Hydrogen is one of the most promising alternative energy sources, also in the automotive sector. Linde Engineering has developed a unique hydrogen fuelling station, based on liquid hydrogen supply (LH2) which is applied in USA. Spangler was responsible for the electrotechnical conception of the prototype as well as further development to series production.

UL certification opens doors
As Spangler has continuously applied EPLAN Electric P8 and Pro Panel, the complete control panel technology, from the 3D design to the digital wiring via Routing was perfectly designed in accordance with the customer’s requirements. Thus, it was ensured that the prototype was already made ready for series production in the early project state. SPANGLER Automation could make use of its strengths: “With our certification at UL Germany, we can produce plants for the North American market according to standard UL508A (Industrial Control Panels) “, says project manager Andre Spitzner. Due to the final application in the United States, this was a basic requirement of the project.

From the conception to the test phases
Every fuelling unity consists of a container with two control panels. These were arranged in a way that both for the users of the gas station as well as for the service and maintenance staff, their own 15-inch touch panel from the Siemens TP-Serie is available for operation. In addition, with the application of an outdoor panel it was guaranteed that in case of direct solar radiation it is possible to safely start and supervise the filling process. The control of the individual aggregates and the evaluation of the sensor system takes place via a failsafe Siemens PLC S7-1516F control.

Project-specific details, which were developed in close cooperation with Linde Engineering, are visible at the construction of the control cabinets. Among other things, Spangler took care that the network components of the end customer can be easily retrofitted. According to the requirements of the explosion protection, the containers were divided and segmented; safety barriers and Ex i-probes were applied. Thanks to this sophisticated concept, the explosion protection measures could be reduced to a minimum. Looking ahead to series production, test systems, which were specifically made, were applied, which simulated the drive technology and the sensor technology and thus guaranteed a 100% output test within a very short period. As some aggregates are only available at the final site of operation, Linde Engineering uses these test systems already with the installation and trial run of the container in its plant. Besides the electrotechnical conception, a huge part of the development effort was also put in the adaptation of the documentation to the US-American standards.  With respect to the way of presentation in North America, this included the comparison of the IEC symbols to the symbols of the UL NEC and the structuring of the wiring diagram, in accordance with customer’s wish.

Long-term partnership
“At the end of last year, Linde Engineering informed us that the first gas stations were successfully put into operation and that there were already enquiries for follow-up projects “, reported Daniel Götz, responsible sales employee at SPANGLER Automation. He is pleased about the now long-term partnership with Linde Engineering. In the meantime, another 15 batches were produced and already delivered. The series production is under way.

In order to achieve the generally defined goal of phasing out coal and due to the amendment of the sewage sludge regulation, the combustion of sewage sludge instead of coal as a fuel is a good alternative. For this reason, two belt dryers with a yearly capacity of 80.000 tons were installed at a plant of an energy provider for increase of capacity. SPANGLER Automation planned, produced and programmed the automation technology on behalf of HUBER SE Berching.

Comprehensive performance package with tight schedule
„The project was very comprehensive. Besides the two new belt dryers, the control technology comprised the corresponding air circulation system, the conveyance of the wet and dry sludge as well as the exhaust air treatment “, Anton Höcker, Spangler Project Manager reported. Beyond that, a power station drawing system was implemented so that with every message in the control system it can be recognized which module in which area has caused the message. In addition to the technical scope the building time of only four months was very tight, for everything – from the machine technology to steel structures and cabling to start-up and bus connection.

Continuous surveillance
As main control Spangler used a Siemens PLC S7-1500, which is operated via HMI via the Siemens WinCC. 27 control cabinet fields and six sub-distribution boxes directly at the machines control both dryer lines, including power supply. Spangler experts programmed the control of the dryers in accordance with a functional specification sheet of HUBER SE. The energy supply of the plant is monitored fully automatically. If one power supply fails, the network is completely switched to the redundantly planned second supply. If both fail, the plant automatically switches to supply via an emergency power generator and thus is permanently available. In addition, the central control system is connected to the existing control system, which already existed prior to the extension, via a bus system. Therefore, the plant can be completely controlled from the remote control room of the energy provider.

Anyone who works in enclosed rooms of waste water treatment plants may be exposed to many underestimated hazards. These must be identified at an early stage so that accidents do not occur at all. From the equipment to entry protection and hazards from gases or oxygen deficiency. In order to ensure our employees‘ safety, Spangler regularly carries out safety trainings. 

Its customers, like for example staff at sewage treatment plants, as well are faced with these challenges and must yearly take part in a training in order to be allowed to carry out necessary work in shafts for example. This led to the idea to invite the customers for this safety training.

Safety training ‘Access in enclosed rooms of waste water treatment plants’
In cooperation with the company Krapp Technologie from Hilpoltstein, which has been a partner as regards safety trainings for Spangler for long time, this professional training was organized. Mr Krapp explained and showed with practical exercises the correct use of protection and rescue equipment. On the one hand in order to avoid accidents, on the other hand to quickly and safely react in the case of a fall, injury or rescue.  Particularly interesting for works at the sewage treatment plant was the proactive approach at work in hazardous atmospheres. The right handling of measuring devices for the free release measurement in case of gas hazards, like Ex-Methane, carbon dioxide/carbon monoxide or the measurement of the oxygen content is lifesaving. Not least, Mr Krapp also emphasized the responsibility of every person involved as regards the right application of devices, the correct use of safety equipment as well as the check of the site of operation. Basically, workers who are well prepared and trained and who use the right, intact equipment, can avoid many dangers.

Personal exchange of experience
During the lunch together and the subsequent tour of the company, the first feedback could be obtained.   “It is similar to First Aid courses. Even if you have done these courses before – you nevertheless forget important procedures again and again “, was many customers’ feedback “Today I was made aware of many risks again. In everyday life you tend to ignore them “, another participant explained. “The safety with working in enclosed rooms is of high priority for us, as our employees and customers are regularly confronted with it “, explained Andreas Amler, Manager Service & Installation and organizer of this training. “Therefore, we are glad to offer these safety trainings and that the response was very positive “, Amler continued. For Spangler this was a successful start for future repeating training sessions. If you are interested, please feel free to get in contact with us. Just click the following link and we will inform you well in advance of the next training: service@spangler-automation.de

Healthy and attractive workplaces have always been a corporate goal for Spangler. This was further emphasized with the introduction of an occupational health and safety system.

Close relation to practice
After profound research it was finally decided to introduce the Occupational Health- and Risk-Management System (OHRIS) of the Bavarian State Government. The main factors for the choice were the close practical relevance and the feasibility which is also designed for medium-sized companies like Spangler.

Quick implementation
Spangler was supported by the certifying body of the labour inspectorate of the district government of Upper Palatinate in Regensburg. A project team was formed at Spangler that was composed of experts of various department. In many cases it was possible to profit from existing knowledge from other certificates, for example quality management standard ISO 9001. This was the reasons why the certification was carried out in the short time of a quarter. The labour inspectorate placed its focus on occupational safety and health protection at Spangler. In order to improve this, new research results from the fields of ergonomics and prevention were incorporated. With the reward of the OHRIS:2018 certificate, Spangler has since then met the requirement of DIN ISO 45001:2018.

Signal effect for the future
Spangler hopes that the certificate will have a signal effect for the future. Particularly with regard to the employees a significant increase in the quality of the workplace is expected due to the further increase in occupational health and safety.  Furthermore, the internationally accepted OHRIS certificate strengthens the trust between Spangler and its customers and opens new doors for offers which require an occupational health and safety management system.

Five apprentices have successfully completed their apprenticeship at Spangler in Töging and start with responsible positions.

With the handing over of the certificates of qualification the last step of the apprenticeship was concluded, and the training years ended. For five of our apprentices, it was that time last week. The training for electronics technicians for automation and systems technology is separated in theoretical and practical study terms. The training sections take part in the company and in schools in Neumarkt and Weiden. It is complemented by trainings of the chamber of handicrafts, which deal with certain subject areas in detail. Five colleagues, four young men and one young woman, received their certificate of apprenticeship.

Spangler’s managers, Tina Lambert and Christian Brandmüller, congratulated the new skilled employees on their good degrees. Tina Lambert thanked the apprentices in a short speech, describing the end of their training as the start of a life-long learning process. She especially stressed the various opportunities for development this vocational job offers. Electronic technicians for automation technology are needed everywhere in the economy to bring power to plants and to provide for the operation. The company’s management handed over presents to the former apprentices to remember their training years.

About seven young professionals are trained at Spangler each year. Besides electronics technicians also office clerks and dual students are employed. For Spangler the experts who are trained in the company are a perfect possibility to fill demanding positions.