TPI March 2024

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The international trade magazine for tube and pipe products

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The trade magazine for tube and pipe products

March 2024

Stainless Tube production high standards & absolute customization

Business & market news

Robots set to patrol and repair hydrogen gas pipelines

LeakVision in operation in a hydrogen pipeline

power homes in conjunction with other renewable energy sources like solar, wind or heat source pumps. The government’s Hydrogen Strategy aims to attract £4bn in investment and launch a leading hydrogen economy that will create over 9,000 jobs by 2030. The aim is for all residential gas boilers to be hydrogen-ready by 2026. The change is predicted to save 21 million tonnes of CO 2 and lower electricity costs by 2050. Simon Langdale, engineering director at Synovate, said: “Hydrogen has the potential to play a significant role in decarbonising the UK. As technology and infrastructure continue to develop, hydrogen is likely to become an increasingly important energy source. Our advanced robot technologies will be essential to ensuring the optimisation and safety of the network.” Hydrogen can also be injected into the natural gas grid, which is used to supply homes with natural gas for heating and cooking. By blending hydrogen with natural gas, homes can use a cleaner energy source that emits fewer greenhouse gases than natural gas alone. The process of injecting hydrogen into the gas grid is being explored and tested by energy companies in several countries.

Advanced trials of robots that are able to detect hydrogen leaks and fix pipes have concluded. The research could help to pave the way for hydrogen to be used in industry, transport and heating. Harrogate, UK-based Synovate, part of the Synthotech Group, teamed up with Northern Gas Networks to undertake the trials at a test facility in Spadeadam, Cumbria. The testing programme assessed if a robot could identify a hydrogen leak and repair an operational pipe. The Spadeadam research and testing facility is operated by DNV, a company that specialises in evaluating the effects of significant hazards on people and property. The LeakVision robots can be deployed remotely for long distances, which speeds up the investigation process to aid safety and reduce environmental impact. Hydrogen can be used as a clean and renewable energy source to power homes in various ways. For example, hydrogen fuel cells can convert the chemical energy stored in hydrogen into electrical energy that can power homes. Fuel cells combine hydrogen and oxygen to produce water and electricity. The process produces zero greenhouse gas emissions and only emits water vapour. Fuel cells are considered efficient and reliable and can be used to

Hydrogen can be burned in boilers to provide heat and hot water for homes. Hydrogen boilers are similar to natural gas boilers and can be used to replace natural gas boilers in homes. Hydrogen boilers produce only water vapour and heat, making them a clean and renewable energy source for homes.

LeakVision is a patented leakage detection system sensor mounted to a robot base. The system was developed during a collaboration between Northern Gas Networks, Synovate, the EIC and a consortium of innovators, including ROSEN, The Technology Partnership and the University of Leeds. Synovate www.syno-vate.co.uk Alleima receives major order for steam generator tubes to be used in the nuclear industry

“We see great potential for growth in the nuclear segment. Our addressable market in the nuclear segment is expected to grow at approximately 9 per cent CAGR in the coming five years and we are aiming to increase our market shares in this field. Although lead-times are relatively long, we are ready to significantly ramp-up our capacity when needed,” said Carl von Schantz, president of tube division “I am pleased that we once again are chosen as a trusted supplier for a prestigious power project such as this. Our competitive advantage is our technology leadership and high-quality offering. Growth in the global nuclear segment is driven by replacements, new-builds, extensions as well as new nuclear power innovations, like for example small modular reactors and we are currently active in several discussions regarding future power projects,” said Nigel Haworth, president of business unit energy, tube division. Alleima www.alleima.com

Alleima has received a major order for steam generator tubes with a total value of approximately SEK220mn. The order reflects Alleima’s strong position in the nuclear segment. The order from one of the world’s leading suppliers of nuclear power equipment is classified as a major order (ie above SEK200mn) and was booked in the fourth quarter of 2023. The order will be reported in the tube division and deliveries are scheduled for the second half of 2025.

The Alleima tubes

Carl von Schantz

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Business & market news

Peninsular De Vástagos opens second facility in Spain

material selection, sourcing and tailor made products. The company also specialises in customised tube solutions and project packages for a wide range of applications such as power generation and heat transfer, automotive, oil & gas, chemical and offshore. “This strategic expansion represents a significant milestone in our goal to bring our customers the largest range of cylinder tubes and chromed bars in Spain, coupled with fast, quality service at competitive prices,” said Francisco Campos, founder of the company. “Everyone in the company is excited by the potential of this new facility. We’ll have more capabilities to better serve applications. The advantages of this system solution combine the modular approach of P+P with the special properties of the individual components. All core components of the TOPAQ hydrogen supply systems are manufactured in-house at P+P. These safety-relevant products include on tank valves, H 2 pipework, parallel charging units, high pressure regulation units and thermal pressure relief devices. Possible areas of use include on- or off road applications, industrial applications or H 2 storage. When used in multi-element

Peninsular de Vástagos, a stockist and supplier of honed tubes and chromed bars for the manufacturing of hydraulic cylinders, has opened a new warehouse in Zaragoza, Spain. With over 1,500m 2 , the new facilities located near the French border and the port of Barcelona boast an excellent strategic location that will allow the company to enhance its service to a large number of customers, both in Spain and across Europe, by significantly reducing distance and lead times. The company carries a large stock of chromed bars and chromed tubes, cylinder tubes and precision steel tubes in carbon steel and stainless steel. It also offers additional services such as cutting, machining, customer-dedicated stocks and a skilled sales team specialised in Hydrogen is seen as the key to a sustainable energy future. The German company Poppe + Potthoff (P+P) develops and manufactures safety relevant H 2 components for the growing H 2 market. These can be combined modularly in the hydrogen supply system. In 2024, the company will be presenting its innovative TOPAQ system solution at international trade fairs. Founded in Werther, Germany in 1928, the specialist for the production of customer-specific precision steel tubes has 1,600 employees and is a technology leader for media-carrying components, particularly in diesel technology. Poppe + Potthoff has transferred this expertise to H 2 applications. Under the TOPAQ brand, P+P offers customers a modular system solution for the safe, reliable and efficient transfer of hydrogen from the tank to the fuel cell or hydrogen combustion engine. Thanks to its modular design, TOPAQ enables application-optimised system architectures – for use in both mobile and industrial applications. TOPAQ serves as an interface between different system landscapes for dual fuel, H 2 -ICE (DFI, PFI) and fuel cell

The new warehouse in Zaragoza, Spain

our customers in Spain and Europe, immediately and into the future. We extend our sincere gratitude to everyone who has been part of this exciting project – our employees, customers and business partners.” Peninsular De Vástagos has also launched its newly redesigned website. The entire site has been designed to be more informative and mobile friendly.

Peninsular De Vástagos SL www.peninsulartubes.com

Poppe + Potthoff presents its TOPAQ hydrogen tube systems at trade events in 2024

gas containers (MEGC), TOPAQ can play an important role in the development of a global H 2 infrastructure. From April Poppe + Potthoff will be presenting its TOPAQ system solution at international trade events such as Tube Düsseldorf, Germany Hydrogen + Fuel Cells Europe in Hanover, Germany, Intermat in Paris, France, the Advanced Clean Transportation Expo in Las Vegas, USA and Hydrogen Technology North

America in Houston, USA. Poppe + Potthoff GmbH www.poppe-potthoff.com

Poppe + Potthoff’s modular and intelligent TOPAQ system enables the safe and efficient transport of hydrogen

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Business & market news

Zekelman invests in facilities and technology Zekelman Industries, the North America based independent steel pipe and tube manufacturer, has introduces a new brand. Executive chairman and CEO Barry Zekelman launched the first ever company-wide townhall live from Zekelman’s newest and most technologically advanced factory in Rochelle, US at the start of the year, streaming to thousands of workers at multiple facilities across the US and Canada. He outlined future plans for the company and encouraged all associates to embrace the company’s new slogan: “believe in what you build.” the past five years, the company has invested over $2.3bn into its business with $1.1bn towards facility modernisation and expansion, and just over $1.2bn in modular construction factories and housing developments. Examples of the company’s commitment to believing in what it builds include: • Launch of Z Modular, reinventing the modular building and construction process. To date, Z Modular has completed four housing projects totalling 1,104 apartments and has an additional eight housing developments with 2,154 units under construction in the US and Canada.

• Atlas Tube jumbo mill in Blytheville, Arkansas, the world’s largest continuous ERW mill manufactures structural steel products not previously available from a domestic producer, creating new opportunities in architectural design and structural engineering. • Wheatland Tube’s Rochelle, Illinois, US plant, the company’s most advanced manufacturing facility dedicated to electrical conduit, fence framework and solar applications. • Continual investments across all factories, with updates including automated warehouses and loading cranes. Mr Zekelman said: “This company has been around for a long time and has never been stronger. When I see all of our employees succeed, that is my proud moment. The greatest thing is to see them do well and build their future with our company.”

“’Believe in what you build’ formalises what has really been the soul of our company, with roots dating back to 1877,” said Mr Zekelman. “It’s a call to action for our teammates, markets and customers we serve, that together we can achieve more.” Zekelman continues to invest heavily in new facilities, technology and training for its staff. The family of Zekelman companies now includes 20 manufacturing locations with more than 2,900 employees across nine US states and Ontario, Canada. In

Zekelman continues to invest in new facilities, technology and training of its staff

Zekelman Industries www.zekelman.com

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Business & market news

Strohm completes first composite pipe jumper in West Africa for TotalEnergies project

it to be transported by a small, multi purpose vessel and installed by local contractors, greatly reducing carbon emissions and costs. Strohm personnel were mobilised offshore to assist in the installation process. Martin van Onna, Strohm CEO, said: “We are immensely proud to see our first TCP jumper for our highly valued client TotalEnergies installed and operational in West Africa. This success reaffirms TCP as an ideal deepwater solution and strengthens our leading position in the market.” Strohm’s TCP provides a robust, corrosion free and field-proven solution features a patented housing with open sides, which reduces the material usage and offers easier access to the threaded plug-in inserts. The new valve also adopts the same general specifications as the rest of the line-up. It is made from plastics that protect it against corrosion and abrasion while reducing the overall weight compared to metal. In addition, it features a Data-Matrix Code for traceability and an optional LED position feedback sensor. The 565 Lug-Style comes with many marine and water approvals including NSF, DNV, Lloyds Register and KTW-BWGL.

Strohm has supplied TotalEnergies with a thermoplastic composite pipe (TCP) Jumper, which has been commissioned in deep water (1600m) in West Africa. This installation has followed a rigorous testing programme, during which TotalEnergies qualified the Netherlands based company’s TCP jumper for permanent subsea applications. All pre deployment inspections and tests were successfully passed, certifying it for its full life cycle on schedule. The installation of Strohm’s 5.2" ID, 340 bar design pressure TCP jumper in the Egina field was supported by a local Nigerian subsea services provider. The pipe’s lightweight properties allowed Swiss flow solutions provider GF Piping systems has completed its portfolio of the lightweight and corrosion free Butterfly Valve 565 with the addition of its latest evolution. The lug-style design of the Butterfly Valve 565 allows for additional use cases in water applications in industries such as water treatment, marine and cooling applications. The wafer-style Butterfly Valve 565 was first introduced in 2021 and was developed as an alternative to metal valves. Due to its lightweight plastic design, identical installation lengths, as well as high pressure and temperature resistance, the 565 is considered cost effective and long lasting. In order to offer the full product range, GF Piping Systems has now introduced the Butterfly Valve 565 Lug-Style. The 565 Lug-Style can be used as an end valve, which enables piping systems to be disassembled one-sided. This facilitates the maintenance and operation of filters, tanks and other installations. As standard, the 565 Lug-Style features plug-in inserts that can be configured to fulfil the needs of a wide variety of applications. The removable inserts have been designed to increase flexibility and customisation during operation and improve material separation at the end of the valve’s service life. The 565 Lug-Style also

Strohm’s TCP jumper

for operators. TCP jumpers can be manufactured and shipped in long continuous lengths, stored onsite for long periods of time, cut to length when required and terminated within hours, with no change to its properties or lifespan. TCP for subsea jumpers as well as flowlines and risers have proven to reduce the CO 2 footprint of pipeline infrastructures by more than 50 per cent. Strohm www.strohm.eu

GF Piping Systems introduces the lightweight and corrosion resistant Butterfly Valve 565

Furthermore, it is the first industrial valve with an Environmental Product Declaration. Depending on the application, the 565 range can be configured to meet different requirements. It can be operated manually with a lockable hand lever or a hand wheel, but it also features a digital interface as standard for plug and-play process automation. Optional equipment includes pneumatic, electric or smart actuators and positioners, as well as compatibility with inductive double sensors and a switching ring for precise feedback on position and performance. As a result, the 565 is designed to be seamlessly integrated into automation loops, which can be controlled and monitored remotely. Sandra Schiller-Mauz, head of sub BU process automation at GF Piping Systems, said: “With the butterfly valve type 565 Wafer-Style, we already set out to create a Butterfly Valve that beats metal alternatives by being lightweight, reliable and cost-effective. “Now, there is a solution for all the demanding requirements of our customer base. The 565 Lug-Style is built for the future.” GF Piping Systems www.gfps.com

The new 565 Lug-Style Butterfly Valve can be used as an end valve and provides flexibility thanks to customisable inserts

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Business & market news

Pipeline boost required for district heating growth District heating is on the rise in the UK and FVB UK is taking part in several large-scale projects. The goal is for ten times as much district heating compared to the current level to be installed by 2050. The main driving force for this growing market is the environmental benefits of district heating. The British heating market mainly consists of heating homes individually with natural gas or oil, but stricter climate requirements are aimed at eliminating fossil fuel energy sources and switching to green alternatives, which is when district heating becomes interesting. “The first district heating systems were built in the UK in the 1950s, but due to a number of issued including poor design and installation their widespread use was not achieved, this was also coupled with the cheap fuel provided by North Sea gas. “District heating now accounts for only around two to three per cent of the heating market,” explained Peter Russett, CEO of FVB UK. “The target that’s been set now calls for district heating to account for 20 to 30 per cent of the country’s requirements by 2050. I’ve seen figures that show expanding the network of district heating pipes alone to meet the target is going to run into hundreds of kilometres of pipe. So there’s a lot that will have to be built over the next 30 years,” stated Mr Russett. Despite the low market share district heating has, there are already a lot of systems installed in the country, but they are often small scale and generally use natural gas as the fuel source. The systems built in recent years and those at the planning stage are increasingly using heat pump technology, with natural gas for peak loads or reserve fuel. The British government wants the district heating industry to decarbonise and support this through several initiatives, including financial support for feasibility studies and the conversion of projects to fossil-free fuels. The government is also behind The Green Heat Network Fund with aim of the fund being to support the commercialisation and construction of CO 2 -free district heating systems. The fund was established in 2022 and Peter Russet believes it will be crucial to the development of fossil-free heating in the UK. “It’s been very important since there has been so little private capital available for investments of this kind, but we have seen a change towards more commercial interest in district heating programmes,” he said. The increased interest in district heating is also evident to FVB, as we are now taking part in many more district heating projects after five years in the UK. “The UK business has grown dramatically in the last two years, and looks set to grow by as much again next year. And that’s thanks to orders from existing and new customers. “Personnel numbers in the UK are also growing, although we do call on our Swedish colleagues for help in peak periods and when we need expertise we do not have here,” added Mr

Plants & Equipment

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TUBE PRODUCTS INTERNATIONAL March 2024 tub2402_Tube_Besucheranzeige_2024_mitText_87x260_INT_ICv2_IntrasMag.indd 1 15.11.23 13:28 15.11.23 13:28

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Business & market news

Asahi/America introduces new manual ball valve limit switch Asahi/America Inc, which specialises in thermoplastic fluid flow technologies, has introduces the new J-Switch ® manual limit switch compatible with Asahi/America’s Type-21/21a ball valves and Type-23 Multiport™ ball valves. The new limit switch is a low-cost manual valve position indication solution. 2 " to 2" sizes, the J-Switch ® features a compact profile, direct mount, glass-filled polypropylene enclosure that requires no tools for simple field installation. The J-Switch ® also features 0-180 AC/DC multi-voltage capabilities, a corrosion-resistant, NEMA 4X enclosure and a cable gland with 2m flying leads. It operates at up to 150°F. Asahi/America is a manufacturer and supplier of thermo- plastic fluid flow and air handling solutions for industrial, environmental, high purity and commercial applications. Asahi’s piping systems, valves and actuators have been installed for more than 40 years in a variety of industries Available in 1 / 2 ", 3 / 4 " to 1”, and 1 1 /

The J-Switch ® features a compact profile, direct mount, glass-filled polypropylene enclosure

including water and wastewater treatment, oil & gas, water parks and aquariums, landfills, semiconductor and pharmaceutical manufacturing. The company maintains fabrication, machine and assembly shops at its Massachusetts, USA headquarters, as well as an extensive custom fabrication department in Louisiana. Asahi/America Inc www.asahi-america.com

Hydraulics · Automotive · Energy

PRODUCTS

• Chromed bars C45, 42CrMo4 & Induction Hardened • Stainless steel chromed bars (AISI 304, 316 & 431) • Nickel and chrome-plated bars (NICROM) • Chromed tubes and tubes for telescopic cylinders

• Seamless and welded honed tubes • Stainless steel honed tubes AISI 316 • Carbon steel and stainless steel hydraulic pressure lines (HPL) • Tubes for automotive applications • Tubes for energy applications • Tubes for boilers and heat exchangers

SERVICES

• Cutting • Large stock availability • Customer-dedicated stocks

• Customized solutions • Project packages • Testing and inspections

SEVILLA HEADQUARTERS: Pol. Ind. San Nicolás C/ San Nicolás Diez, 52 41500, Alcalá de Guadaíra, Sevilla (Spain) Tel: +34 954 25 90 22 · info@peninsulardevastagos.es

ZARAGOZA OFFICE: Ctra. Castellón Km. 6,3 Pol. Ind. Tecnum, nave 8-9, 50720 Cartuja Baja, Zaragoza (Spain) Tel: +34 876 615 601 · zaragoza@peninsulardevastagos.es NEW OPENING!

www.peninsulartubes.com

Business & market news

Danfoss PVG 48 valve improves precision and controllability

proportional valve, then in development, emerged as the perfect solution. PVG 48 is a pre-compensated proportional control valve for

Danfoss Power Solutions, a global supplier of mobile and industrial hydraulics as well as electric powertrain systems, has partnered with Australian crane manufacturer Franna to improve the performance of its MAC 25 crane. With the PVG 48 proportional valve at the heart of the work and steering subsystems, Danfoss is delivering a reliable, precise solution. Franna, a Terex brand, is a manufacturer of pick and carry cranes with a rich heritage of design and engineering excellence. For more than 40 years, Franna has been operating successfully in the Australian market and its products are at work in more than 30 countries globally. Franna’s MAC 25 mobile articulated crane features a maximum lifting capacity of 25 tonnes and a maximum boom length of 18.4m. The crane offers safety, excellent roadability, intuitive operation and versatility. In 2021, Franna began looking at other options for the MAC 25 crane’s main control valve. The company required a solution that was precise, reliable and future proof to accommodate increasingly sophisticated electronic control systems. The Danfoss PVG 48

Danfoss launched the PVG 48 valve to the general market in June 2023 with Franna as a key pilot customer

machine functions so the crane assists – or even takes over from – the operator. Such a function can be advantageous in many situations, particularly when instant reaction is required to ensure safety. With the change to PVG 48, Franna also switched to Danfoss counterbalance valves. Together with PVG 48, they ensure smooth and safe activation of the crane’s boom. “Controllability is smooth and even – very refined,” said Quentin Bourke, product support technician, Franna. “The initial tiny bounce on the front tyres, which you sometimes see when operators raise or lower the boom, is completely gone. Extension or subtraction of the boom is impressively smooth, too.” The Danfoss PVG 48 proportional valve is already at work in more than 100 of Franna’s MAC 25 cranes throughout

applications requiring flow rates of up to 180 litres per minute. The latest member of the PVG load-sensing valve family, PVG 48 is ideal for machines such as wheel loaders, aerial lifts and cranes in which precise flow and controllability are essential. Danfoss launched the PVG 48 valve to the general market in June 2023 with Franna as a key pilot customer. On the MAC 25, the valve turns operator joystick inputs into quick, accurate boom movement. “The PVG is extremely precise and reliable. It does what you want it to do repeatedly,” said Adam Murchie, project engineer, Franna. “It’s the ideal choice for MAC 25 and likely to end up in other of our cranes, too – not least in future launches where more advanced electronic controls are key. We wanted a future-proof valve. PVG 48 is it.” The PVG 48 valve integrates easily with electric actuators, sensors, and digital controls, opening a range of possibilities. One of them is to automate certain

Australia. Danfoss www.danfoss.com

Bridgestone HosePower acquires Cline Hose & Hydraulics to expand mobile hose and fittings solutions and service

“Bridgestone HosePower shares in our commitment to customer service. For 75 years, our family has taken great pride in exceeding customer expectations. Now, with HosePower, we will be able to serve more businesses, help more people, and provide more opportunities to employees.” Bridgestone HosePower has 47 locations across the US including five OEM sales centres. Approved by each company’s board of directors, the transaction

our capacity to service a larger customer base with speed and flexibility.” Cline Hose & Hydraulics is a family owned business founded in 1948. Over the last 75 years, the Cline family has grown the company to include two retail locations in Greenville and Augusta, Georgia, US along with a fleet of mobile service trucks to meet customer needs throughout the Southeast US. “We are honoured to join Bridgestone HosePower, a company we’ve long admired as the leader in our industry,” said Scott Cline, co-owner of Cline Hose & Hydraulics.

Bridgestone HosePower LLC, a wholly owned indirect subsidiary of Bridgestone Corporation, has acquired South Carolina, US-based Cline Hose & Hydraulics, LLC. The acquisition expands HosePower’s hydraulic and industrial hose solutions and service business. “Cline Hose & Hydraulics has an exceptional reputation for quality and has a very similar business model as Bridgestone HosePower,” said Tom Henry, president and CEO, Bridgestone HosePower. “This acquisition expands upon our capabilities while increasing

closed at the end of 2023. Bridgestone HosePower www.hosepower.com

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Business & market news

INEOS polymer used to create sustainable pipeline INEOS produced bio-based high density polyethylene (HDPE) has been used to create the world’s first fully sustainable gas pipeline. Installed by French gas utility network operator, GRDF, the pipeline only uses low carbon footprint polymer. Rob Ingram, INEOS Olefins & Polymers North CEO, said: “Our congratulations to GRDF for this world first. At INEOS, we are very proud to play a part in this game-changing sustainable pipeline innovation.

The result is a polymer with a significantly lower carbon footprint than conventional, fossil-based polymers and because of this it has been recognised by the International Sustainability and Carbon Certification (ISCC), an independent, third-party organisation. ISCC have certified that the production of the pipes laid by GRDF meet ISCC Plus standards by replacing the use of fossil fuel derived feedstocks to produce the new material. Importantly, the bio-polymer has the same technical characteristics as conventional polymers, enabling a partner like GRDF to meet the highest standards of safety while reducing the environmental impact of networks it operates on behalf of local authorities. It also creates the potential for the innovation to be repeated for other gas and water pipelines. All polymers offered by INEOS Olefins & Polymers Europe are also 100 per cent recyclable, alongside the lower carbon footprint associated with the bio-based HDPE.

“Alongside the work we are doing to drive down emissions and reduce plastic waste in the polyolefins industry, it’s another example of our commitment to working with partners to develop efficient, lower emission solutions for transporting important utilities and goods around Europe’s cities.” Alexandre Pierru, GRDF innovation project manager, said: “GRDF has proven that it’s possible to distribute biomethane, a bio-based gas, with bio based certified polyethylene pipes. “It’s thanks to our collaboration with partners such as INEOS. They showed a strong will to find solutions to decarbonise the raw material of our

The new pipeline is installed in Clermont Auvergne Métropole, in the French city of Clermont-Ferrand, as part of a GRDF program to ‘green’ pipelines in parts of the region with a similar commitment to reducing their carbon footprint. One kilometre of pipeline will be laid across three sites in the Clermont Auvergne Métropole gas network. The pipeline is made from bio-based, certified HDPE supplied by INEOS Olefins & Polymers Europe. It is made from wood processing residues from the paper industry, which are transformed into tall oil – a bio-naphtha. The tall oil is turned into bio-ethylene at INEOS Cologne and transported to INEOS’ polymer plant in Lillo, Belgium, where it is used to manufacture bio based HDPE.

pipes.” INEOS www.ineos.com

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More productive processes Industry suppliers are also increasingly leveraging the potential of automation for their own processes. AS-Schneider, for instance, significantly boosts its productivity through a high degree of automation. Collaborative robots (cobots) are set to take over simple and repetitive activities in the assembly department: employees are freed up and lead times shortened. Cobots could be used for laser marking, tape winding of screw plugs, greasing of valve tops and drying after pressure testing. “Productivity increases could amount to between ten and 15 per cent,” explained a spokesperson for AS-Schneider. Valve and actuator industry components are absolutely essential for plant automation. Air Torque for instance experienced an increasing demand for actuators as an essential part of automation. Depending on the control medium, the company is noticing different trends emerging. “With electrically driven actuators, the integration of control, monitoring and maintenance functions has been state of “The bulk of the market (US$76bn) will then consist of the automation of process industries such as the chemical or oil & gas sectors, followed by production environments such as automotive or semiconductor manufacturing with US$32bn in volume,” explained the McKinsey report – software will increasingly be used to automate factories. The current challenges facing the valve industry are numerous. More than ever, competitive pressure, the energy crisis, supply chain risks, sustainability and the growing shortage of skilled workers call for effective solutions. But there is an effective way to make these hurdles more manageable with the help of automation. More and more companies are relying on automation and the automation of industrial production will continue to accelerate due to new technologies and vendors, according to analysis by McKinsey & Company. The market for industrial automation will therefore grow by almost four per cent annually to over US$115bn by 2025. Cloud and Industrial lnternet of Things (IIoT) solutions in particular are leading the way. Valve and actuator industry are essential for the future of plant automation By Messe Düsseldorf

the art for some time – take predictive maintenance for example,” reported a spokesperson for Air Torque. And in addition to the increasing digitisation and networking variance of valve actuators in pneumatic actuators, there is a clear development towards a modular attachment of logic and control elements. A game changer Bar pneumatische Steuerungssysteme sees a trend towards greater automation in gas applications, triggered by conversions to LNG, hydrogen plus methanol for fuel production and CO 2 capture in high-emission industries. According to bar, industries such as shipbuilding, storage and gas removal, the transport and distribution sector are also open to automation. The chemical industry, on the other hand, sees its competence rather in its own production performance and expects ready-made automation solutions adapted to process technology. Digitalisation is considered a game changer in automation. As the spokesperson for Bar stated, it provides important momentum. Depending on focus, the relevance of data can therefore be used for production measurement or predictive maintenance.

Thanks to a high degree of automation, AS-Schneider was able to render its manufacturing processes more productive. Simple and repetitive tasks during assembly could now be taken over by collaborative robots

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A sophisticatedly programmed automatic valve “also increases protection against unauthorised interventions in the process sequences”. System availability is improved by digitised actuators, controls and valves and maintenance costs are reduced thanks to higher quality and productivity is increased. The controller, equipped with suitable communication technology, is part of the future smart factory. Proper data management will allow for reduced emissions, improved recycling processes and minimised production waste. Sensor and actuator profiles Digitalisation is taking automation to a new level: as such, the aim is to further optimise the IO-Link – as a communication system for linking intelligent sensors and actuators to an automation system. The goal is an even broader and more efficient use of IO-Link in automation. This has already been achieved through the development of the smart sensor profile (SSP). This standard allows a 1:1 exchange of similar devices from different manufacturers with their basic functions – without the need to adapt any function blocks. “Thanks to digital transmission via IO-Link, conversion errors are a thing of the past,” the IO-Link community spokesperson explained. Now for the next step: “We are currently working on creating a smart actuator profile, because users also wish to see uniform profiles in actuator technology,” the IO-Link community spokesperson added. Automation for projects As evidenced by countless projects, automation is in higher demand than ever. Valmet for instance is providing automation for a UK energy-from-waste project in Sandwell and Dudley in the West Midlands. Among others, this order includes a DNA automation system, integrated controllers and an electrical control system. The start of full operations is planned for 2025. Another order was received by Valmet from Kuwait, to retrofit the automation system of the Sabiya energy and water distillation station – the commissioning will be completed in autumn 2024. Emerson provides automation solutions for safety and reliability of the first large-scale photovoltaic (PV) solar power project in New Zealand. The order includes a decentralised process control system and controllers. The aim is to minimise the impact of fluctuations and interruptions in PV power generation. Great savings potential Great progress has been made, but the industry is already eying up the next development milestone: the use of artificial intelligence (AI). According to the Federal Association of German Industry (BDI), a 20 per cent improvement in plant use is possible if AI maintenance work is carried out proactively.

In addition, a systematic cooperation of robots and employees will make a 20 per cent higher productivity of individual work steps feasible. “AI can make quality monitoring 50 per cent more productive – for example, through automatic visual error detection for products,” said the BDI spokesperson. In certain areas, a waste reduction of up to 30 per cent is possible. The potential of digitalisation and artificial intelligence for automation is therefore enormous, while at the same time there is a great need to catch up. Openness towards technology could therefore become a recipe for success for companies trying to master current challenges. Further trends and highlights from the rapidly evolving valve industry can be experienced at Valve World Expo taking place from 3-5 December 2024 in Düsseldorf, Germany. As a digital enablement tool for smart field devices, Emerson’s AMS Device Manager connects to thousands of systems and millions of devices worldwide via standard protocols such as Hart ® , Foundation™ Fieldbus, WirelessHart ® , and Profibus. The AMS Device Manager Data Server enables users to “unleash the full potential of data from these smart field devices for advanced aggregation and analysis so to drive digital transformation and bundle operational systems,” explained a spokesperson from Emerson

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