Monday, 30 June 2025

Energy storage for months at a time.

The first commercial-scale AirBattery project in Germany is to be built by Augwind Energy. The facility will be the world’s first industrial-scale operational installation of Augwind’s AirBattery Hydraulic Compressed Air Energy Storage (CAES) technology designed specifically for grid-scale storage for up to months at a time - a game-changer for the global energy transition.

In regions in central Europe, long periods of low solar and wind output known as ‘Dunkelflautes’ severely challenge grid stability. Augwind’s AirBattery offers a resilient buffer, providing backup for up to months helping utilities, grid operators and traders to deal with renewables intermittency and stabilise electricity markets.

Or Yogov
“This is more than a project; it’s a milestone for achieving net zero," declares Or Yogov, Founder & CEO of Augwind (pictured).  "With the AirBattery, we’re introducing a storage solution that finally matches the scale and rhythm of renewable energy. Germany’s redundant salt caverns, industrial leadership, and climate ambition make it the perfect launchpad for our first commercial deployment. Our goal is to become Europe’s preferred partner for multiweek storage solutions. With this German launch, we are proving that long term energy storage to balance the grid is not only technically feasible, but it’s economically sound.”

This revolutionary AirBattery system combines two well-established technologies in an innovative way: it merges pumped hydroelectric principles with compressed air storage, circulating water between underground chambers to compress and decompress air at vast scales (see video below).

Excess energy is used to compress air to pressures from 50 bar all the way to above 200 bar, depending on the demand and geomorphic structure of the cavern, and feed the pressurised air into vast underground caverns, larger than the Empire State building. The excess renewable energy is effectively stored for times that the sun doesn’t shine, and the wind doesn't blow with a typical cavern having the potential to store enough compressed air to generate 3-8 GWh of electricity.

The energy is recovered from the system by simply returning the high-pressure air back through the water filled chambers, streaming the water to spin a turbine and generate electricity. Augwind has already reached a 47% AC-to-AC round-trip efficiency at its AirBattery demonstration facility in Israel, validating that commercial installations will exceed 60%.

Their first commercial scale AirBattery facility will be built in Germany and will utilize a mined salt cavern suited for such long-duration energy storage. The cavern will serve as a low-cost, high-capacity compressed-air reservoir, enabling scalable and cost-effective energy storage for up to several months, a vital capability as Europe races to increase renewable energy penetration beyond 50%.

With an initial target commissioning window of 2027–2028, Augwind is now working closely with local cavern owners, utilities, energy traders and industrial off takers to secure permitting and finalize the system design. The project will not only showcase the techno-economic viability of Augwind’s Hydraulic CAES but also lay the groundwork for broader deployment across Europe by 2030.



@Influenceemob #Augwind #Energy #Sustainability

Price rises cause "Supply Chain Chaos!"

Distributor advises ‘lead times likely to move out rapidly’ as market picks up.

Concerns in the market that lead times are predicted to move out rapidly later in the year now that the market appears to be picking up have been voiced by Anglia Components. News from many sources confirm that the excess inventory which has built up over the past two years has mostly been consumed, and at least one major supplier, Texas Instruments, has announced global price increases covering over 3,300 analogue product SKUs*.

Analyst company, Bernstein noted that the majority of the price hikes are below 30%, targeting general-purpose analogue components where competition is fierce…a smaller portion of high-precision ADC/DAC chips, will see price increases exceeding 100%.

John Bowman, the Anglia’s Marketing Director with Anglia commented, “All the signs are showing that the market is picking up rapidly, and the theme from many suppliers at our recent sales conference centred on their concerns that if customers do not start placing backlog now, they will run into problems later this year as lead-times are forecast to quickly lengthen.”

In order to protect themselves from the inevitable supply chain chaos this will cause, Anglia is advising customers to be vigilant and requests that they place forward orders as soon as possible.


* TI stock rating maintained amid price hike strategy (Investing.com)

@angliaComponent @TXInstruments #Electronics #PAuto

Friday, 27 June 2025

Excellence in energy efficiency.

Wisconsin state energy efficiency program recognises foundry for outstanding commitment to saving energy

Emerson's Appleton Group iron casting facility has received a 2025 Energy Excellence Award from Focus on Energy®. The award recognizes companies in that US state that go above and beyond basic energy efficiency solutions, both within their own organizations and those they support. As one of 11 recipients, the South Milwaukee foundry proves how energy-efficient industrial facilities can reduce costs, contribute to a healthier environment and strengthen local economies.

“Emerson's foundry shows that even energy-intensive operations can be leaders in energy efficiency,” said Erin Soman, managing director of Focus on Energy. “This award isn’t just about saving energy – it’s about people coming together to think differently about how we use energy and what that means for Wisconsin’s future.”

LtoR: Doug Presny, CleanTech Partners; Joe Pater, Wisconsin Public Service Commission; Paul Kling, Focus on Energy; John Schuster, Emerson; Bob Axtell, Emerson; Bill Bolhuis, Franklin Energy; Chris Larson, Chris Jansen, Wisconsin State Senator, District 7; Jim Garbowski, WEC Energy Group. 
Focus on Energy is the statewide energy efficiency and renewable energy program for businesses and residents in Wisconsin. It offers a range of rebates and incentives for energy-saving technologies as well as services that help organizations reduce energy use and costs.

The Appleton foundry, which manufactures electrical fittings, enclosures and other cast products for electrical infrastructure, has worked with the Focus on Energy initiative since 2017. In that time, the partnership has made it possible for the foundry to identify, evaluate, design and implement many successful energy efficiency and utility cost-savings projects.

These updates include new controls on its makeup air units, the replacement of channel furnaces with cordless induction melting furnaces and the replacement of over 800 fluorescent lights with Appleton industrial LED fixtures. Combined, the energy improvements save the facility over 10,000 megawatt-hours (MWh), 65,000 million British thermal units (MMBtu) and $1 million in energy costs annually. The team also identified nearly $350,000 in energy-related incentives throughout this period.

The foundry team’s commitment to optimizing energy efficiency has cut the facility’s total energy consumption and emissions by about a third since 2017, drastically reducing its own emissions and operating expenses. These reductions are especially significant given that the century-old foundry had been among the largest energy-consuming facilities across all of Emerson.

“The Energy Efficiency Excellence award highlights the dedication of our team to improve our own environmental impact, support our cost reductions in Wisconsin’s energy system and work with external organizations to move toward a more sustainable future,” said John Schuster, plant manager at Emerson’s discrete automation business. “What we've achieved in South Milwaukee is a success story for the Emerson portfolio, as well as for the castings industry overall. It’s an honor to be acknowledged in this way.”


• See also: Innovative BMS at foundry recognised. (20/6/1025)

@AppletonEC @EmersonExchange @Emerson_News @focusonenergy #Energy #Sustainability #USA 

The Flame Ionisation Detection (FID) method for monitoring emissions.

The Flame Ionisation Detection (FID) method was first developed in the 1950s for the laboratory analysis of organic chemicals. Later, when environmental regulations began to limit the emissions of volatile organic chemicals (VOCs) in the 1970’s and 1980’s, the FID method was adapted for emissions monitoring. Signal Group was one of the first companies in the world to develop VOC emissions analysers, and in this article James Clements, Managing Director, explains why FID became the reference method, and why it lasted the test of time.

Background
Organic chemicals have always been widely used in industrial processes, but awareness of the harmful effects of VOCs on health and the environment did not become significant until the 1970s. At that time, President Richard Nixon presented proposals on environmental protection which included the establishment of a federal Environmental Protection Agency (EPA). This led to the development of maximum allowable concentrations for pollutants, many of which were subsequently adopted around the world.

VOCs are common constituents in the emissions of processes that involve petrochemicals, paints, coatings, adhesives, waxes, disinfectants and cleaning chemicals. In many of these processes, solvents play a major role and the release of VOCs represents a risk to health and the environment. Similarly, combustion processes give rise to VOC emissions, particularly where combustion involves the use of an organic fuel. This includes fossil fuels such as petrol, diesel and oil, as well as wastes and biofuels.

By monitoring total organic carbon (TOC) concentration in emissions, process operators can demonstrate compliance with relevant legislation. However, such measurements also provide insights for process optimisation, because, for example, the presence of organic compounds may be an indicator of incomplete combustion. In addition, TOC is frequently measured post-abatement in order to measure abatement efficiency.

Why was FID chosen as the reference method for VOC emissions monitoring?
It is normal practice for regulators to specify a standard reference method for monitoring pollutants, so that compliance measurements are accurate and directly comparable with the limits, and with measurements from other process operators. FID has been widely acknowledged as the reference method for VOCs for over 50 years, and there are many reasons for this:

  1. Already proven - initially developed as a detection method for laboratory Gas Chromatographs, FID was already well-established as a reliable technology for the detection of hydrocarbons. Adaptation for measuring VOC emissions was therefore relatively straightforward. As a consequence, Signal Group has been developing and supplying thousands of FID analysers all over the world for almost as long as FID has been the reference method.
  2. Cost – in comparison with methods such as mass spectrometry (MS) or Fourier transform infrared spectroscopy (FTIR), FID is relatively simple and therefore less costly to manufacture. This is important because, globally, the number of processes that generate VOC emissions is enormous, so it is important that reference method technology is affordable for the organisations, large and small, that are required to monitor their hydrocarbon emissions, or that need to monitor for other purposes such as process control or abatement management.
  3. Specificity – the FID detection method is specifically designed to detect carbon-hydrogen (C-H) bonds, making it highly selective for organic compounds. Unlike some other detection methods, FID does not respond significantly to inorganic gases which helps to minimise interference from non-VOCs, providing more accurate and reliable emissions measurements.
  4. High sensitivity – the FID method is highly sensitive to hydrocarbons, which makes it ideal for even low-level measurements, particularly as environmental regulations become more stringent. Signal Group’s latest FIDs, for example, offer measurement resolution down to 0.01ppm. It is also important to note that FID sensitivity is much less variable than other techniques. Photoionisation detection (PID) for example exhibits widely varying response factors for individual hydrocarbons, rendering it inappropriate for the measurement of hydrocarbon mixtures. In contrast, FID is ideal for the measurement of total hydrocarbon content, whether the hydrocarbon is an individual compound or a mixture of species.
  5. Wide range – in addition to their high sensitivity, FIDs are also able to make measurements at significantly higher ranges. The S4 Solar FID (shown right) for example, has a number of user-selectable ranges, all the way from 0 to 1ppm with a resolution of 0.01ppm, up to 0 to 300,000 ppm with a resolution of 1ppm.
  6. Fast response - FID analysers provide an almost immediate response to a sample gas, which is extremely important for regulatory compliance, particularly with processes emissions that can vary significantly from one minute to the next. The typical response time for Signal’s latest FIDs can be less than 1 second. This is also important for process control and engine emissions testing.
  7. Stability and reproducibility - decades of experience in a wide variety of applications have shown FID’s ability to produce stable measurements in the long-term. Similarly, when identical FID units measure the same sample gas, the same results are given. This is an extremely important feature of standard reference methods because it provides confidence in measurements – for both the user and the regulator.
  8. Applicable to continuous monitoring – many VOC emissions regulations necessitate continuous monitoring, so an important feature of FIDs is their compatibility with Continuous Emissions Monitoring Systems (CEMS). Nevertheless, FIDs should be sufficiently flexible to be suitable for discontinuous monitoring with portable instruments. Consequently, Signal Group developed lightweight ruggedised versions of its FID technology so that, where regulations permit, a single portable FID can be used to measure the VOC emissions of multiple sources – at the same site or at different sites.

FID development – manufacturer’s perspective.
Although the latest range of FIDs from Signal Group feature a fourth-generation detector, it is truly remarkable that the core measurement technology has changed very little since the company first developed a FID in the 1970s. The main reason for this is that each generation of Signal’s FID has featured the company’s unique precision-machined monobloc detector which guarantees uniformity of production in a compact, leak-free design.

Most of Signal’s FID development work has therefore focused on issues outside of the core technology. These issues have either been application specific, or have addressed ease of operation, connectivity and data management.

In addition to fixed and portable FIDs, the company has developed both hot and cold FIDs for ambient or post-combustion applications. Dual FIDs have also been developed, featuring two FIDs in one instrument, so that methane and non-methane hydrocarbons (NMHCs) can be monitored simultaneously. This is an important differentiation because methane’s primary significance is as a greenhouse gas (around 30 times more powerful as a greenhouse gas than carbon dioxide), whereas NMHCs contribute to the photochemical generation of smog and atmospheric ozone. So, methane emissions are important because of their role in climate change, whereas NMHC emissions affect air quality and health.

Their development work  has also focused on automation, datalogging, sample conditioning and advanced calibration tools. In addition, the most recent generation of instruments features a wireless tablet capable of connecting via Wi-Fi to the analyser from a distance of up to 50 metres. This provides users with the ability to view live data in a different location, and even manage datalogging, alarms and calibration from a distance.

In addition, all Series IV instruments, including the new SOLAR XPLORE (right), have their own IP address, and are compatible with 3G, 4G, 5G, GPRS, Bluetooth and satellite communications. This provides users with simple and secure access to their analysers at any time, from anywhere.

Conclusion.
In summary, Signal’s first FID analysers in the 1970s were able to provide accurate consistent measurements for total hydrocarbons. Now, thousands of instruments later, their successors are still producing the same reliable data, but with built-in tools and accessories that make the monitoring process easier and less prone to human error. Employing the standard reference method, supported by over 50 years of rigorous work in every conceivable application, FID has stood the test of time, offering operators and regulators confidence and trust in VOC measurements.


F@GasAnalysers @StandardLithium @_Enviro_News #PAuto #Environment

Ball valve.

A Rising Stem Ball Valve is being added  Trillium Flow's to its extensive Red Point® production catalogue of ball, check, double block and bleed, gate, and globe valves. This latest innovation is designed to reduce friction on moving components, extend maximum service life, and provide a low-maintenance design. The Rising Stem Ball Valve is widely used in the oil and gas industry, where its robust design and reliability in preventing leakage are valued.

Fred Jansen, the General Manager of their facility in the Netherlands, where Red Point valves are manufactured, said, “We’re proud to solve more customer challenges by adding this solution to our growing portfolio.”

The new valve’s friction-free sealing and non-contact ball movement achieve longer potential service life and, combined with the single-seated design, features a broad operating temperature range from -196°C to 450°C. The impact of thermal expansion has been minimized by the configuration of the valve components, allowing for this impressive temperature range.

This newest model is suitable for dirty service with a uniquely designed bottom trunnion that ensures the prevention of solid particle ingress into the valve.

The distinct quarter-turn helix-shaped stem mechanism design is fully enclosed within the valve body, providing additional protection against environmental factors and eliminating the requirement for frequent lubrication. When closing the valve, the downward linear movement of the helix passing through the roller bars on the top of the ball causes the ball to rotate 90 degrees without physical contact, ensuring friction-free operation.

Regular ball and pin assembly designs often suffer from potential welding-related cracking issues. The new RSBV design eliminates this by employing an innovative weld-free design, enhancing its reliability and longevity. Additionally, we have addressed further weld cracking and thermal expansion concerns arising from the use of different metals with a non-shrink fitted/welded seat design.

The extensively tested Outside Screw and Yoke design is renowned for its reliability and lightweight construction, making it a preferred choice for operations worldwide. As always with Red Point designs, valves are made according to the best fit solution based on each customer’s specifications. The new RSBV design is no exception and comes in a wide range of materials, depending on what’s most appropriate.

Targeting applications where the demand is for a long-serving and reliable valve, Red Point’s latest offering is testament to its heritage of finding innovative and effective engineering solutions to the industry’s problems. As part of Trillium Flow Technologies’ commitment to excellence, the new design is a great example of our ability to bring new ideas to old problems and put forward simple but effective solutions with top-tier products and services.


@Trilliumflow #PAuto

Automate Ai workflows.

Automate model selection while reducing infrastructure costs.

Zerve has announced a partnership with Arcee AI, an industry-leading language model builder and the creators of the intelligent model routing system, Arcee Conductor. The new integration brings model optimisation and automation capabilities to the Zerve platform, enabling data science and Ai professionals to build faster, smarter, and more efficient Ai workflows at scale.

Through the new partnership and integration, Zerve and Arcee Ai enable users to automate Ai model selection within their existing workflows using an OpenAI-compatible API, without incurring infrastructure overhead. Arcee Conductor enhances Ai pipeline efficiency for users by intelligently selecting between small language models (SLMs) and large language models (LLMs) based on input complexity, cost, domain relevance, and other variables.

This collaboration allows data science and Ai engineering teams to:
- Optimise model usage by routing tasks to the most appropriate model, improving accuracy and runtime performance
- Enhance automation by combining Conductor’s routing with the Zerve Agent’s dynamic workflow control
- Maintain seamless integration through plug-and-play compatibility with existing Zerve environments
- Cut costs by deploying lightweight, lower-cost models where applicable

Arcee & Zerve will demo
July 9, 12:00 noon Eastern time.
Watch the livestream here. 

“Partnering with Zerve enables us to bring our intelligent model routing capabilities to a broader audience,” said Mark McQuade, CEO of Arcee AI. “By embedding Arcee Conductor into Zerve's platform, we're helping teams optimise their Ai workflows and achieve better performance at a lower cost.”

Zerve has rapidly become the preferred platform for modern data teams looking to streamline operations and maximise operations at all levels. As an increasing number of enterprises rely on Zerve for real-time collaboration, their development processes are optimised with the solution’s visual workflow design and infrastructure-free Ai deployment. The addition of Arcee Conductor extends these benefits by allowing teams to tap into Arcee’s proprietary SLMs or third-party LLMs from OpenAI, Anthropic, and DeepSeek, within a unified development environment.

“This integration strengthens Zerve’s position as the best place to build and run Ai workflows,” said Phily Hayes, CEO of Zerve. “By incorporating Arcee Conductor, we’re making it easier for our users to create scalable, cost-efficient Ai systems directly on the Zerve platform. It aligns perfectly with our mission to deliver the most powerful tools for data and Ai development.”

This partnership strengthens the ability to orchestrate Ai development intelligently and sets a new bar for performance-aware automation across enterprise-grade Ai workflows.


@arcee_ai #Zerve #AI #Automation

Test bench for airship programme.

Vincent Guibout CEO, Flying Whales & Stephan Lassausse, Managing Director, Emitech Group
The Emitech Group has been selected by Flying Whales under an exclusive negotiation agreement for the development and supply of the PowerWhale test bench, a strategic piece of equipment for the LCA60T heavy airship programme. This collaboration is part of a letter of intent (LOI) signed between the two companies, marking a mutual commitment to move quickly toward a final contractual agreement.

A strategic milestone for the Emitech/Flying Whale collaboration.
The letter of intent signed between the two companies formalizes:

  • The selection of Emitech as the exclusive partner for the development, manufacture and support of the PowerWhale test bench,
  • The launch this summer of an initial engineering study phase, prior to the technical validation (Preliminary Design Review) and contractual stages.

The PowerWhale test bench: a tailor-made test facility for innovation.
The test bench will enable the critical subsystems of the LCA60T airship to be validated in a controlled environment. It will include:

  • Powerful energy sources (AC/DC),
  • A test bench for the battery included in the electrical chain,
  • Active charging systems,
  • A set of multi-physical sensors and software supervision,
  • A modular architecture to support program developments.

A partnership based on trust and technical commitment.
The Emitech Group and Flying Whales are continuing their joint approach with the aim of:

  • Optimizing the technical solutions offered,
  • Securing the budgetary aspects of the project,
  • Supporting the associated public funding mechanisms (CIR, CEE).

This partnership illustrates the Emitech Group's ability to get involved in groundbreaking industrial projects at an early stage, supporting its customers through all the critical stages: engineering, testing, qualification, and long-term support.

“We are proud of the trust Flying Whales has placed in us through this exclusive agreement. Our teams are fully committed to contributing to the success of the LCA60T program.”Stephan Lassausse, CEO of the Emitech Group


 @EMITECH_SA @_FLYING_WHALES_ @mepaxIntPR #Transport #TandM #France 

Analog becomes Digital.

Converter digitises up to three analogue signals – compact, rugged, and ideal for retrofits in harsh industrial environments.

Analog sensors remain a staple in many industrial environments – reliable and robust, but not digitally connected. To help bring this legacy technology into modern automation systems, STEGO has introduced the IOC 074 IO-Link Converter. This compact device transforms analog signals into digital process data and transmits them via the IO-Link protocol – enabling efficient retrofitting of existing infrastructures.

The IOC 074 is the first IO-Link converter on the market capable of digitizing up to three analog signals (4–20 mA and 0–20 mA) simultaneously. With dimensions of just 14 mm in diameter and 63 mm in length, it is perfectly suited for tight installation spaces, control cabinets, enclosures or compact system layouts. Its stainless steel housing is rated IP65, IP66, and IP67, offering reliable protection even in harsh industrial environments.

Installation is straightforward: the converter is connected between the analog sensor and the IO-Link master using standard M12 connectors and cables. A universal pipe clip is included for secure and flexible mounting.

No calculations needed.
Configuration is fully software-based using IO-Link tools such as “LR-Device” and the corresponding IODD file. Users can easily define measurement ranges for temperature, pressure, or other physical parameters.

The IOC 074 handles the scaling automatically and supplies pre-processed values to the control system – with no need for manual conversions or additional hardware. This makes it a user-friendly solution that integrates seamlessly into existing infrastructures and significantly simplifies commissioning.

Future-ready retrofit.
For machine builders, plant operators, or retrofit projects in manufacturing, the IOC 074 delivers real added value: analog sensors can be upgraded to IO-Link with minimal effort. This not only enables integration into modern control systems but also enhances process transparency and operational efficiency. This is a smart, straightforward, and cost-effective path toward digitalization in industrial environments - a practical answer to the challenges of connected manufacturing.


@UkStego @stego_de @PresseBox #PAuto #Manufacturing

Thursday, 26 June 2025

Battery trading in Japan backed by Ireland.

First battery has gone live in Japan’s Energy Market.

GridBeyond has officially commenced energy trading in Japan using a front-of-the-meter (FTM) battery asset. The announcement was made on June 24 during the Ireland Innovation Seminar hosted at the Embassy of Ireland in Tokyo, where GridBeyond presented alongside its local partner, PORT Inc.

Ahead of the announcement, PORT successfully brought online a 2 MW / 8 MWh grid-scale battery located in Gunma Prefecture. This asset marks GridBeyond’s first active trading project in Japan and serves as a launchpad for a broader portfolio of battery projects scheduled to go live between 2025 and 2028.

The event was also attended by Ireland’s Minister for Enterprise, Tourism and Employment, Peter Burke TD, who made the following remarks regarding the collaboration between the two companies: “Ireland is a global-leading innovation hub, particularly in digital fields such as AI and energy tech. GridBeyond is one of our key companies, a leading example of an Irish advanced technology and sustainable business. The launch of this new initiative in Japan, a critical growth market for the Irish economy, in partnership with PORT, is a testament to the global value of Irish technology, and we are extremely proud of this work. I look forward to seeing both companies achieve further success in contributing to Japan’s decarbonisation and energy optimisation.”

PORT, whose mission is “Transforming social debt into future opportunities,” announced its entry into the FTM battery power plant sector in March. This move aligns with Japan’s 2050 carbon neutrality goal and the country’s accelerating adoption of renewable energy. Since then, PORT has been working closely with GridBeyond to optimise battery operations.

Commenting on the project launch, PORT’s President and CEO Hirofumi Kasuga said: “This first trading milestone not only strengthens our business foundation but also marks a significant step toward large-scale battery deployment in Japan. Our collaboration with GridBeyond goes beyond a technical partnership—I believe it opens up new potential for the energy market as a whole. Together, we aim to expand installations and usage of energy storage systems, contributing to a more sustainable energy infrastructure.”

Atsushi Ito, Country Manager at GridBeyond GK (Japan entity), added: “In addition to grid battery operations, we are rolling out strategies that support flexibility on both the supply and demand sides, such as CHP optimisation, demand response using data centers, and AI-powered energy asset management. By leveraging our overseas expertise and adapting our services to Japan’s unique market structures and regulations, we aim to earn the trust of even more customers.”

GridBeyond is committed to delivering flexibility services in Japan and accelerating efforts to support the country’s decarbonisation goals as a trusted long-term partner.


@GridBeyond_ @Entirl @peterburkefg @IEAmbJapan @IrelandatExpo #PAuto #Energy #Japan #Ireland 

Ethernet-APL proves its value.

Expanded testing shows broad industry adoption.

Ethernet-APL has moved beyond readiness. Endress+Hauser has successfully conducted another set of load tests of a realistic PROFINET over Ethernet-APL setup. Two years after the last successful multi-vendor tests, the technology has proven its strength again in a realistic simulation.

The load tests were tailored to meet customer-specific requirements, demonstrating that components from various manufacturers can seamlessly work together to build a robust and reliable system based on PROFINET over Ethernet-APL. Requirements were defined from the end-user perspective by the global chemical company BASF. On the supplier side, devices from Endress+Hauser, Pepperl+Fuchs, R. Stahl, Phoenix Contact, and Samson were integrated into an Emerson control system and their interoperability was confirmed.

Ethernet-APL proves consistently high performance.
Two years after the first set of successful tests with other automation systems, Emerson DeltaV was in scope of the mass load test with nearly 240 Endress+Hauser measuring devices, including flow, pressure, temperature and level sensors, as well as positioners from Samson. They were tested in a ring topology consisting of Ethernet-APL field switches from Pepperl+Fuchs, Phoenix Contact and R. Stahl. Emerson provided the control system DeltaV DCS including PROFINET System Redundancy (S2) support as well as the AMS Device Manager System.

The results spoke for themselves: Ethernet-APL performs reliably under full-scale conditions. The test scenarios on a network with the maximum number of devices successfully verified both, performance and reliability with the Pepperl+Fuchs switches. Key performance metrics - such as total net load and redundancy switchover times - met and even surpassed the required standards.

The field switches from Phoenix Contact were subsequently subjected to similar tests and were able to demonstrate their performance. The pre-series switches from R. Stahl were tested as well and based on the valuable results, the optimised devices will be now available for the market launch.

Gerd Niedermayer, Senior Expert Emerging Automation Technologies at BASF extends his gratitude: “Thank you to Endress+Hauser for the opportunity to conduct the scalability tests with our PROFINET-APL partners. With the help of their digital field devices, we are able to optimize diverse topics centering around engineering, commissioning and lifecycle in BASF plants and save CAPEX and OPEX costs.”

A technology with a bright future ahead.
“With the success of the recent scalability test, the cooperating companies have again proven that the multi-vendor infrastructure is open, future-proof and ready for the Industrial Internet of Things (IIoT)”, emphasizes Harald Müller, technical lead of Ethernet-APL and director technology at Endress+Hauser Temperature+System Products. This gives planners and end users further evidence that Ethernet-APL is an enabler to create more flexible, efficient and cost-effective industrial automation systems, leveraging the full scale of benefits through digitalisation.

Karl Büttner, expert product manager system integration and marketing lead of Ethernet-APL at Endress+Hauser Flow, is proud and excited about the proven success of this technology: “Since 2023 we provide instrumentation for Ethernet-APL projects worldwide. Endress+Hauser is pleased with the successful launch of the technology, which helps our customers to digitalize their process plants.”

Endress+Hauser’s PROFINET support for Netilion is an additional step to support the Ethernet-based communication. It ensures remote access for example to process values and health diagnostics for all native and PROFINET-APL devices, ensuring high plant availability.

Ethernet-APL, already backed by a wide ecosystem, sees even more devices and manufacturers coming on board. The high market demand and worldwide successful implementations in the first medium-sized and large projects prove that Ethernet-based field communication in process automation has a bright future.


@Endress_Hauser @Endress_IN @Endress_UK @Endress_US #PAuto #Ethernet

Miniature size integrated servomotor.

Applied Motion Products Inc. (AMP) has expanded its TSM StepSERVO™ integrated motor line with a brand new, truly miniature, NEMA 8 frame model – the USA based motion control leader’s smallest all-in-one closed loop servo motor, drive and controller combination. Available with full support from Mclennan, the TSM08X3L-R is perfectly suited to distributed, space-constrained motion control applications, delivering higher accuracy, acceleration and torque than open-loop stepper motor-based solutions with much improved energy efficiency. Measuring just 61 mm in length with a 16 mm square face mounting and 20 mm square frame the diminutive motion solution features several different external control modes and built-in I/O as well as programmable on-board memory for maximum application flexibility.

Powered from an external 24 VDC supply the TSM08 delivers 0.05 Nm holding torque and a 30% torque boost capability (0.5 seconds) whilst a 16-bit magnetic, single turn absolute encoder has a 20000 pulse per rev resolution for a static positioning accuracy of up to ±0.018°. Real-time position correction provides improved dynamic accuracy. Operating modes for this all-in-one motion solution cover dual RS-485 ports for configuration, programming and daisy-chain networking for Modbus RTU as well as communication with PLCs and HMIs. The TSM08 also features stand-alone capability using AMP’s Q programming software with pre-programmed command sequences stored in non-volatile memory for motion, I/O, conditional processing, multi-tasking, math functions, and more. A complement of 4 high-speed (1 MHz) digital inputs and 2 digital outputs (5-24 VDC) may be utilised for connecting pulse & direction signals, end-of-travel limit switches, quadrature encoder signals, PLC outputs, sensors, or other signal types.

The TSM08X3L-R is available in two versions: a single connector model or multi connector model (power, I/O and communications) – the latter simplifies daisy chaining and Modbus RTU set-ups. Configuring the TSM integrated motor is made easy using AMP’s StepSERVO Quick Tuner package which is built into the Q Programming software. Compatible power and daisy chaining cables make for straightforward commissioning and Mclennan are on hand to add compatible motion and automation controls, precision gear units or other ancillary components where required.

AMP’s TSM series StepSERVO integrated motors are also available in larger frame sizes from NEMA size 11 to 34 packages with torque output up to 8 Nm, motor speeds up to 3600 rpm and encoder resolutions of 20,000 counts/rev. A wide selection of control and interfacing options including Ethernet, EtherNet IP and CANopen as well as the above-mentioned facilities make the range suitable for a very wide range of motion control applications.


@ampmotion @mepaxIntPR #mclennan #PAuto

Wednesday, 25 June 2025

Modular product for drive solutions.

Tailor-made drive solutions for a wide range of requirements.

NORD Drivesystems offers countless combinations of motors, gear units and drive electronics components with its range of modular products. The company develops drive solutions that perfectly address the needs of more than 100 industries.

Whether conveying goods, mixing dough or lifting heavy loads: every movement needs drive. However, different applications have different requirements. As a developer of drive solutions, NORD offers via its modular product range all components of drive technology that can be combined in various configurations. NORD implements the appropriate selection, design and calculation of the drives. Drive systems consisting of gear unit, motor and drive electronics thus become tailor-made solutions for specific industry applications. Hence, NORD is able to fulfil a wide range of specific requirements.

A modular system offering numerous solutions.
One example is the requirement for energy efficiency. NORD has electric motors that can be used worldwide and comply with all relevant international regulations. With its IE5+ synchronous motors, the developer surpasses the efficiencies of the currently highest defined energy efficiency class (IE5). They are also part of the integrated gear unit/motor concept DuoDrive that combines the IE5+ motor with a single-stage helical gear unit in one housing. DuoDrive achieves one of the highest efficiencies on the market within this power class. Users also benefit from NORD's expertise and additional services, such as the NORD ECO efficiency analysis that allows the implementation of upcoming drive tasks with optimal energy consumption.

Another current example is condition monitoring that NORD can integrate into its drive solutions. With an IIoT solution, it is possible to determine and analyse drive and status data via the integrated PLC of the frequency inverter. The data can also be made available to the central systems of the users. This provides important information for predictive maintenance, allowing machinery and equipment to be maintained proactively, while reducing downtimes and increasing overall system efficiency.

“Requirements are changing – and we are actively following this path” reports Jörg Niermann, Head of Marketing at NORD. “We are continuously developing our drive components to provide our customers with solutions that help them progress technically, economically and environmentally.” By combining a wide modular product range with technical expertise and knowledge in more than 100 industries, NORD creates drive systems that are tailored to specific needs and delivered as complete solutions from a single source.


@NORD_Drive @mepaxIntPR #PAuto #Drives

Hardware-based security in South Korea

Xiphera has entered into a strategic partnership with South Korea–based Austin Electric Co., Ltd. This collaboration will extend Xiphera’s advanced cryptographic IP core solutions to a broader customer base in South Korea, especially in the aerospace, industrial automation, critical infrastructure, IoT, and automotive sectors.

This partnership is an important milestone in the company's international growth and reinforces the company’s commitment to delivering robust, transparent, and future-proof cryptographic solutions to customers around the world.

Xiphera designs and develops all its cryptographic solutions entirely in-house. Its mission is to help customers secure their systems against the growing spectrum of cybersecurity threats—including those emerging from the era of quantum computing.

“At Xiphera, we focus on building highly secure and optimised cryptographic IP cores for ASICs and FPGAs,” said Tommi Lampila, Chief Revenue Officer at Xiphera. “Our hardware-based security solutions are engineered to protect critical systems from data breaches, unauthorized access, and the evolving threat landscape. Through our partnership with Austin Electric, we can now serve the South Korean market more effectively with trusted, high-performance security technology.”

Driving secure semiconductor innovation in South Korea.
South Korea’s semiconductor industry—valued at USD 115.7 billion in 2024—is one of the most advanced in the world and is expected to more than double by 2034. As a key player in chip manufacturing, South Korea plays a pivotal role in driving secure digital infrastructure. Xiphera contributes to this ecosystem by offering cryptographic IP cores that embed security directly into silicon—ensuring that protection is foundational, not an add-on.

Austin Electric, a well-established electronics company based in South Korea, will represent Xiphera locally and support the integration of its cryptographic IP solutions across Korean industry verticals.

Korea is a technology leader in IT, automotive, and semiconductor industries, and recently entered the Industrial 4.0 revolution, so we believe that Xiphera's semiconductor (hardware) based encryption and cyber security IP solutions will play a great role across AI, military defense, IoT, smart home appliances, and smart factory industries, and we are confident that the Korean market will be a stepstone for us to expand globally.” said Kenny Yoon, CMO of Austin Electric.


• See also: Innovation in cybersecurity. (22/5/2025) 

@xiphera #AustinElectric #PAuto #Cybersecurity #Korea

Tuesday, 24 June 2025

Battery energy storage system (BESS) solutions.

Energy and asset management software improves return on investment.

The release of specialised battery energy storage system (BESS) solutions featuring energy and asset management software for Emerson's Ovation™ Green portfolio of renewable energy solutions has been announced. Combining field-proven, purpose-built power plant controllers, energy management strategies and supervisory control and data acquisition software (SCADA), Emerson’s BESS solution connects devices and systems across manufacturers, aggregating and contextualising battery storage data into actionable insights to help optimise battery usage and extended battery life, enabling higher profitability, efficiency and sustainability.

Emerson’s Ovation Green BESS solutions will be on display at the Ovation Users’ Group conference, on July 27-31, 2025, in Pittsburgh, USA

The global battery energy storage market has reached an inflection point as technology advancements and global demand for sustainable electricity drive increasing value in renewable energy storage and grid management. As the International Energy Agency forecasts global electricity demand to grow at close to 4% annually through 2027, grid operators are bracing for increased load demand – a shift that will create dynamic changes in energy markets. Battery storage sites can capitalise on this market shift, but only if they can navigate the complexities of battery energy storage operation: siloed data, higher maintenance costs and a need for flexible operation to allow for safe, effective and efficient demand management.

“Today’s energy producers are increasingly creating hybrid projects with multiple renewable energy types – solar, wind, battery and more – aggregated together,” said Bob Yeager, president of Emerson’s power and water business. “This wide array of options empowers them to get the best return on investment, whether supplying energy directly to the grid in times of high demand or storing it when demand is low. Capitalising on constantly shifting markets means switching operating modes quickly on demand. This in turn requires a powerful, proven battery energy management system that integrates seamlessly with the site’s SCADA system.”

Ovation Green BESS solutions include an advanced, specialised battery algorithm suite that streamlines battery control through out-of-the-box, customisable function blocks that distribute proportioned setpoints to individual components such as inverters and battery management systems. The resulting control strategy automatically optimises charge and discharge cycles and grid interactions for fast, precise and reliable demand management.

Emerson’s collaboration with Zitara Technologies*, a leader in advanced battery management software, expands Ovation Green BESS capabilities by integrating cutting-edge battery management with the industry-leading Ovation Automation Platform. The enhanced solution provides operators with instant and accurate visibility into the state of charge and health conditions for batteries, improving the site’s energy power and availability forecasting and adding predictive safety features.

Through increased visibility and more granular control of all batteries, BESS owners and operators can achieve optimised battery usage and extended battery life, enabling higher profitability, efficiency and sustainability. In addition, the more standardised, repeatable approach to battery energy management enables faster deployment across multiple sites, reduces site visits and ensures consistent operations by eliminating the need to train every operator on a wide variety of OEM battery management interfaces.



@EmersonExchange  @Emerson_News  @EMR_Automation @HHC_Lewis #Zitara #PAuto #Battery

Water quality centre.

A new water quality service centre has been inaugurated by Meteor Communications. It is 250% larger than their previous facility. “This expansion reflects the rapidly growing demand for remote river and final effluent monitoring systems, and in particular the continuous water quality monitoring requirements of the Environment Act 2021, Section 82,” explains Managing Director, Matt Dibbs.

Meteor provides a maintenance and calibration service for many of its customers, either as a service contract or as part of its ‘Water Quality as a Service’ offering. “This means that we have staff operating all over the UK, managing hundreds of multiparameter water quality sondes that mostly have to be swapped for recalibration on a monthly basis,” Matt explains. “We have therefore developed a highly efficient process in which large numbers of sondes can be cleaned, serviced and calibrated as quickly and as effectively as possible. However, such has been the demand for these services that we have invested in this new, much larger facility at Andromeda House in Aldermaston.

The company’s remote water quality monitors, known as ESNETs, were initially developed to meet the requirements of the British Environment Agency for continuous river water quality monitoring. However, in recent years ESNETs have become popular with a much wider group of organisations, all of which are seeking to enhance the protection of the countries rivers.

Looking forward, the demand for ESNET systems is set to grow further: in compliance with the Environment Act 2021; to provide monitoring data for the baseline, construction and operation phases of development, and as water and sewerage undertakers find new ways to exploit the benefits of real-time multiparameter water quality data - in final effluent for example.

Summarising the investment justification for Andromeda House, Matt says: “Accurate continuous water quality data is extremely important for many different stakeholders including regulators, water companies, farmers, consultants, engineers, researchers and members of the public such as wild water swimmers, anglers and paddle boarders. However, reliable measurements can only be achieved if the monitors are maintained and calibrated correctly, so Meteor is making the necessary investments in staff, training, equipment, vehicles and a highly efficient calibration and service laboratory. The development of the new Aldermaston facility means that we will be able to meet the demand for remote water quality monitoring for many years to come.”


@MeteorComms @_Enviro_News #Environmental #Water #Britain

Industrial Ethernet switch an I/O & Networking winner.

Industrial enterprises are increasingly digitizing operations by connecting and automating critical network infrastructure. This shift aims to streamline processing, improve efficiency, and enhance data-driven decision-making. Managed Ethernet switches are the cornerstones of these initiatives, acting as a central hub, connecting multiple devices to form a LAN or connect to a broader network infrastructure.

The Antaira LMP-0702G-SFP-24-T-V2 Managed Gigabit PoE Industrial Switch is designed for this task. As a fully manageable Light Layer 3 switch, it streamlines connectivity through four Gigabit RJ45 ports with PoE+ (30W) power delivery, two dual-rate SFP fibre slots for long-distance communication, and a single non-PoE Gigabit port. A low-voltage internal booster enables it to supply full PoE+ to critical devices, such as IP cameras, WAPs and sensors, in environments where power input ranges from 12 to 55VDC, including cabinets where 24VDC is common.

Antaira’s emphasis on providing its customers with the most secure, reliable solutions is demonstrated in the LMP-0702G-SFP-24-T-V2. It offers highly configurable features for network optimization and redundancy with support for ITU-T G.8032 Ethernet Ring Protection Switch (ERPS) protocol that has a <50ms 802.1x="" access="" activity.="" administrators="" allowing="" and="" authentication="" control="" elevate="" for="" leverages="" monitor="" network="" p="" port="" protection="" qos="" recovery="" restrict="" security="" segment="" switch="" the="" time.="" to="" unauthorized="" vlans=""> NAT has been added to the V6.2 firmware. NAT is used for communications between networks by translating IP addresses and port numbers from one network to IP addresses and port numbers in another network by modifying the IP packet header as it transits the inside local VLAN interface to the outside global VLAN interface. NAT Options on Firmware Version 6.2 include; Static NAT: 1-to-1 address translation, Overloading (PAT): 1-to-many port address translation, Port-Forwarding: Allows remote hosts with global IP addresses to connect directly with hosts on the private network.

Built for industrial application settings with an IP30 DIN-Rail mountable metal housing, the LMP-0702G-SFP-24-T-V2 withstands extreme temperatures (-40° to 75° C), as well as high exposure to high EFT/ESD.

Bronze Award Winner.
This industrial switch recently earned a bronze award in the I/O & Networking category of the Control Engineering 2025 Product of the Year program. Being recognized by an audience of engineers and automation professionals solidifies the LMP-0702G-SFP-24-T-V2 as a key PoE network switch for automation applications. This award demonstrates Antaira's commitment to advancing networking solutions that transform industrial operations, enhancing productivity, reliability, and security, while laying a foundation for the Industrial IoT.

"We are deeply honored to be recognized by the renowned Control Engineering 2025 Product of the Year awards for our groundbreaking LMP-0702G-SFP-24-T-V2. This award recognition reinforces Antaira's commitment to offering a comprehensive portfolio of industrial-grade solutions that maximize customers' investments by solving their most pressing network needs,’" said Joe Cook, General Manager America’s at Antaira Technologies.

The Control Engineering Product of the Year program highlights the best new control, instrumentation, and automation products as chosen by Control Engineering’s print and online subscribers. It is widely recognized as a benchmark for excellence in the controls and automation industry.


@AntairaTech @OConnell_PR @ControlEngTips #PAuto  #Ethernet

Beam alignment.

Laser Components has added the third edition to the PR Series – IR THz Receivers, enabling real-time beam displacement measurements using the PR No3. This uncooled 4-quadrant pyroelectric receiver expands on the previous editions by implementing a unique 2.0 mm round active area, divided into four segments, with vertical and horizontal side lengths at 980 µm × 980 µm, separated by a small gap.

The PR No3 delivers consistent performance over a wide spectrum, from the ultraviolet (UV) to the far-infrared (FIR). The device includes four individual analog outputs, excellent channel-to-channel uniformity, and precise quadrant alignment relative to the housing. Make full use of the PR No3 in applications like beam positioning with at 50 kHz -3 dB bandwidth (typical for the IR version), long beam path experiments, calculating fast pulse-to-pulse fluctuations, and hysteresis correction in scanning systems.

The two configurations available include the PR No3 IR that supports wavelengths up to 30 µm, and the PR No3 THz designed for frequencies down to 40 GHz with 10x higher responsivity at an 8kHz bandwidth. Both versions of the PR No3 are individually calibrated for responsivity and noise over frequency, offering a plug-and-play solution for traditionally difficult IR systems.


@LCGermany @lasercomp_uk @PresseBox #Automation

Next-level gas detection safety .

New portable dual-gas instrument detects two gases simultaneously.

Teledyne Gas & Flame Detection (Teledyne GFD) new PS DUO is a portable dual-gas detector set to enhance personal safety in gas monitoring applications. This innovative handheld device features real-time monitoring with audible, visual (bright LED) and vibrating alarms, providing immediate alerts when gas levels exceed safety thresholds.

The new PS DUO uses passive diffusion sensing for the continuous detection of harmful gases in potentially hazardous environments, enhancing safety for personnel. It can monitor two gases simultaneously from a wide selection that includes carbon monoxide (CO), hydrogen sulphide (H₂S), sulphur dioxide (SO₂), ammonia (NH₃), oxygen (O₂), hydrogen (H₂), nitrogen dioxide (NO₂) and ozone (O₃).

Users of the ATEX/IECEx-rated PS DUO can select flexible gas pairings according to their specific application. The result? Enhanced safety, flexibility and peace of mind in the field, backed by a 2-year warranty.

For applications in regions such as the Middle East, H₂S/ SO₂ capability will prove especially useful. The PS DUO offers a measuring range for H₂S of 0~100 ppm with 0.1 ppm resolution, while 10 ppm and 15 ppm represent the low alarm and high alarm respectively. For SO₂, users can take advantage of 0~20 ppm measuring range, 0.1 ppm resolution, 2 ppm low alarm and 5 ppm high alarm.

The LCD display provides continuous real-time gas concentration information, while the internal memory supports up to 30 alarm logs. Wireless connectivity allows seamless data retrieval and safety system integration.

Of particular note is the instrument’s rugged, IP67-rated rubberised enclosure, which combines with an ergonomic, compact (56 x 89 x 21mm) and lightweight (200g) design for optimal user comfort, convenience and safety. The PS DUO will operate for up to 2 years on a single replaceable battery under normal use.

“With its reliable performance, flexible gas pairings and wireless integration, our PS DUO offers a powerful new option for industrial safety programmes - backed by Teledyne’s global service and support,” states Pawel Kulik, Product Manager-Portables, Teledyne Gas and Flame Detection. “It adds to an existing and highly successful range of personal safety and gas monitoring solutions that includes our portable Protégé ZM and PS200.”

Available in O₂, CO, H₂S and SO₂ models, the easy-to-use Protégé ZM (Zero Maintenance) single-gas monitor delivers high performance in a small, ergonomically designed package. Offering proven reliability in the field, industrial workers and first responders gain the confidence to focus on the task at hand, not on their equipment.

Teledyne GFD’s PS200 four-gas compliance monitor is compact, lightweight, water resistant and extremely robust. This user-friendly device is a proven performer in hazardous locations with its ability to measure any combination of LEL (Lower Explosive Limit), O₂, CO and H₂S. The PS200 pumped gas detector features an internal sampling pump for optimal use in confined space applications.


@mepaxIntPR #TeledyneGFD #PAuto #Safety

Monday, 23 June 2025

Breakthrough light source for spectroscopy applications.

Combines high brightness and high spectral stability enabling high sensitivity & short integration times

SuperLight Photonics has announced a major advancement in industrial spectroscopy with its compact, high-performance light source, purpose-built for the most demanding high-speed measurement applications.

Spectroscopy is a powerful analytical technique that measures how materials interact with light - through absorption, transmission, or emission - providing detailed insights into their chemical composition and physical properties.

Many of today’s spectroscopy systems use halogen light sources, which couple poorly into optical fibers, resulting in significant power loss. To compensate, they require long integration times, making them unsuitable for fast-paced industrial or medical applications. Wideband lasers offer far more efficient fiber coupling, delivering significantly higher brightness than halogen sources. However, traditional wideband lasers suffer from spectral instability, which often requires averaging across thousands of pulses. This again limits their use in high-speed industrial environments where real-time performance is critical.

Designed to transform spectroscopy in production environments, SuperLight Photonics’ latest solution delivers exceptional results compared to traditional light sources. Its spectral stability is unprecedented relative to legacy supercontinuum lasers, and its brightness outclasses halogen-based alternatives. Its combination of high sensitivity, short integration times, and its miniaturized, portable form factor enables rapid inline spectroscopy analysis.

Jeroen Biesterbos, CCO of SuperLight Photonics states: “Our technology delivers an alternative light source to traditional halogen and laser-based spectroscopy systems. By combining exceptional spectral stability, high brightness, and a compact form factor, we enable real-time, inline testing and analysis, bringing high-performance spectroscopy directly to the production line for demanding industrial applications.”

Key advantages of the SLP-1050 Wideband Light Source:

  • Fast, real-time measurements to support high-throughput industrial processes
  • Superior spectral stability, the SLP-1050 improves spectral stability by an order of magnitude vs. legacy supercontinuum sources
  • Class IIIb laser enables use in manufacturing environments with minimal safety requirements, allowing operation by non-specialist personnel
  • Effortless integration for easy adoption in OEM and industrial setups
  • Compact design optimized for space-constrained setups and integration into portable or mobile instruments
  • Ideal for inline spectroscopy, ensuring process control without interruption

"This new generation of wideband light source is set to drive higher quality control standards in sectors such as semiconductors, pharmaceuticals, food and beverage, and materials manufacturing."


#Superlight #TandM #Photonics #Spectroscopy 

Friday, 20 June 2025

Monitoring at the bar!

Off-grid monitoring solution for remote Cornish location.

The Loe Bar in Cornwall is a shingle and flint bank that separates the sea from Loe Pool, presenting an unusual set of challenges in both flood risk management and environmental protection. In the following article, Rob Rhyder from Nivus explains here how a bespoke monitoring solution was developed for the Environment Agency (EA) to meet the specific requirements of this unique location.

Background.
Situated within an Area of Outstanding Natural Beauty (AONB) in Cornwall, Loe Pool is fed by the river Cober and a number of smaller streams. Both the pool and the bar are designated a Site of Special Scientific Interest (SSSI) due to their unique wildlife and habitat.

As the most southerly town on the island of Great Britain, Helston sits on the banks of the River Cober, upstream of Loe Pool, and has experienced significant flooding in the past. Loe Pool is Cornwall’s largest natural freshwater lake, protected by Loe Bar which is approximately half a mile in length. However, the bar is geographically remote and exposed to the ferocity of the Atlantic Ocean, so environmental monitoring equipment needs to be able to operate in harsh conditions, without mains power, and with limited communications connectivity.

Historically, Helston’s flood risk resulted from backing up in the Loe Pool and the River Cober, so alleviation measures primarily included the emergency creation of a relief channel in the bar. However, this was obviously a hazardous operation, so in the 1980s and engineered outflow was created in the form of a concrete pipe, installed to operate as an overflow for the pool. The pipe allowed excess water to drain from the pool through the bar, but was overwhelmed by river flows during high flow events. This necessitated expensive and invasive over-pumping operations that also had a significant lead-in time to bring all the equipment to such a remote site. In addition, as a result of high tides and extreme weather, the outfall of the pipe was largely blocked by sand and shingle, which had to be removed during periods of flood risk. This process was inefficient, costly and time-consuming, so a second engineered outfall was developed.

Engineered outflow solution.
The second, more advanced outflow was built in 2020 to largely eliminate the requirement for over-pumping. The additional capacity provided by the second pipe meant that the pool drains by gravity rather than costly and carbon-intensive pumping operations. “The new outflow featured penstocks, pumps, flow monitors and remote communications, and was developed to provide a number of important advantages,” says Will Hancock, Project Lead at the EA.

Level and flow monitors were installed in the River Cober, the Loe Pool and in the new outfall pipe. “This provided us with the ability to monitor the site remotely,” Will explains, “which meant that less site visits were necessary, lowering project costs and carbon footprint, and enabling us to respond to flood risk in a faster and more timely manner.”

The new monitoring system was designed to detect the excessive accumulation of water in the pool, so that the second outflow could be implemented when necessary. Under such circumstances, an excavator is used to expose and open the outfall cover before the sluice gate is opened and the pumps are allowed to remove water from the pool, for discharge to the beach. Over the last 5 years, the second outfall has been opened on two occasions.

New flow monitoring technology.
Prior to the installation of the new monitoring system from Nivus, flow was measured in Helston and in the discharge pipes with a traditional Doppler flow meter, and the failure of one of these units provided the EA with an opportunity to review and upgrade the monitors.

Explaining the evaluation process, Will Hancock says: “These measurement instruments perform a critically important function. Not only do they help manage the Loe Pool to lower flood risk, they also feed data into our flood forecasting model, so it was essential that we utilise accurate, reliable instrumentation.”

The EA has extensive experience with flow measurement technologies, including the cross-correlation method from Nivus, so it was determined that this would be the appropriate solution for the discharge pipes and the river monitor. The key advantage to this area velocity flow measurement technique over the instruments which it replaced is that it provides a 3-dimensional flow profile that is calculated in real-time to provide reproducible and verifiable flow values in full or partially filled channels or pipes. Older Doppler methods are less accurate because they only measure 2-dimensional flow.

The method utilises particles, minerals or gas bubbles which act as reflectors within the water body. Reflections are saved as images or echo patterns, and compared with a further scan which is conducted a few milliseconds later. Velocity is determined by measuring the beam angle of the positions of unambiguously identifiable reflectors. The method produces highly accurate readings without the need for additional calibration.

Explaining the background to the decision to invest in a cross-correlation solution, Will says: “The Nivus equipment has been assessed by the EA, and we now run both fixed and portable versions of the technology. Nivus is also a Framework Partner, so the procedure for implementing this solution was relatively simple, despite the specific challenges that this site presented.”

Uniquely challenging environment at Loe Bar.

As a remote location Loe Bar does not benefit from easy access to utilities, so it was necessary for the monitoring solution to be able to operate off-grid; solar/battery power was therefore adopted. The solution also needed to be sufficiently rugged to be unaffected by its proximity to the beach. “Nivus proposed a complete low-power solution, which calculated the power requirements and specified the solar generation capacity that would be necessary to ensure continuous monitoring in all weathers,” Will explains. “The solar panels were fitted at an angle to the sea, which was less ideal for power generation, but necessary to avoid potential damage from sand-blasting.”

Special low-power versions of the Nivus equipment were also deployed. For example, a Nivus NF750 transmitter employs low-power electronics, and consumption is minimised by setting the monitor to sleep, then wake up after 15 minutes to take a measurement, and then return to sleep mode.

For redundancy purposes, two Nivus CS2 bed-mounted, cross-correlation sensors were fitted in each of the discharge pipes, and the same dual-sensor redundancy arrangements were established in the river flow monitor at Helston, albeit in a cross-channel configuration.

The EA’s standard remote communication equipment was installed inside a kiosk along with the transmitter, a multiplexer, rechargeable batteries and a solar power regulator.

Access to the monitoring site is also limited. The closest that EA vehicles can access is 200m away, so any site visits would necessitate manual portability for any necessary equipment. Access to the monitoring locations within the pipes is also potentially hazardous – necessitating breathing apparatus and other PPE. Fortunately, therefore, the newly installed monitoring system does not require regular service or calibration.

Summary.
Nivus installed the new monitoring system in March 2025, and Will says: “The performance to-date has been good – there have been no outages and there have been no requirements for a site visit. We performed manual checks on the monitors using a portable NivuFlow Stick and they are monitoring very accurately, representing a significant improvement on their predecessors. It is also comforting to know that we have the redundancy measures in place.”

Looking forward, Will says: “Given the importance of the Loe Bar as an ecological asset, and of flood management in Helston, we are delighted with the performance of the monitoring system, and will be applying for the Loe Pool and Bar to be recognised as a ‘Strategically Important Asset’.

“At the EA, we are accustomed to managing remote sites, but Loe Bar is probably one of our most challenging locations, so it has been gratifying to be able to establish a robust, reliable, and off-grid solution to meet the twin goals of environmental protection and flood risk reduction.”


@_Enviro_News  #Nivus  #MCERTS #Wastewater #Environment #Britain