount to see and do to maximise the Return on Investment for a visitor. As well as the events mentioned in this article taking place at the NEC at the same time are other relevant events including the UK Garage & Bodyshop event run by Messe Frankfurt; Med-Tech Innovation Expo and TCT 3Sixty from Rapid News Group and Subcon from the Mark Allen Group. With so much going on during Smart Manufacturing & Engineering Week the organisers will be creating ‘visitor trails’ to help attendees tailor their experience to their own areas of interest. To build a personal trail visitors must be registered in advance at: https://www.mandeweek.co.uk/
KNOWLEDGE BASE With sustainability paramount for modern industry, refurbishment projects support corporate goals by enabling the reuse of components, rather than installing allnew equipment, which requires more resources and investment. Research carried out by a major IOC compared the investment value for new equipment with the final value of the project, and found that for offshore locations, project costs were five to seven times the investment. Therefore, the final cost of installing a new USD 5 million pump on an FPSO could be between USD 25 and 35 million. In contrast, retrofitting existing equipment would equate to approximately 60% of the new pump price. Considering that it will be reinstalled without further modifications, there are no additional costs. Comparing total project costs makes the retrofit investment just 10% of the whole project to install a new pump in an offshore situation. Extending equipment life while realising carbon reductions Relocation projects begin with establishing a scope of works for vessel upgrades. Improvements can be achieved via new equipment or modifying existing assets. However, every solution must be 16 HYDRAULICS & PNEUMATICS March 2024 www.hpmag.co.uk capable of delivering a service life dictated by the contract – typically 20-25 years. Central to an FPSO are the water injection pumps which pressurise the well and maximise its productivity. It’s imperative that all pumps and auxiliary equipment are refurbished to the highest standard. Sulzer research has shown that within the upstream business, production platforms account for 82% of CO2 emissions and of these, water injection pumps are responsible for 50% of the power requirement. Therefore, optimising equipment for the new application and upgrading pump efficiency can significantly impact carbon footprint and operational costs. Case Study In one project for example, Sulzer says that an FPSO is being prepared for relocation to the North Sea. When the vessel was built, the company supplied three water injection pump packages: 8stage pumps designed to deliver 3’500 m head with a flow rate of 350 m3/hr using a 4.5 MW motor. Before relocation, the vessel must undergo a refit. For example, an additional 20 m of height will be added to Floating production storage and offloading (FPSO) vessels are used for processing oil and transferring it to tankers or pipelines. Positioned close to an oilfield, they remain there until the field is exhausted. Originally designed with a service life of over 20 years, FPSOs represent a huge investment for international oil companies (IOCs) and to maximise their potential, they are refitted and relocated once a project is completed. H&P reports. the bow to handle waves in the North Sea. All work will be carried out in a dry dock and as the original equipment manufacturer (OEM) of the pumps, and a leading retrofit expert, Sulzer is contracted to deliver the modifications. Retrofits offer significant benefits over pump replacement. Financial savings equate to approximately 10% of the cost of a new pump. However, money isn’t everything, time is often the priority. With its global engineering facilities, Sulzer says it delivers a pump retrofit in around six weeks. Double duty Equally important are pump efficiency and reliability. To attain optimum application performance, pumps need fine-tuning. In this case, two duty points were required – flows between 330 m3/hr and 387 m3/hr with a differential head of 1750 m as well as a low flow, high pressure point of 104 m3/hr at 1960 m head. To achieve the best solution, Sulzer proposed a pump de-staging, removing four of the eight stages. Super Duplex stainless steel de-staging tubes will guide the flow between the remaining impellers, preventing turbulence and maintaining efficiency. The reduction in output also equates to Retrofitting pumps for a new role Floating production storage and offloading (FPSO) vessels are used around the world for processing oil and transferring this resource to tankers or pipelines that transport it to refineries.
lower power input. Here, the original fixed-speed, 11 kV, 5.5 MW motor could be replaced with a 3 kV, 3.5 MW unit controlled via a variable speed drive. Power will be reduced from 4.5 MW to 1.8 – 2.0 MW, depending on operating conditions, while motor efficiency will increase from 96.4% to 96.9%, providing considerable energy savings. This reduces carbon footprint, important when governments are imposing environmental taxes based on carbon emissions. Measure twice, fit once The reduction in motor power and discharge head enabled many original components to be retained, but a new lateral analysis of the de-staged unit was conducted, confirming the pump rotor stability throughout the operating speed range. Due to the reduced speed of the new electric motor, the lube oil system output had to increase. A modification of the lube oil pump increased output by 30%, satisfying the demand of the pump, gearbox and motor. Pipework also needs to be approached carefully to avoid costly reworks on site. This can be achieved cost-effectively by using pipework with ‘green ends’ allowing it to be cut and welded in position on site, achieving a perfect fit. An alternative is to deliver the pipe and fittings to all the pipework to be fabricated on site. Taking advantage of retrofit Using updated equipment that fits back into the original footprint and performs at the best efficiency point has clear benefits. In many cases, time is of the essence and with refits being completed in dry docks, it’s important to minimize the project time. A well-planned retrofit project can be completed within six weeks and minimizes changes to surrounding pipework and infrastructure. There are also environmental advantages. Retaining most of the components means the original asset isn’t disposed of, producing less waste. In the previous case study, the electrical motor was the only major item that wasn’t reused and instead recycled. Moreover, retrofits require much less energy and materials, maximising sustainability and contributing to environmental, social and corporate governance (ESG) goals. 0114 349 0766 • info@plascompo.com • www.plascompo.com ECO RANGE OF PROTECTIVE CAPS & PLUGS Made entirely from second-life plastic Available now… Retrofits offer significant benefits compared to procuring replacement pumps. The most obvious is the financial saving – approximately 10% of the cost of a new pump.
APPLICATIONS Robots are on the rise in medical environments and are being increasingly relied-upon to carry out more complex procedures. Although martensitic stainless steels have been favoured for bearings in robot applications, their performance is falling short against rising standards to prevent contamination in medical environments. Analyst GlobalData predicts the medical robotics market will rise from $4.7 billion in 2020 to $14.5 billion in 2030, and those robots will “be cast more as companions providing emotional support, rather than seen as tools.” The quote refers to artificial intelligence (AI) becoming more advanced, allowing robots to offer increasingly therapeutic support to patients in ways we can’t imagine today, and counter staff shortages. From surgical assistance robots that help perform minimally invasive surgeries, to AI-equipped therapeutic robots used in rehabilitation for injuries and paralysis, medical robots have come a long way since simple robotic arm technologies were first introduced in the 1980s. Although surgical robots are becoming cheaper, modern medical applications are also demanding higher precision and speed capabilities from these robots. Traditionally, in medical instruments, bearings — that optimise the rotation of axes like robot arms by limiting or avoiding friction and jolts — have been made from high purity metals such as martensitic stainless steel. Examples include medical robots that help undertake keyhole surgery where the utmost precision is required. Surgical robot bearings must deliver the highest possible rotational accuracy, while also being small enough to fit into these often compact and portable hospital devices. However, steel bearings have limitations including contamination. While steel bearings are tough and capable of withstanding highly-corrosive environments, they are susceptible to particulate contamination due to the very high cotact pressures against the steel within the bearing while it moves. If left unchecked, this contamination can cause denting and wear. Of course, contamination in general is unacceptable in health and safety environments. As robots become more prevalent in medical applications, regulations are getting stricter in order to prevent contamination. Replacing steel The need to avoid contamination accompanies other design requirements such as high speeds, low noise and nonmagnetic properties. For instance, because Magnetic Resonance Imaging (MRI) scanners use a strong magnetic field to generate two- or three-dimensional images of any living subject, steel bearings cannot be used due to their 18 HYDRAULICS & PNEUMATICS March 2024 www.hpmag.co.uk Ceramic bearings for medical robots Ceramic bearings allow high speeds, low noise and non-magnetic properties in medical devices. Chris Johnson, managing director at specialist ceramic bearings supplier SMB Bearings, explains why ceramic high-precision bearings hold the answer.
magnetic properties. All of these factors influence the choice of material for bearings in medical environments — but what material can replace steel? The medical equipment sector is increasingly choosing bearings made exclusively of zirconia (ZrO2), or other exotic ceramic compounds. According to the Institute of Materials, Minerals and Mining, “ceramic bearings made from ZrO? are tough with similar expansion properties to chrome steel and 440 stainless steel, although they are 30% lighter.” Indeed, full ceramic precision bearings are harder than steel, with superior corrosion and heat resistance, higher dimensional stability and lower density. However, ceramic bearings are expensive. This is a big issue for health institutes that operate within tight budgets, so the decision to invest in them must be well-considered. Fortunately, ceramic bearings hold a number of advantages for medical environments. One is that the bearings don’t react to chemicals. That means they don’t corrode or weaken when subjected to harsh chemicals used for sterilisation in hospitals. Ceramics don’t require lubrication that would otherwise draw there are other instances where using the wrong components in such medical or laboratory equipment can contaminate study conditions, or cause the study to cease altogether. Instead, the extra investment in ceramic bearings can help ensure that medical robots run with effectiveness and longevity — especially as they are “cast more as companions providing emotional support, rather than seen as tools.” contaminants like dust, water or humidity and this also eliminates the need for maintenance processes like relubrication. They are also water-resistant, so can be washed-down regularly. High-value applications So, is investing in ceramic bearings for medical environments worth it? There are still certain applications where the speed and precision of steel are crucial, like in surgical robots for example. However, • Pig’s Tail® Protective Wrapping is designed to protect hydraulic and pneumatic hoses against impact and abrasion. Also suitable for protection of cables including fibreoptics either singular or bundled. • It is a heavy duty form of spiral protection suited to heavy industrial applications. • Made from High Density Polyethylene (HDPE). • Can be used for single hoses or multiple hose bundles. • Operating temperatures -50°C up to +120°C. • Suitable for use with all hydraulic fluids including glycol and phosphate ester based products. • Rounded edges for enhanced performance and safe handling. 0114 349 0766 info@plascompo.com www.plascompo.com PIG’S TAIL Wrapping ALSO PIG’S TAIL RAIL • Flame Retardant – UL94 class V-0 • Complies with EN45545 HL2 • Suitable for use in underground rail
HYDRAULICS The need for more powerful and efficient fluid handling systems to bolster the ongoing energy transition is highlighted by Lulian Maciuca, Celeros Flow Technology’s Renewables Industry Sector Manager, who commented: “The race to decarbonise the world’s energy supply is placing new challenges on energy generation technology and by association on the safety-critical pumps and valves on which energy infrastructure relies. As a full lifecycle partner, Celeros Flow Technology is working to anticipate the operational and sustainability challenges of the renewables sector, ensuring that our flow control equipment and services continue to deliver the performance and reliability required to deliver the energy transition.” Offshore wind is a prime example of the new challenges facing flow control equipment. Dogger Bank, the world’s largest offshore windfarm, is currently under construction of the coast of Northern England. It will deploy 277 turbines that are 260m tall. They require a specialist vessel with a lifting capacity of 3,200 tonnes – another world record – to erect them. It is predicted that, by 2030, the industry will be deploying 20MW turbines with rotors of up to 300m in diameter. This growth in turbine size means that essential vessels such as jack-up rigs, self-elevating heavy lift crane barges and WTIVs (wind turbine installation vessels) must be able to cope with the additional strain of transporting and erecting giant turbines. Raw water (seawater) is critical to activities including drilling, firewater duties, and providing ballast on semisubmersible structures used in offshore wind turbine erection. Maximizing operational life and minimising total cost of ownership of critical flow control systems is paramount, particularly in offshore installations which are less accessible for routine maintenance. The S&N Pumps range of ESPs from Celeros Flow Technology features high grade construction using robust, corrosion-resistant materials such as stainless steel. A Duplex material grade design is also available. These pumps can be oriented horizontally or vertically and are available in diameters of between 4” and 24”. Equipped with powerful motors up to 750 hp, they can achieve flow rates of up to 4500 gpm. ESP pumps may also form part of a pre-loading reel system which provides a means of storing, lowering, and retrieving a hose to secure a reliable supply of raw water. Designed to mount directly to the main deck, reel systems are an improvement on mounting the pump in the leg of the crane or platform and make deployment quicker and easier. However, the hoses can stretch, puncture or fracture, and this damage can lead to reel system snagging and related delays in deployment. Failure of a hose system can therefore be extremely expensive and cause major project delays. Celeros Flow Technology says it offers a solution that minimises this risk. The E-Z Fit Reel System from S&N Pumps features a hose with reinforcing wire along its entire length. This reinforced hose will support the combined weight of the pumps, shroud and full water columns, eliminating hose stretch and extending hose life. The reinforcement of the hose is complemented by a custom engineered roller deployment system that intuitively maintains the radius bend of the hose throughout deployment and retraction. The E-Z Fit systems are easily retrofitted to an existing vessel or supplied for new construction. For further information please visit: www.celerosft.com Fluid handling solutions evolve to meet needs of larger offshore wind turbines Better, more powerful and more efficient fluid handling systems are urgently required to support the energy transition, according to Celeros Flow Technology. H&P reports. Offshore wind turbines are getting larger. WTIVs and associated flow control equipment must be able to cope with the additional strain of transporting and erecting them, says Celeros FT. The S&N Pumps range of electrical submersible pumps (ESPs) from Celeros Flow Technology are specifically engineered for seawater service. 20 HYDRAULICS & PNEUMATICS March 2024 www.hpmag.co.uk
RkJQdWJsaXNoZXIy MjQ0NzM=