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VOL. 51 | ISSUE NO. 8 | AUGUST 2016 | MUMBAI | ` 150 NEWS Industry News 6 Technology News 28
NEWS FEATURE
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4 • August 2016
Sizing and Selecting the Proper Metering Pump 38 - Tom O’Donnell- Neptune Chemical Pump Company & PSG, Ravi Prasad- PSG India Selection of Correct Non Return Valve in a Piping System for Larger Benefits 44 - Dinesh Upadhyay- CRANE ChemPharma & Energy Flow Solutions, India Der Antrieb is in control 50 - Jyoti Mishra- NORD Drivesystems Pvt Ltd Alarm Management is A Continual Process 54 - Ulhas Deshpande- Honeywell Process Solutions, India
MARKETING INTIATIVES Shavo Technologies offers Customized Solutions with Technological Expertise Garlock India offers Innovative Fluid Sealing Technology for Industrial Applications KUMARS Forge & Valves Pvt Ltd Forging Ahead…….Creating Values DelVal Flow Controls Delivering Value, always! Vacuum Technology With An Attitude: Reducing the Life Cycle Cost
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INTERVIEW
80 “All in all GST is a welcome move” - Rajeev Jain, Managing Director, KSB Pumps Limited
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Chemical Engineering World
CEW Press Release LANXESS increases Earnings Forecast for 2016 Mumbai, India: Specialty Chemicals Company LANXESS raises its earnings forecast for 2016. The company now expects EBITDA pre-exceptional within a range of EUR 930 million and EUR 970 million mainly due to good business prospects in the “new” LANXESS segments for the second half of the year. Previously, LANXESS had assumed earnings of between EUR 900 million and EUR 950 million. In a strong second quarter of 2016, EBITDA pre-exceptional rose by 8.5 percent to EUR 293 million, compared with EUR 270 million a year earlier. The EBITDA margin pre-exceptional improved year-on-year from 12.8 percent to 15.1 percent. The good overall performance was due particularly to the strong development of the “new” LANXESS segments Advanced Intermediates, Performance Chemicals and High Performance Materials.
Praj to be the First Indian Technology Provider to Launch ‘Green Fund’ for 2G Ethanol Projects Pune, India: Praj has announced that it is going to be the first technology provider in the Country to par ticipate in 2G ethanol projects through ‘Green Fund’. This Green Fund will be contributed to accelerate 2nd Generation ‘Biomass to Ethanol’ projects in various par ts of the country. “In order to accomplish 20% ethanol blending program set up by the gover nment, the OMC’s, project developers and technology providers like us need to ramp up our actions and develop a sustainable eco-system. To achieve this ambitious blending target, 2nd generation biofuels play a pivotal role. Globally it has been accepted that 2G Ethanol is the answer to sustainability and reducing GHG emission. The Green Fund
“The strong operating result derived especially from increased volumes, leaner cost structures and an improved product mix achieved by the “new” LANXESS segments. This shows that our realignment has enabled us to create a powerful and efficient organization and that we are operating in the right markets with the right products,” said LANXESS Chairman of the Board of Management Matthias Zachert. “We are very optimistic for the second half of the year and expect “new” LANXESS to improve earnings against the prior year. Although the rubber business remains difficult, we are again raising our forecast for the full year.” LANXESS expects to close the acquisition of the Clean and Disinfect business of U.S.-based chemical company Chemours by the end of the third quarter at the latest. The acquisition will be accretive to the company’s earnings per share in the first fiscal year. The acquired business is expected to deliver an annual EBITDA contribution of around EUR 20 million, which will be gradually increased by synergy effects to about EUR 30 million by 2020. In the second quarter of 2016, net income stood at a good level of EUR 75 million. Also in this quarter, LANXESS for the first time deducted a share of the profits to Saudi Aramco for its 50-percent interest in ARLANXEO, the joint venture for synthetic rubber. The income of EUR 87 million in the same period last year also included the proceeds from the sale of non-current assets. Adjusted for exceptional, net income amounted to EUR 76 million compared with EUR 67 million in the prior-year quarter. Earnings per share pre-exceptional were EUR 0.83, after EUR 0.73 a year earlier.
will play as catalyst in building sustainable industry that our future generations will benefit from. Further, we have prepared ourselves to execute 2G ethanol projects worth Rs. 2500–3000 crores in 2 years” said Mr. Pramod Chaudhar i, Executive Chairman, Praj Industries. Farmer centric Biomass supply chain model, Praj has devised a farmer centric biomass supply chain model which will benefit farmers and ensure a better livelihood. This sustainable model will help farming community to generate additional revenues from their agr i waste which will be consumed to produce b i o e t h a n o l . T h i s w i l l a l s o g e n e ra t e r u ra l e m p l oy m e n t & entrepreneurship opportunities for the youth in nearby villages. Praj will also be the first technology provider to offer 2nd Generation ‘Biomass to Ethanol’ Projects based on Build, Operate & Maintain (BOM) package. Under this package, Praj will not only provide the technology and build the plant but also will assist in operating and maintaining it. Second Generation (2G) Ethanol is produced from biomass which includes agricultural residues such as bagasse, corn cobs, rice & wheat straw, cotton stalk, empty fruit bunches etc. Praj offers end-to-end solution to set up 2G smar t Biorefinery; this will be capable of producing a range of products – from Bio-ethanol, Bio-CNG, Power and variety of Bio chemicals.
Group sales declined by 7.7 percent in the second quarter of 2016 to EUR 1.94 billion, compared with EUR 2.1 billion in the prior-year quarter. Lower procurement prices for raw materials were passed on to customers. Higher volumes could not compensate for price reductions and the slightly unfavorable currency effect of the U.S. dollar. 6 • August 2016
I t i s P ra j ’s e n d e avo u r t o c r e a t e a u n i q u e Te c h n o - S o c i o Economic revolution in India that has the potential to catalyse rural economy while saving precious foreign exchange and reducing GHG emissions. Chemical Engineering World
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CEW Press Release Universal Robots to Make Robot Automation Accessible to All Levels of Industry
Honeywell Appoints Ashish Gaikwad as Managing Director of Honeywell Automation India Limited
Mumbai, India: Universal Robots, a Danish robot manufacturer that pioneered collaborative robots discussed the future of cobots in India and accessibility to such technology that could bring about a revolution in various industries. The event was graced by Esben Østergaard, Chief Technology Officer of Universal Robots and Pradeep David, General Manager, India.
Pune, India: Honeywell Automation India Limited has announced that Ashish Gaikwad has been appointed a s i t s m a n a g i n g d i r e c t o r e f fe c t i ve October 1, 2016. Gaikwad succeeds Vikas Chadha, who was recently named
Co-bots are designed to work with humans and assist them with a variety of tasks which help to automate and streamline repetitive and potentially unsafe processes thus, ensuring safe work environment while increasing productivity and efficiency. With the small and medium-sized enterprises (SMEs) set to grow, they are eager to adopt this technology. To ensure the success and adaptability of co-bots, a study was conducted by MIT researchers at a BMW factory, where it was seen and analyzed that teams made of humans and robots collaborating efficiently can be around 85% more productive than teams made of either humans or robots alone. Also, the cooperative process reduced human idle time by virtue of its pace-setting ability.
Mr. Ashish Gaikwad Managing Director Honeywell Automation India Limited
president, Honeywell India.
Speaking about the appointment, Suresh Senapaty, chairman, HAIL, said, “HAIL has a 25-year legacy in India, in developing and manufacturing technologies that serve a diverse and extensive customer base across verticals including oil and gas, power, metals, pharmaceuticals, chemicals, mining, infrastructure, IT/ ITeS, telecom, banking, healthcare, hospitality, automobiles, defense, aerospace, transportation, and the residential sector. With more than 25 years of experience in automation, control, and advanced software applications in the process industry,
“Evolution has been evident in the past and we thrive to nurture it and take it to the next step with human robot collaboration. Collaborative robotic technology can be used to benefit all aspects of task-based businesses irrespective of their size. Our robot arms are advanced tools that can be used by all levels of production staff to help increase productivity, reduce injury and boost morale. With a Universal Robots robot arm, you can automate and streamline repetitive or potentially unsafe processes, so staff can be assigned to jobs that provide them with new challenges. We are delighted to be able to provide the platform required for the Indian market for increasing productivity, quality, and market competitiveness. Our collaborative robots will help to ease out processes in task driven industries like manufacturing, assembly and food processing,” said Esben Østergaard, Chief Technology Officer, Universal Robots. Pradeep David, General Manager, Universal Robots (India) fur ther added, “Our three different collaborative robots are easily integrated into existing production environments. With six articulation points, and a wide scope of flexibility, the collaborative robot arms are designed to mimic the range of motion of a human arm. The latest collaborative robot technology should be available to all businesses. The nominal investment cost is quickly recovered as our robotic arms have an average payback period of just six months. The need of advanced robotics is required for accessibility to anybody who wants to increase productivity while maintaining high safety standards. We are growing our channel partner strength in all major locations of the country and will continue to expand our network in the coming years. With the government also supporting the growth of industries and sectors, the demand and requirement for this technology is growing” 8 • August 2016
Ashish will strategically lead HAIL to continued growth in the region, and strengthen the brand and its equity with customers and other key stakeholders.” Vikas Chadha, president, Honeywell India, said, “This appointment is a testimony of the matur ity and depth of Honeywell’s leadership pipeline and focus on building talent from within. Ashish has successfully driven the growth of the Advanced Solutions business for the Asia Pacific region. With his hands-on knowledge of the latest in automation and control solutions, including software solutions, digital transformation, the Industrial Internet of Things (IIoT), and his understanding of the Indian market, I am confident Ashish will take HAIL to new heights.” “Not only is India among our top high growth regions globally, it is expected to contribute significantly to Honeywell’s global growth for years to come. With seven state-of-the-art manufacturing facilities and five technology development centers, a lot of Honeywell’s software engineering and product development capabilities are also right here. So, it is a great time for me to take on this responsibility in India, especially as Honeywell continues its evolution as a cyber-industrial company. I’m looking forward to driving HAIL forward, and to serving our customers with some of the world’s leading technologies, said Gaikwad.” Chemical Engineering World
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CEW Industry News RIL Set to Commission USD 35 billion Projects in FY17
MRPL Targets to Expand Market for Polypropylene
Mumbai, India: Reliance Industries (RIL) has announced that it expects to commission projects with an overall investment of USD 35 billion in 2016-17. Its annual report for 2015-16 talks about petrochemical expansion projects that would place RIL among the top 10 global producers in that sector. RIL has also pursued shareholders’ endorsement to raise Rs. 100 billion through nonconvertible debentures (NCDs) this fiscal year.
Mangaluru, India: Mangalore Refinery and Petrochemicals Ltd (MRPL) has announced that in lieu of planning to magnify market for polypropylene, is pursuing to sell around 0.44 million tonnes (mt) of polypropylene a year.
In a letter to shareholders, Mukesh Ambani, Chairman, RIL stated that, “In the polyester chain, we added substantial volumes in an effort to further integrate our business. Reliance is confident of placing all our incremental output from the new projects in the domestic markets to meet India’s growing demand.” RIL said its petrochemical plant expansion was on schedule and would provide the company the capacity and earning potential of a top producer in the world. During the year, RIL and its subsidiaries arranged long-term foreign currency facilities of about USD 6.3 billion. RIL, which reported a gross refining margin of USD 10.8 a barrel in 2015-16, managing to outperform the Singapore benchmark with a premium of USD 3.3 a barrel, expects mar gin pressure, but hopes to perform better than the benchmark. The company also stated that, the ability to operate at high utilisation levels and switch products latest conditions enabled to suit market conditions enabled RIL to capture margin optimisation opportunities in the market. Overall, effective utilisation of secondary processing units, innovative approach to optimise logistics cost and utilisation, production flexibility to swing to higher netback products and sourcing of best value crude and feedstock-enabled RIL to sustain its performance even in a challenging margin environment. The company asserted that, it is expanded its fuel retail pump network to 1,000. It sees opportunity for further expansion. Both Reliance and its partner BP are assessing the new policy and investment plans to develop discovered resources.
Deepak Fertilisers to Invest in Dahej, Gujarat G u j a r a t , I n d i a : D e e p a k Fe r t i l i s e r s a n d Pe t r o c h e m i c a l s Corporation Ltd (DFPCL) has announced its plans to set up a manufacturing facility at Dahej in Gujarat to develop its nitric acid capacities, with an investment of ` 500 crore. The aim is to upsurge the current capacity of 840,000 MTPA to 148,000 MTPA. Scheduled to go operational by 2018, the land for setting up the project has already been acquired. Commenting upon the development, Sailesh Mehta, CMD, DFPCL stated that, “This new facility will be the initial step of development of a mega multi products site at Dahej, which would accommodate to the demand of several intermediates and specialty chemicals manufacturers in India.” 10 • August 2016
The 28th annual report of MRPL for 2015-16 mentioned that the company has positively penetrated the polypropylene market in a short span of nine months with a sales volume of 0.139 mt and sales value of ` 1,039 crore. It also said that, the company is in the development of expanding its market reach in order to sell 0.44 mt of polypropylene a year. To leverage the extremely profitable polypropylene and to position MRPL as a niche player, inclusive pricing of various grades of polypropylene has been put in place along with customer enrolment activity. MRPL has appointed Del Credere Agents cum Consignment Stockist to partner in addressing major demand clusters in the south and west of India.
Yara Buys Tata Chemicals’ Urea Business Babrala, India: Norwegian chemical company Yara International has announced that it has acquired Tata Chemicals’ (TCL) Babrala urea plant and distribution business in Uttar Pradesh, India, for USD 400 million on a debt and cash free basis, which also comprises normalised net working capital. TCL’s Babrala plant every year produces 0.7 million tonnes of ammonia and 1.2 million tonnes of urea. Over the financial year that ended on 31st March, the Babrala plant created revenues and earnings before interest, taxes, depreciation, and amortisation (EBITDA) of USD 350 million and USD 35 million, respectively. Svein Tore Holsether, President-CEO, Yara International said, “This well operated plant and its highly skilled employees will make an excellent addition to Yara’s global production system. This acquisition represents another significant step in our growth strategy, creating an integrated position in the world’s second-largest fertiliser market. “India has strong population growth and increasing living standards, and significant potential to improve agricultural productivity. He also added that, “We are impressed with the world-class operations we have seen in Babrala. The workforce is committed to high HESQ standards, and has a solid safety track record. Yara has been operating in India since 1990, and has recently focused on the sale of premium products in the southern and western regions of the country. The agreement will be subject to governing approvals and authorising by courts in India. The company anticipates the process to be completed in between the period of 9-12 month. Chemical Engineering World
CEW Industry News Govt Gives Nod for Revival of Fertiliser Units
Oil Min Fines RIL for Low gas output
New Delhi, India: The Union Cabinet has announced that it approved proposals for the revival of closed fertilizer units at Talcher, Ramagundam, Barauni, Gorakhpur and Sindri.
New Delhi, India: The oil ministry has levied an additional penalty ` 2,500 crore on Reliance Industries and its partners for producing less than the assured quantity of gas from its Andhra offshore field in 2014-15, as per the company’s regulatory filings to the bourses.
The Cabinet Committee on Economic Affairs (CCEA) in its meeting has approved the revival of these units on “nomination route” through PSUs. Rashtriya Chemicals & Fertilizers Limited, Gail (India) Ltd, Coal India Limited and Fertilizer Corporation India Limited (FCIL) have been nominated to revive the Talcher unit while National Fertilizers Limited, Engineers India Limited and FCIL have been nominated to revive the Ramagundam unit. In order to facilitate the revival of closed units of FCIL, the CCEA approved waiver of Government of India loan and interest on FCIL to make the net worth of FCIL positive and to seek its de-registration from Board for Industrial and Financial Reconstruction and paves way for revival of closed units of FCIL. Pre-Project activities to revive these two units are currently in progress. The Union Cabinet in its meeting has approved to revive these closed fertilizer units by means of a Special Purpose Vehicle of Public Sector Units namely, National Thermal Power Corporation, Coal India Limited, Indian Oil Corporation Limited and Fertilizer Corporation India Limited/Hindustan Fertilizer Corporation Limited, through “nomination route” instead of bidding route as approved earlier. This information was given by the Minister of State (MoS) in the Ministry of Chemicals and Fer tilizers Mansukh L. Mandaviya in the Rajya Sabha.
DCM Shriram to Expand Chlor Alkali Capacity in Rajasthan Rajasthan, India: DCM Shriram Ltd has announced that it is planning to develop its chlor alkali plant and associated flakers & stable bleaching powder plants at Kota, Rajasthan with an outlay of Rs 97 crores. In its BSE filling, DCM Shriram stated that, “The board has approved an investment proposal estimating to ` 97.3 crores to be financed through internal generation and debts, for expansion of its chlor alkali plant and related flakers & stable bleaching powder plants at Kota (Rajasthan) for increase in its existing capacity of 330 tonnes per day (TPD) to 410 TPD (proposed),” The proposed expansion project is likely to be operational by the end of Q3 FY18. The company is presently augmenting capacity of chlor alkali at Bharuch, Gujarat plant through a multi-phase expansion project. As part of this exercise, DCM commissioned 420 TPD of additional chlor alkali capacity at its Bharuch plant in June this year. With the commissioning, the total chlor alkali capacity of DCM Shriram has gone up to 1200 TPD. The balance chlor alkali capacity and power expansion project at Bharuch is anticipated to be commissioned in phases by September-October 2016. 12 • August 2016
The ministry enforces the penalty in the form of not permitting the company to recover part of its investment in the infrastructure for bringing the KG-D6 block into production. With the latest fine, which the company has disputed and is challenging through arbitration, the overall penalty for five fiscals beginning April 1, 2010 has augmented to USD 2.76 billion. In its regulatory filling, RIL stated that, “Up to financial year 2013-14, the cost recovery proposed to be disallowed was USD 2.38 billion and consequent demand of government of India share of additional profit petroleum of USD 195.3 million on cumulative basis. On June 3, 2016, the company received a revised claim up to year 2014-15 with a disallowance of USD 2.76 billion on cumulative basis and consequent demand of government of India share of additional profit petroleum of USD 246.9 million, also on cumulative basis.” It further added that, “Every year, based on its own interpretations of the PSC (production sharing contract) and assumptions (with which the contractor group does not agree), ministry of petroleum and natural gas revises the total cost it proposes to disallow and consequently aggregates the figure with figures of the previous years... It also demands additional profit petroleum (in total including previous year claims as well) as government of India share.” “Of the additional profit petroleum claimed, the government has already collected USD 81.7 million in gas pool account. The government had for 2010-11 disallowed USD 457 million of cost, USD 548 million for 2011-12, USD 792 million for 2012-13 and USD 579 million for 201314. Now, another USD 380 million cost has been disallowed for output lagging behind target in 2014-15.”, asserted RIL.
Comprehensive viability study underway for Mega Oil Refinery in Maharashtra New Delhi, India: The Minister of State (I/C) for Petroleum & Natural Gas Dharmendra Pradhan informed the Rajya Sabha in a written reply that Oil PSUs namely Indian Oil Corporation Limited (IOCL), Bharat Petroleum Corporation Limited (BPCL) and Hindustan Petroleum Corporation Limited (HPCL) have announced the plan to jointly set up an integrated refinery-cum-petrochemical complex with a refining capacity of 60 MMTPA (million metric tonnes per annum) in 2 phases in Maharashtra. Engineers India Limited (EIL) is carrying out detailed feasibility study. Oil PSUs and EIL are in the process of site selection for the refiner y in consultation with Govt. of Maharashtra. Setting of operationalisation targets depend on land availability, environment clearance etc. Chemical Engineering World
CEW Industry News SRF to Invest in Chemical Plants at Dahej Gujarat, India: As part of the plan to develop its chemicals business, SRF Ltd has announced that it will invest ` 345 crore in two projects for specialty chemicals and chloromethane at its Dahej complex. The Board agreed on two separate capex proposals aggregating ` 345 crore in the meeting. One of the suggestions pertains to setting up a multi-purpose plant for specialty chemicals at an estimated cost of Rs 180 crore and the second one for chloromethane (CMS) plant at an estimated cost of ` 165 crore in its chemical complex at Dahej in Gujarat. The new multi-purpose plant is expected to further extend SRF’s capability to develop and commercialise new molecules for agrochemicals and pharmaceutical sectors. Set up essentially with a view to providing further flexibility in its manufacturing capability, the new unit will enable SRF to cater to wider range of specialty products for emerging needs of the sector. The capex is in tune with the business objective of enhancing its product portfolio in order to continue to serve its customers on an ongoing basis. The second project aims to double SRF’s capacity for chloromethanes to 80,000 tonnes per annum. The existing chloromethane plant is situated at Bhiwadi in Rajasthan. The new chloromethane plant will enable SRF to meet the growing needs of its pharma customers for methylene dichloride (MDC) and will strengthen its foothold in the Indian market, which remains a net importer of methylene dichloride (MDC). The new plant will thus make SRF the only Indian integrated producer of HFC 32, a refrigerant to be increasingly used in room air-conditioners in future. The expansion of chloromethanes plant is, however, strongly linked to captive consumption of chloroform, which has limited usage. SRF is, therefore, uniquely positioned to leverage the opportunity as it has the capability for captive consumption of the other two ingredients, chloroform and carbon tetra chloride (CTC). Apart from its usage as a solvent in the growing pharmaceutical drugs, MDC is also used for various applications such as foam blowing segments, aerosols, polycarbonate resins and adhesive formulations. Chloroform is mainly used as raw material to manufacture HCFC 22 and also in pharma and CTC as feedstock in agrochemical intermediates. SRF will thus consume a large part of chloroform for manufacturing HCFC 22, which will be increasingly used as a feedstock for specialty chemicals, a business of SRF that has been growing steadily for last five to six years. Similarly, the captive consumption of CTC at SRF will also increase as feedstock for its specialty chemicals. The new chloromethane plant with an annual capacity of 40,000 tonnes is scheduled to be commissioned in December 2017. The chloromethanes along with tr ichloroethylene (TCE), perchloroethylene (PCE) and dilute hydrofluoric (DHF) acid jointly form SRF’s portfolio of solvent products under its fluorochemicals Business. 16 • August 2016
Nuberg awarded with National Fertilizer’s EPC contract for sulphur bentonite plant Noida, India: National Fertilizers Limited has announced that it has awarded contract to Nuberg Engineering for the construction of its sulphur bentonite plant project in Panipat on engineering, procurement & construction (EPC) and lump sum turnkey (LSTK) basis. The plant will manufacture 25000 metric tonne per annum (MTPA) of sulphur bentonite, a novel type of environment friendly fertiliser used in agriculture sector for improved output and yield. The Chemicals and Fertilizers Minister, Anant Kumar, had announced three major projects in Haryana which included a sulphur bentonite plant in Panipat. The project of accomplishing this distinctive fertiliser plant is yet another achievement to Nuberg’s growing portfolio of worldwide EPC & LSTK projects. A K Tyagi, Chairman, Nuberg Engineering, said, “We have always been present in the fertiliser industry and have successfully delivered projects on time but this notable project levitates us to the niche of the mix fertiliser industry. Our experienced engineering team and project professionals will utilise their extensive experience and expertise to place the project in the best position moving forward. This project adds to Nuberg’s depth of projects the company has participated in as well as strengthens its longstanding leadership position in EPC & LSTK projects globally.” For NFL project, Nuberg’s EPC scope of work from concept to commissioning comprise process know-how, license and technology, technology, basic, FEED and detail engineering, fabrication, procurement and supply, construction and erection of all civil, mechanical, electrical and instrumentation works, installation, obtaining all necessary statutory approvals, testing, mechanical completion, pre-commissioning, commissioning, performance guarantee test run including total project management and handing over the plant on single point responsibility basis.
Wood Group Bags Contract with Petrochemical Manufacturer SABIC UK: Wood Group has announced that it has been awarded a new contract by petrochemical manufacturer SABIC, in the UK. Engineering design services will be provided to the SABIC Teesside complex in Wilton, UK under the contract, which is effective immediately. The contract, which will be delivered by Wood Group’s operations in Woking, extends the company’s support of SABIC globally; Wood Group currently supports SABIC operations in Saudi Arabia and USA. Robin Watson, CEO, Wood Group said: “This contract, which extends our support of SABIC into the UK, demonstrates the strong relationship we have with this client based on our proven track record of excellence, quality and assurance in our technical service delivery. “Our diverse and robust expertise and capabilities position us strongly to add value for clients in the petrochemical market, which represents a good long-term opportunity for Wood Group. We will leverage our knowledge of working with SABIC globally towards the successful, efficient and effective delivery of this new contract.” Chemical Engineering World
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CEW Industry News Large potential of growth for bio-fuels in the country: Pradhan New Delhi, India: The Minister of State (Independent Charge) for Petroleum & Natural Gas Dharmendra Pradhan has said that there is a large potential of Bio-Fuel business in India to grow from present ` 6500 crore to ` 1 lakh crore in the next 10 years. Speaking at the National Conference on the World Bio-Fuel Day in New Delhi, he said that the Prime Minister has set a target of 10 per cent import reduction in crude by 2022 and bio-fuels can play an important role in achieving the target. Shifting the fuel consumption profile to biofuels derived from domestic feed stocks would lead to decrease in this dependence on crude oil imports. He said in the last 2 years, lot of work has been done in Ethanol Blending Programme, Bio-Diesel as well as using the Bio-waste for converting to energy but more needs to be done speedily. He said India’s energy consumption is increasing very fast and it has become the third largest consumer in the world. Mr. Dharmendra Pradhan said that the Bio-fuel Programme has the capacity to provide better remuneration for farmers, address environmental concerns, reduce dependence on imports and help in foreign exchange savings. The Petroleum Minister said the Government is willing to provide conducive policy environment to support development of Bio-fuel but import of raw material or waste for this purpose cannot be allowed. Speaking on the occasion, Minister of State (I/C) for Power, Coal, New & Renewable Energy and Mines Mr. Piyush Goyal said that rapid strides have been made in the last two years in the field. He said that Viability Gap Funding Scheme for the sector can be evolved in consultation with the stakeholders. Further, the Minister laid down a vision for the growth and development of the bio-fuel sector. He called for organizing an International competition, under the aegis of the MoPNG, MNRE and the Department of Biotechnology (DBT), and invite stakeholders from all around the World to brainstorm and
devise innovative technologies and novel ideas to integrate the use of bio-fuels in the lives of the common man. Mr. Goyal said speed, skill and scale are important for success of any programme and they should be included in the Bio-fuel programme also. He further added that bio-fuels are closely linked to increasing the quality of life of the common man as they would provide a sustainable way to convert human generated wastes to energy and reduce pollution as well. The Minister pointed out that a major challenge that faces the sector is the sustainable availability of feedstock for the bio-fuel generation plants. On the occasion of Bio-fuel World Day, National Conference on ‘Energy Security for India – Creating a Bio-fuel Economy’ was organized. The World Bio-fuel Day is celebrated every year to commemorate the anniversary of the successful working of a diesel engine, run on peanut oil, by German innovator Rudolf Diesel in 1893. The National conference brought together stakeholders of the Bio-fuel sector viz., the Government, Public Sector Undertakings and the Private Sector. Investment announcements were made by Private Equity and Public Sector Oil Marketing Companies. IOC, BPC, HPC and NRL have identified 10 locations for setting up 2G ethanol plants with an estimated investment of ` 5000/- crore. Private players like CMC Bio-refineries, Praj Industries Ltd., Munzer, Novozymes and Shell have also announced an investment of ` 5000/- crore in the field of Bio-fuels in India. The conference aimed at accelerating the bio-fuel programme in the country and draw up a road map to reduce the consumption of fossils fuels by replacing it with locally produced bio fuels thus reducing the foreign exchange out flow, generate rural employment and protect environment.
Essar Oil to Invest in Vadinar Refinery Mumbai, India: Essar Oil Limited has announced that it plans for upgradation of its 20 MTPA Vadinar refiner y with an investment of ` 1,600 crores to ear n an additional USD 1.50 per barrel (bbl) of crude on its gross refiner y margin (GRM). While the company has by now invested ` 400 crore during a 28-day deliberate shutdown of the refiner y in SeptemberOctober last year, it will fur ther invest ` 1,200 crore to make supplementar y upgrades in the various refiner y units over the next 2-3 years. The shutdown or tur naround activity involved not just routine inspection and maintenance, but also entailed the conversion of the VGO-HT unit into a mild hydrocracker (MHC) unit and the setting up of facilities to process high acid (TAN) crudes. Ever since, the refiner y has been able to conver t its entire vacuum gas oil (VGO) production into higher margin products. 20 • August 2016
Over the next 2-3 years, Essar Oil will invest ` 1,200 crore to upgrade its naphtha hydro treater (NHT), isomerisation unit, continuous catalytic reformer (CCR) units and also facilities for further recovery of sulphur to further improve its margins. Lalit Kumar Gupta, Managing Director-CEO of Essar Oil, said, “With the shutdown having been successfully completed, EBITDA and PAT in the current financial year is expected to be significantly higher because of the full availability of the refinery, stable crude oil prices, and our ability to optimally leverage on the investments in the MHC and high TAN facilities.” Refinery margins at Essar Oil have remained continuously above the industry benchmarks. In the quarter ended 30 June 2016, the CP-GRM of USD 10.29 per bbl (unaudited) bettered the IEA margin for Singapore complex refineries by around USD6 per bbl.
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CEW Industry News Initiatives taken to take forward Biodiesel Programme: Pradhan New Delhi, India: The Minister of State (I/C) for Petroleum & Natural Gas Dharmendra Pradhan informed the Lok Sabha in a written reply that the Ministry of Petroleum and Natural Gas had announced a Biodiesel Purchase Policy in October 2005, under which, Oil Marketing Companies (OMCs) would purchase bio-diesel at a uniform price as may be decided by the OMCs from time to time, for blending with High Speed Diesel (HSD) to the extent of 5 per cent at identified 20 purchase centres across the country. However, OMCs could not procure biodiesel upto August, 2015 as biodiesel producers were not coming forward to supply their biodiesel at the prices decided by OMCs from time to time. The Government allowed the sale of Bio-diesel (B100) by private manufacturers to bulk consumers like Railways, State Transport Corporations and other bulk consumers. Also, retailing of bio-diesel blended diesel by Public Sector Oil Marketing Companies (OMCs) has started on the same day. As a result, the biodiesel procurement by Public Sector OMCs has started. 1.32 crore litre Biodiesel (B100) has been procured by Public Sector OMCs. During the current Financial Year also, OMCs have finalised a quantity of 4.01 crore litres of biodiesel for the period of April – September, 2016.
Production of fertilizers in the country insufficient to meet local demand: Mandaviya New Delhi, India: Production of fertilizers in the country is not sufficient to meet the local demand. There is gap between domestic production and demand. The gap is met through imports. The details of production of major fertilizers in the country during last two years are given below:Urea is the only fertilizer under statutory price control and its import is restricted and permitted through State Trading Enterprises ( STEs), namely Metals and Mineral Trading Corporation of India (MMTC), State Trading Corporation Limited (STC) and Indian Potash Limited (IPL), under the Foreign Trade Policy of the Government. Urea for direct agricultural use is imported on Government account to bridge the gap between assessed demand and indigenous production. Government is also importing approximately 20 Lakh Metric Tonnes urea from Oman India Fertilizer Company (OMIFCO) under a Long Term Urea off Take Agreement (UOTA) between GOI & OMIFCO. Import of fertilizers (other than Urea) is free, commonly known as Open General License (OGL). Various companies import these fertilizers as per their commercial judgment. Muriate of Potash (MOP) is the only fertilizer, whose demand is fully met through imports as there are no viable sources of MOP in the country. This information was given by the Minister of State (MoS) in the Ministry of Chemicals and Fertilizers Mansukh L Mandaviya in the Rajya Sabha. 22 • August 2016
Rajeev Jain appointed as New MD of KSB Pumps Limited, India
Mr. Rajeev Jain Managing Director KSB Pumps Limited
Mumbai, India: KSB Pumps Limited has announced the appointment of Mr. Rajeev Jain as Managing Director. He will also accept the portfolios and responsibilities as the Chairman of MIL Controls Ltd. and will head the Global Design Center – KSB Tech as its Managing Director, located in Pune along with heading KSB groups’ Asia West operations as the Regional Executive Officer.
Prior to assuming this very important role, Mr. Jain was the Managing Director at KSB in Indonesia for over a decade and successfully steered the company to a leadership position in that region. During this tenure in Indonesia, he also was the Managing Director of KSB Singapore and the Regional Executive Officer for South East Asia The objective and Vision of Mr. Jain, while assuming this plum assignment, is not only to consolidate and safeguard the existing strong position of the company, but also to steer, propel and fast track the growth in business of KSB in India with sustained profits in the near future - to an undisputed leadership position in the major segments the company operates in! Currently, from its 5 plants in India, KSB manufactures and supplies Power Driven Centrifugal Pumps and Industrial Valves, reliably and safely, to address the needs of customers from the Water and Waste Water; Agriculture; Construction; General industries; Oil, Refineries and Petrochemicals; and Power Plants including Super Critical Power Plants and Nuclear Power plants.
Shree Pushkar strategies commercial production at fertiliser plant in Sept, 2016 Mumbai, India: Shree Pushkar Chemicals & Fertilisers Ltd has announced that it is planning to start commercial production at its new sulphate of potash (SOP) plant, located at Lote Parshuram, Ratnagiri (Maharashtra), in September this year. In its BSE filling, Shree Pushkar Chemicals stated that, “The main plant has been imported on turnkey basis from China and has been successfully commissioned on August 01, 2016. The Company is currently in the process of conducting trial runs, and the full commercial production at the plant is scheduled to commence by September 2016 along with the calcium chloride plant, a by-product in the manufacturing process,” The company, along with its development plans for manufacture of reactive dyes through the proceeds of the IPO, is presently setting up a plant for manufacturing sulphate of potash, a soluble potassic fertiliser, with a capacity of 10,000 metric tonnes per annum (MTPA). Chemical Engineering World
CEW Industry News Wood Group Bags Contract with Petrochemical Manufacturer SABIC
NORD DRIVESYSTEMS Launches Robust New SingleStage Helical Inline Gears for Pumps, Fans, and Mixers
UK: Wood Group has announced that it has been awarded a new contract by petrochemical manufacturer SABIC, in the UK. Engineering design services will be provided to the SABIC Teesside complex in Wilton, UK under the contract, which is effective immediately. The contract, which will be delivered by Wood Group’s operations in Woking, extends the company’s support of SABIC globally; Wood Group currently supports SABIC operations in Saudi Arabia and USA Robin Watson, CEO, Wood Group said: “This contract, which extends our support of SABIC into the UK, demonstrates the strong relationship we have with this client based on our proven track record of excellence, quality and assurance in our technical service delivery. “Our diverse and robust expertise and capabilities position us strongly to add value for clients in the petrochemical market, which represents a good long-term opportunity for Wood Group. We will leverage our knowledge of working with SABIC globally towards the successful, efficient and effective delivery of this new contract.”
Exxon’s New Plastics Technology Set to Enhance Petrochemical Sector Georgia, USA: ExxonMobil has announced that researchers from ExxonMobil and the Georgia Institute of Technology have revealed a new form of plastics making that could diminish manufacturing costs and emissions. The novel system, which was published in the academic journal Science, would supposedly save the petrochemicals industry US$2 billion, and lower the emissions equivalent to the emissions from about 5 million U.S. homes. Mike Kerby, Corporate Strategic Research Manager, Exxon Mobil said that, “In effect, we’d be using a filter with microscopic holes to do what an massive amount of heat and energy currently do in a chemical process alike to that found in oil refining.” Further testing is needed, but Exxon Mobil is poised with the results thus far and is interested in following the technology for a wider global implementation, he further added. The petrochemicals industry in the U.S. has experienced a boom following the spike in fracking that began nearly a decade ago. This has generated increased development of infrastructure in several U.S. Gulf states including planned and future projects, which the American Chemistry Council estimates will create around 70,000 jobs. One of these plans was announced by Exxon Mobil and the stateowned Saudi Arabia Basic Industries Corp. for the construction of a multibillion-dollar petrochemical complex either in Texas or Louisiana. The abundant and economical amount of natural gas extracted via fracking has made it more affordable for the manufacturing of plastics. 24 • August 2016
Illustration: Featuring superior torsional rigidity, the robust new single-stage helical inline gearboxes from NORD DRIVESYSTEMS are particularly well-suited for pumps, mixers, and fans
Brazil, South America: NORD DRIVESYSTEMS has announced that it has launched a new line of single-stage helical inline gearboxes with a NORDBLOC.1 light alloy case at the 2016 Hannover Messe exhibition. The gear unit series is particularly suited to pump, agitator, fan, and intra-logistics applications. NORD has worked closely with renowned manufacturers in these fields throughout the development process. Above all, these new gears achieve a very high torsional rigidity through a robust design that was thoroughly tested, amongst others with abruptly increased pump pressures and shaft vibration. In high-speed applications, these helical inline gearboxes are a more powerful solution than two-stage units. Highly precise manufacturing and high-quality materials also ensure the products are very lightweight, smooth-running, and exceptionally efficient. The nsd tupH surface treatment is optionally available to make the units highly resistant to corrosion, for instance for long-term use in aggressive ambient atmospheres. IEC and NEMA motor mounting options as well as various shaft, bearing, and lubrication variants enable versatile bespoke configurations. The new NORDBLOC.1 products will initially be available in five sizes.
SensoTech’s LiquiSonic Assists in Monitoring the Oil Concentration in Cooling Processes Magdeburg–Barleben, Germany: For the lubrication of compressors in air-conditioning systems, refrigerant oils circulate in the refrigeration cycle, however, they reduce the cooling effectiveness. Therefore, continuous monitoring of the oil content is especially important in the development of air-conditioning systems in order to determine the optimum oil circulation ratio that depends on the used refrigerant, compressor and process conditions. The concentration measurement of oil in the refrigerant places high demands on the analysis. On the one hand, there are high pressures, which may be up to 150 bar in case of CO2. With the LiquiSonic® OCR analyzer by SensoTech, specifically designed for refrigerant applications, the oil circulation ratio in the refrigerant can be monitored online and directly in the process using sonic velocity measurement. Due to the chemical and physical properties of refrigerants, sonic velocity measurement is ideal for determining the concentration. The LiquiSonic® sensor is installed in the pipeline and combined with a pressure transducer. Additionally, two Pt1000 temperature probes are integrated in the sensor, so that from the values sonic velocity, temperature and pressure the temperature- and pressurecompensated oil concentration can be calculated in real time. Chemical Engineering World
CEW Technology News TEMA’s Innovative Design for Screw Plug Heat Exchangers for Refineries- Impeccable Response to Air Pollution Mumbai, India: The industrial community the world over are emphasizing on reducing greenhouse emissions; especially in the transportation sector they intended to curb large scale emissions of pollutants by implementing stringent emission standards. These emission standards adopted by various countries mandated that the fuel combustion equipment in vehicles to undergo drastic design changes and also by using cleaner fuels from the refineries with reduced sulphur content. However, refining fuels with can satisfy stringent pollution control norms (i.e. to produce cleaner fuels) are the biggest challenge being faced by refineries across the globe. The current emission standard EURO VI or equivalent requires 10 ppm sulphur content which is an even greater challenge for the global refiners.
Traditionally, all fossil fuels have sulphur content which needs to be de-sulphurised using various refining processes like hydrotreating and hydrocracking. The difficulty is that the process of reducing sulphur involves high pressure and high temperature and further compounded by intermixing of fluids in gasketed heat exchangers causing sulphur slippage in the refining process by using the existing equipment. So this requirement for clean fuels compels the refineries to revamp their existing hydro cracker and hydro treating units or set up new modules which enable them to produce fuel with 10 ppm sulphur content. To achieve this task the refineries need a unique heat exchanger which can operate under high temperature and high pressure and at the same time the heat exchanger should not allow intermixing of fluids. Also due to its use in the dirty service it should provide ease of maintenance. This challenge can be overcome by the refining world by turning to essentially a highly effective Screw Plug Heat Exchanger designed and manufactured by TEMA. Breech Lock or Screw Plug Exchangers are basically U-tube exchangers. The channel side operates at high temperature and pressure and it has a threaded end closure. In some designs, the shell side may also be at high pressure. The tube bundle is removable without having to dismantle the channel or disconnect the nozzles from the pipeline. Thus screw plug exchangers help to reduce fabrication cost; moreover its design is such that it enables quick and effortless in-service maintenance. The major problems encountered with the use of such end closures were • •
Jamming of the threaded plug, due to “Bell Mouthing” Leakage through the tubesheet gasket.
These issues are successfully resolved with the modified Screw Plug Heat Exchanger design by TEMA. There are around 150 TEMA-make Screw Plug Heat Exchangers in service all around the world. With the emphasis on clean fuels and adherence to EURO VI or equivalent emission standards are around the globe this new approach to refining clean fuels using Screw Plug Heat Exchanger is the only way out. 28 • August 2016
Govt Approves `1,554 crores Project to Develop Technology for Power Plants New Delhi, India: Gover nment has announced that it has sanctioned ` 1,554 crore R&D project to develop advanced ultrasuper critical (AUSC) technology for thermal power plants, a step to safeguard energy security.
T h e C C E A " s a n c t i o n e d a p r o p o s a l o f R & D p r o j e c t fo r development of Advanced Ultra Super Critical (AUSC) technology for thermal power plant with an estimated cost of Rs 1,554 crore and providing one time budgetary support of ` 900 crore spread over a period of three years, commencing from 2017-18, to be provided as plan Gross Budgetary Support to BHEL for implementation of the R&D project," Ministry of Heavy Industry and Public Enterprises said in a statement. A consortium of three government entities -- Bharat Heavy Electr icals Ltd (BHEL), Indira Gandhi Centre of Atomic Research (IGCAR) and NTPC -- have proposed a R&D project for development of AUSC technology for thermal power plants of future, foreseeing reduced coal consumption as well as Carbon Di-Oxide (CO2) emission, it said. The project is articulated with a timecycle of two and a half years, with an estimated cost of ` 1,554 crore, with a contribution of ` 270 crore from BHEL, ` 50 crore from NTPC, ` 234 crore from IGCAR, ` 100 crore from Department of Science and Technology (DST). Balance amount of ` 900 crore will be funded by Department of Heavy Industry (DHI) as grant, the statement said. The project will allow Indian industries to design, manufacture and commission higher efficiency coal-fired power plants with indigenously developed technology and manufacturing processes. This will be the first time large power plant equipment will be manufactured with advanced technologies, but without any technological collaboration/licensing agreement with foreign companies. "The proposed technology is still in research stage. It is still not developed and demonstrated anywhere in the world," it said. The consortium partners are working on the project from the basics of material development, characterisation of alloys for high temperature and high pressure applications, basic principles of thermal engineering useful in design from scratch for large equipment like boiler among others. Power generation from coal contributes to about 38 percent of CO2 pollution in the atmosphere. Twenty percent reduction in CO2 emission at source combined with 20 percent saving in coal consumption compared to a sub-critical plant and by about 11 per cent compared to a supercritical plant are the primary reasons justifying this project. Use of this technology in all future large power plants will ensure energy security for the country for a longer period, along with a greener environment. Chemical Engineering World
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Covestro-designed Solar Impulse completes its Initial Global Flight Covestro was principally responsible for the design and construction of the Solar Impulse’s Si2 cockpit which employs the most innovative polyurethane and polycarbonate systems, considerably reducing the weight of the plane while safeguarding ultimate protection for the pilot.
S
olar Impulse has made histor y by completing the first ever roundthe-world flight powered solitar y by solar energy. The plane landed at its star ting point in Abu Dhabi at 04:05 am local time, after a final leg of 48 hours and 37 minutes from Cairo.
T h e a i r c r a f t t o o k o f f f r o m C a i r o fo r the last leg of its circumnavigation of t h e g l o b e. I t f l ew m o r e t h a n 4 0 , 0 0 0 kilometers without using a drop of fuel, breaking numerous world records. Covestro was on board with ultralightweight materials. The company was
responsible, in par ticular, for the design of the cockpit. “On behalf of all employees of Covestro, I s i n c e r e l y c o n gra t u l a t e yo u o n t h i s courageous work,” said Covestro CEO Patrick Thomas. “We are very proud of having contributed to the success of this project and of pushing boundaries with the materials we developed.” An official par tner of the Solar Impulse project, Covestro shares the pilots’ delight about their successful premiere. During its flight around the world, Solar Impulse made stopovers on four continents (Asia, North America, Europe and Africa), and flew across two oceans (the Pacific and the Atlantic), as well as the Mediterranean Sea and the Arabian Peninsula. On the way, it set several new aviation records, including that of the longest solo duration for an airplane (117 hours, 52 minutes) achieved by André Borschberg on the leg from Japan t o H aw a i i , a n d t h e f i r s t c r o s s i n g o f the Atlantic Ocean in a solar air plane achieved by Bertrand Piccard. “It’s a historic first for renewable energy and clean technologies, not only for aviation”, said Solar Impulse pilot, initiator and chairman Bertrand Piccard, on arrival.
“On behalf of all employees of Covestro, I sincerely congratulate you on this courageous work,” said Covestro CEO Patrick Thomas. “We are very proud of having contributed to the success of this project and of pushing boundaries with the materials Mr. Patrick Thomas CEO, Covestro
32 • August 2016
we developed.”
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CEW Features Case Study
Watson-Marlow provides Dynamic Dosing Operations and Maintenance Savings to Tissue Manufacturer Watson-Marlow Fluid Technology Group’s extensive range of peristaltic hose pumps are being installed by a well-known European manufacturer of toilet & paper toilets in its production processes. The pumps, which comprise several APEX and Qdos models, are at present performing vital dosing operations, archetypally on a 24 hour basis. Both the stoutness and compact maintenance necessities of Watson-Marlow pumps have proved striking, while their innate precision has also helped the company to condense its chemical consumption considerably. The case study looks at the successful trials of APEX & Qdos models & explores its distinctive features.
O
ne of Europe’s largest manufacturers of toilet tissue and paper towels is now using an extensive range of peristaltic hose pumps from Watson-Marlow Fluid Technology Group in its production processes. The pumps, which include numerous APEX and Qdos models, are today performing vital dosing operations, typically on a 24 hour basis. Both the robustness and reduced maintenance requirements of Watson-Marlow pumps have proved attractive to this manufacturer, while their inherent accuracy has also seen the company reduce its chemical consumption significantly.
factor considering the pumps would be required to run 24 hours a day. Now, the enzyme dosing station is equipped with two 521F/R2C pumps, on which the Watson-Marlow Marprene tubing is very rarely changed. 521F/R2C models offer flow rates up to 250 litre/h at 2 bar peak pressure, and feature 520 LoadSure elements. Moreover, the 520REL pumphead delivers large swept volume with sprung rollers for high accuracy. A year later the company was facing another challenge and once more turned to Watson-Marlow for the solution. In the company’s offset printing production
process, the transfer of sheet paper is performed using a rubber ‘mat’. In short, images on metal plates are transferred (offset) to rubber blankets, or mats, and then on to the toilet tissue. Rubber is used because it readily conforms to the surface of the tissue, however, the company was finding that the mat was becoming subject to increasing levels of fouling. To address the problem, a dosing station for sodium hydroxide was installed and Watson-Marlow was called upon once more for this application. After consultation, a Bredel APEX 20 hose pump was selected, not simply for its
The main mill at this high technology plant consists of two machines for the production of paper and eight converting machines. The production machines comprise numerous dosing stations, where since 2011 the company has been enjoying the benefits of Watson-Marlow 521F/ RC close-coupled pumps. These were selected by its Methods and Processes Project Manager, in response to a request for a reliable system that could dose enzyme at the pulp preparation stage. Successful trials Trials showed that Watson-Marlow’s peristaltic pump technology was extremely robust, thus minimising any maintenance requirements – a principal 34 • August 2016
Chemical Engineering World
CEW Features
Diaphragm pumps replaced Most recently, electromagnetic diaphragm pumps on the company’s coating stations started to prove problematic. Not only were there issues of backpressure, which meant valves were getting blocked, engineers reported that maintenance was becoming long, complicated and dangerous. The three diaphragm pumps at this station were replaced with three Qdos30 Universal+ chemical metering pumps for the necessary coating chemicals. The advantages of Qdos30 Universal+ pumps include the absence of valves and the fact that the chemicals remain completely confined within the ReNu pumphead,
thus delivering total operator safety. Maintenance is also quick and tool-free, which means production downtime is minimised. With flow rates up to 500 ml/min and 7 bar pressure, the Qdos30 Universal+ is enhanced by offering the flexibility for automatic and manual control together with configurable 4-20 mA input and output, thus allowing connection directly to the process controller.
the two paper production machines, and three coagulant dosing pumps for treating water in the company’s flotation units. The factory is booming and a third production line is now planned, with the goal of producing 90,000 tonnes of paper per year. The plan is for the new line to be equipped Watson-Marlow dosing pumps to ensure continued dosing accuracy.
Cost savings The company has reported that it is “very happy” with the Qdos pumps as they provide complete peace of mind, safety and cost savings. Use of coating chemicals has reduced significantly.
Author’s Details
The performance of the Qdos pumps has been so impressive, that the company has also adopted six further Qdos models on the dryer protection station serving
Joanne Lucas Group Marketing PR Coordinator Watson-Marlow Fluid Technology Group Email: joanne.lucas@wmftg.com
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advantageous peristaltic operating technology, but its ability to run dry, as well as its high extraction rate. The APEX 20 is capable of delivering flow rates of 8.7-870 litre/hr and pressures up to 8 bar.
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36 • August 2016
Chemical Engineering World
CEW Features Technical Article
Sizing and Selecting the Proper Metering Pump In process application, large amounts of chemicals are used during daily operations and the volumes of chemicals are large and very precise, with exact amounts delivered according to strict injection schedules. Thus the pressures - from very high to very low – for injecting the chemicals should be governed precisely. Metering pumps have—whether mechanically, hydraulically or electronically actuated—raised to the fore as a technology of first choice for the injection of chemicals in processing and agricultural applications, but within the realm of metering pumps there are many different styles and modes of operation. The article explains the different metering-pump technologies and illustrates how the user should select the proper size and style depending on the injection application for which the pump will be tasked.
A
typical process application can consume large amounts of chemicals during daily operations. While the volumes may be large, though, they must also be very precise, with exact amounts delivered according to strict injection schedules. The pressures—from very high to very low—that the chemicals are injected at must also be governed precisely. This demand for precise flow rates at predetermined schedules and pressures requires the use of a very specific pumping technology, one that can ensure successful, reliable adherence to the injection schedule and fluid volumes. Metering pumps have—whether mechanically, hydraulically or electronically actuated—risen to the fore as a technology of first choice for the injection of chemicals in processing and agricultural applications. Today’s metering-pump technology can be easily set to deliver exact volumes according to a set schedule, and at varying pressures. But within the realm of metering pumps there are many different styles and modes of operation. Know the Variables When determining which metering pump is the best option for a chemicalinjection application there are a number of variables that must be taken into consideration, including:
38 • August 2016
• Flow Rate: Metering pumps should never be oversized, meaning that determining the exact flow rate that is required for the application is of paramount importance. With that in mind, a metering pump should be sized so that the maximum expected flow rate is 85 to 90 per cent of the pump’s capacity, which will leave room for additional capacity, if needed. • Materials of Construction: Metering pumps are available in a variety of materials, most commonly 316 stainless steel, C-20 stainless steel, PVC and Kynar PVDF. When selecting a metering pump’s materials of construction, the corrosion, erosion and solvent action of the chemical must be taken into consideration. For example, solvent-based chemicals may dissolve plastic-headed pumps, while acids and caustics may require stainless-steel models. The effects of erosion must also be considered when the chemical takes the form of abrasive slurry. • Chemical Makeup: Chemicals come in many formulations, from extremely thin to highly viscous, while they can also be classified as a slurry or off-gas when transferred. Standard metering pumps are typically able to handle clear liquids with viscosities ranging from water-like to 1,500 cPs. Chemicals with viscosities that approach 5,000 cPs or have light
suspensions will require special liquid ends. Those with viscosities up to 20,000 cPs or that contain up to 10 per cent solids will require special diaphragms, while ones that automatically vent accumulated gas will need their own variety of liquid ends. • Driver: Drivers, which can be powered by electricity, water, gas, air or the sun, must be selected according to the utilities that are available. Driver selection must also take into account any environmental hazards that may be found in the operating area, with the operator realising that pumps used in remote locations may not be able to be inspected as often as those in controlled environments. • Environment: Determine if the pump will be operating indoors or outdoors. If used outdoors, the pump must be sheltered from direct sunlight. Any pumps that will be used in freezing temperatures can only pump fluids that will not freeze at that temperature. • Method of Control: The operator must know how the pump will be used, either manual continuous operation, on/off operation of operation that is governed by a process signal. When all is said and done, method of control may be the most important variable when choosing a metering Chemical Engineering World
CEW Features Metering pumps have long set the standard in chemical-injection applications, but only if the operator selects a model that addresses all of the many operational variables. pump, so let’s take a closer look. Many styles of metering pumps allow their flow rate to be adjusted manually through the use of a micrometer dial. Adjusting this dial changes the pump’s stroke length and allows the pump to be operated anywhere between 10 per cent and 100 per cent of its rated flow capacity. Metering pumps with micrometer dials may also feature a variable speed drive that allows adjustment of the pump’s stroke speed. Utilising the two in unison can allow additional adjustability or turndown capabilities over the range of the drive, depending on the pump’s stroking speed. For example, a pump operating at 75 strokes per minute (spm) would produce a 5:1 turndown ratio on speed with the variable speed drive and a 10:1 turndown ratio on stroke length via the micrometer dial. Flow rates can also be controlled automatically by a process signal and through the implementation of electric or pneumatic positioners that can adjust the stroke length, which will deliver a full 10:1 turndown ratio. In this method of control, the number of doses will remain constant with the size of each dose reduced, resulting in doses that are uniformly distributed in a constantly flowing line.
the timing of each stroke from start to finish is uniform at every stroking speed. Planning a Metering-Pump Installation So now that all of the variables have been identified and reviewed, it’s time to design the pumping system, keeping in mind any location or environmental concerns that may be present. For best results, the system’s design should originate from the liquid source or feed tank and work its way to the injection point while keeping in mind that metering pumps will be able to ‘push’ against great pressures but will struggle to ‘pull’ over longer distances. This means that suction lift should be limited to no more than four feet (1.2 meters) and that a foot valve should be used in top-mount installations. Flooded suction is always preferred in a meteringpump installation as it makes the pump easier to prime, but the length of the flooded suction should be limited to six or seven feet (1.8 to 2.1 meters). And, as with all pump installations, adequately sized lines should be used and piping runs should have minimal bends, elbows
or other design characteristics that may restrict or limit flow. Other components of the installation to consider include: • Suction Piping: The traditional rule of thumb is to use suction piping that is one size larger than the pump’s suction connection, though it is acceptable to use piping that is the same size as the suction connection if the metering pump will be operating at a slow speed when transferring low-viscosity chemicals. Generally, do not use hard piping that is smaller than 1/2” in diameter or that is smaller than 3/8” in diameter for low-flow applications that use plastic tubing. • Discharge Piping: The size of discharge piping is not as critical as that of suction piping, but the piping must be suitable for the discharge pressure. Typically, matching the pipe size to the discharge connection should be sufficient to ensure proper and reliable operation. • Suction Strainer: A suction strainer should always be used as it will prevent foreign matter from entering the pump’s ball checks.
Metering pumps that use a variable speed drive will deliver a turndown ratio that is determined by dividing the pump’s stroke speed by its minimum operating speed. A variable speed drive will enable the pump to inject a dose of the same size on each stroke, but since the stroke speeds will change, the doses themselves will be less frequent. Additionally, it is not practical to use a variable speed drive on motordriven pumps that normally operate at speeds less than 100 to 150 spm since slowing the motor causes each stroke to take longer to complete from start to finish. However, electronic metering pumps, which are pulsed by a solenoid, can operate at less than one spm because 40 • August 2016
Chemical Engineering World
CEW Features spikes that may be caused under these acceleration circumstances and, in the case of high-volume pumps, reduce piping harmonics.
• Flanges/Unions/Compression Fittings: At least one of these must be installed at the pump’s suction and discharge ports in order to more easily facilitate maintenance procedures. • Isolation Valves: Large-port, quickopening isolation valves should be placed at both the suction and discharge ends of the installation as a way to ease maintenance operations. Ball valves are usually the best choice for this operation, while needle valves should not be used because their design will cause the creation of a flow restriction. • Calibration Column: Because metering pumps very often feature pulsed flow at low volumes a drawdown calibration column is the most accurate and convenient method to measure pump performance, provided that the liquid in the column draws down smoothly and stops precisely at the end of each suction stroke. A tall, thin column should be used to ensure ease of reading and reporting accuracy. Calibration columns can also be helpful in determining if any wear has occurred or dirt has accumulated in the pump’s check valves; if the liquid in the column ‘bounces,’ that may indicate that the valves are worn or dirty. • Relief Valve: Though the metering pump may be constructed with an internal relief valve, it is recommended that an external relief valve also be installed. The external relief valve should be set at 50 psi (3.5 bar) or 10 per cent above the maximum operating pressure, whichever is greater. Any 42 • August 2016
chemical that flows through the relief valve is piped back to the feed tank. Using transparent tubing for the relief valve will allow the operator to observe any returned fluid and identify any impurities. When piping the relief valve’s return to the suction side of the installation, the return must be upstream of the pump’s isolation valve so that the flow path will not become blocked. • Back-Pressure Valve: This component is only necessary when the installation does not produce adequate back pressure and the pump does not contain a built-in back-pressure device. Back-pressure valves are also required when a system has a low-pressure injection point that is hydraulically lower than the feed tank. • Pressure Gauge: If this optional device is installed, a diaphragm seal must be used if the pump is to be transferring chemicals that arte corrosive to stainless-steel gauge parts, or are viscous or contain particles that could clog the Bourdon tube within the gauge. The pressure gauge should be sized 30 per cent to 50 per cent larger than the maximum expected pressure that is produced by the system. • Pulsation Dampener: Pulsation dampeners are most commonly required in systems that feature long discharge lines where fluid acceleration during the pumping process can adversely affect the pump’s maximum pressure capacity or relief-valve setting. The pulsation dampener will minimise the pressure
• Injection Quills/Check Valves: An injection quill that is installed at the pump’s injection pump will serve as a check valve while providing better dispersion of the chemical. In lowpressure applications, an injection quill that incorporates a corporation stop, which allows the injection quill to be inserted or removed without having to drain or shutdown the system, will improve efficiency and overall performance. Conclusion In process or agricultural applications where precise, reliable, efficient injection of chemicals is critical to optimising performance, metering pumps have been proven over the years to deliver the required method of operation. However, knowing that requiring a metering pump is not nearly enough to ensure that the best pump will be chosen for the job. A long list of important variables must be considered, along with an array of pump components that will help optimise performance, if deployed appropriately. Successful chemical injection via metering pump will only be achieved if all variables are taken into consideration and system installation adheres to suggested protocols.
Authors’ Details Tom O’Donnell Director - Business Development Neptune Chemical Pump Company & PSG Email: Tom.ODonnell@psgdover.com Ravi Prasad Director of Sales PSG India Email: sales.psgindia@psgdover.com Chemical Engineering World
When others stop, Saurus939 carries on. The vacuum pump unique in reliability, performances and operating costs.
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CEW Features Technical Article
Selection of Correct Non Return Valve in a Piping System for Larger Benefits For several decades, Swing Check valves have been largely used in industries to act as Non Return valve in a piping system. However in a sophisticated piping system, it is substantial to select the valves not only functioning as return valve but considering the consequences it can have in the entire piping system safety and in overall cost. End user can advantage significantly by understanding the capabilities, limitations, advantages & disadvantages of the check valve they employ. The article scrutinizes three types of Check valves - Swing Check Valve, Dual Plate Check Valves and Axial Check valves. In order to find the best fit for a given application, several operating parameters need deliberation. All these may not be imperative for a given application but they all play a role in the selection process.
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he use of check valves in a piping system is a very common practice, most piping systems depend on fluid moving equipment to energise the media, the protection of such equipment e.g. Pumps and compressor from back flow must be carefully planned in any piping system and Check valves (Non return Valves) are frequently utilised for this purpose. Though these are relatively simply devices from functional standpoint, they are often installed without adequate consideration of their performance characteristics and without proper understanding of the limitation of various designs available. For many decades, Swing Check valves have been predominantly used in industries to act as Non Return valve in a piping system. However in a sophisticated piping system it is important to select the valves not only functioning as return valve but considering the consequences it can have in the entire piping system safety and in overall cost. End user can benefit greatly by understanding the capabilities, limitations, advantages & Disadvantages of the check valve they employ. Often decisions are made on past references
and to some extent on marketing. It should however always will be remembered that more often than not, no two piping systems are identical and the Check valve that is adequate for one application may not be suitable for another necessitating valve modification or in some instances a totally different valve design. For simplicity in this article, we will examine three types of Check valves - Swing Check Valve, Dual Plate Check Valves and Axial Check valves. In order to find the best fit for a given application, several operating parameters need consideration. All these may not be important for a given application but they all play a role in the selection process. The main Criteria’s one need to consider while selecting the right type of check valves are: • • • • • •
Initial Cost Maintenance Cost Pressure loss and Energy Cost Non Slam Behaviour Flow characteristics Fluid compatibility
Often decisions are made on past references and to some extent on marketing. It should however always will be remembered that more often than not, no two piping systems are identical and the Check valve that is adequate for one application may not be suitable for another necessitating valve modification or in some instances a totally different valve design. 44 • August 2016
Initial Cost: It is the factor of cost user needs to incur in procuring the valve from supplier and cost which he needs to incur in the installation of valve. Now if we compare Swing Check valves V/s Dual Plate check valves weight for 12” size there is difference of almost 30% part of this material saving is consumed in precision machining and lapping to achieve high level of performance over a longer run. Normally sizes 6” and above of Dual plate valve will cost lesser than Swing Check valve. Higher the size and material grade higher is the saving in product. Now in installation also you need lesser supporting structure for Dual Plate due to lesser weight and you need fewer numbers of fasteners to clamp Dual plate with adjacent pipe flanges. So on both counts Dual Plate check scores better over Swing Check. Noz check is a high end valves used for specific application and is costlier to both Swing Check and Dual Plate Check Valve. Maintenance Cost: It is safe to say that more moving parts in a valve more is the maintenance cost. Swing Check valves if not chosen correctly which is often the case can cost heavily due to immature failure on account of fatigue and slamming. It is important to choose the correct size matching with flow rate, one study points out that almost in 70% cases swing check valve is found oversized causing partial opening resulting into Chemical Engineering World
CEW Features chattering and slamming besides high pressure drop. On other side for Dual plate it is important that valve is chosen from proven manufacturer who has strict control in design and quality as it is spring which is the heart of valve if not chosen correctly may fail prematurely and can cause disruption in operation besides needing a replacement thus adding to the cost of maintenance. Nozzle check valve though has the spring but it works on compression mode unlike torsional mode in Dual plate check valve thus chances of spring failure is minimal. Crane Fluid handling associated with invention of Dual Plate check valves (Mission Valves) has experience in selecting the springs from proven source which are tested for millions and millions of cycle to perform. Pressure Loss & Energy Cost: Pump or compressors needs to generate the discharge to overcome static and frictional loss of given piping system. While static head is the difference in elevation between the source and highest point of service. The frictional loss is caused by roughness in the pipe and loss by valves and fittings. Valve body geometry dictates the general flow area through the valve and some valves restrict the flow are to below 80% of pipe area thus causing huge head loss, 2nd design of closing member also plays an important role in head loss of valves, if disc swings or rotates out of the flow path can induce lower loss another important factor is special contour and shapes to fully open at low fluid velocity and create a smooth path through the valve thus inducing lower loss. In correctly engineered Swing Check valve Disc is normally moves out of flow path when in fully open condition but reality is different as in almost 70% cases it is found that it is never 100% open and thus never moves out of flow path fully. Its Disc is heavy and not engineered to open at low fluid velocity. In Dual Plate check valves Plates shape is engineered to achieve smooth path and are also much lighter in weight thus fully opening at low fluid velocity, Highly engineered 46 • August 2016
Dual Plate Check valves use PTFE/ Graphite Sleeve and Long leg Springs to make movement of plates frictionless and highly smooth thus reducing frictional loss to a higher degree Same is the case with Noz check rather in smaller sizes pressure loss is lower than Dual plate and Swing Check valves. Pressure loss is normally measured by CV flow coefficient which is defined as the amount of water in gallons per minute that will pass through a valve with a 1PSI pressure drop, hence more efficient the valve greater is the CV value. Another coefficient used for calculation of head loss is resistance coefficient Kv which is defined as Kv = 890 d^4/Cv^2 H = Kv V^2/2G G:Gravity in ft/Se2
Pump or compressor to overcome the additional head loss from the valve with the equation Flow Characteristics; Water hammer and its associated problem of surge pressure, vibration and shock can have serious consequences in a piping system conveying fluid, if check valves are chosen without proper consideration to their dynamic performance. They can be a major contributor to the aforementioned problem. Dynamic performance is a term used to describe how a check valve performs under various pump shutdown situation and normally illustrated by a plot of reverse velocity V/s deceleration (dv/ dt). All check valve permit some degree of reverse flow prior to closure in a
D: Diameter of valve in inch , CV: Flow coefficient of Valve Kv: Resistance coefficient V: Fluid Velocity in Ft/Se H: Head loss feet of water column.
The lesson here is while it is important to consider Kv value between type of valves, the head loss between various suppliers of a given valve type does not typically produced significant change in system operation. As head loss is a clear function of fluid velocity so flow condition can affect the valve head loss. Further the velocity may affect the open position of valve. Swing check valve may require between 4-8 Ft/Se of velocity to be forced fully open by the flow. If the valve is not fully open the head loss can be significantly higher than the published head loss, even double. Hence the minimum full open velocity should be used when sizing and computing head loss for swing check valve. The head loss from various valves can be converted into annual energy cost related to electrical power needed by the A= (1.65QHSgCU)/E Gallon per minute
pump shutdown situation and it is sudden reduction of this backflow to zero which yield a rising surge in pressure, this can be coupled with a pressure drop on the upstream side ,resulting in the formation of vaporise cavities ,compounding the water hammer phenomena and Slamming. The higher the revers velocity, the higher is the surge pressure developed and the higher the impacting force generated upon valve closure. Therefore it is important to minimise the reverse velocity, as the surge pressure generated and impact force may damage the pipe system and excessive noise may be created Slamming relates more specifically to the valve itself and depends upon the right type of check valve selection. Valve slam occurs after a pump or compressor stops when forward flow decelerates, reverse
A: Annual energy Cost ion $ per year, Q: Flow rate in
H : Head Loss in Ft of water, Sg- Specific Gravity ( for water 1) , C : Cost of electricity $/ KWH U : usage percent X100 ( 1 equal to 24 Hrs per day), E : Efficient of Motor ( Usually 80%)
Chemical Engineering World
CEW Features
Vr Reverse Velocity (m/s)
Swing-Check
Dual Disc Check Valve
Figure 3, Dynamic response curve.
Nozzle Check Valve -0-0-
dv / dt Deceleration (m/s2)
and accelerate back. The check valves must close quickly before the reverse velocity is too high, in order to minimize the surge pressure and protect the line. Extensive research has been conducted into the dynamic response of all check valves and it has been found that slam can be reduced by improving dynamic response of valve. This is achieved by ensuring that • The Disc has low inertia and friction • The travel of Disc is short • The closure of the disc is assisted with springs On all above parameters Axial Check (Noz Chek) scores high over Swing type and Dual Plate type, another feature this valve has is maintenance free as spring is centrally guided and spring force is on compression unlike in Dual plate check valves where spring force is torsional As clearly visible Swing check has a poor response to changes in a fluid movement in a pipeline, Spring loaded Wafer Check Valve such as crane Duocheck using a maximum torque independent springs has a better response whereas a system which requires a very fast response Axial ( Nozzle )check provide excellent response time ,the reason is moving components are of lower mass
.have a shorter distance to travel and use of properly size spring is helpful. In making a decision on what type check valve to use, on basis of dynamic performance, following guidelines can be useful It should be noted that because the Nozzle check valves has the best dynamic performance, this does not mean it has to be selected for all liquid application . It is more suitable for very rapid deceleration rates specifically in incompressible flow.
reduced, with this mind Dual Plate or nozzle Check valves should not be used for the media containing high solids Now that the types of check valves and their performances are understood, one needs to apply rational process for specific application that satisfies System parameters. There is no single Check valve that is best for all application. Every Piping systems and Installation will require different weights to be given to selection criteria to arrive best suited type of check valves
Fluid Compatibility: Line media is critical for selection of type of check valve, Normally most type will handle clean media and will need special attention if suspended solid concentration is on higher side, If the valve has a straight smooth flow path, the potential for clogging is greatly
Author’s Details Mr. Dinesh Upadhyay Sales Director- India CRANE ChemPharma & Energy Flow Solutions, India Email id: dupadhyay@cranecpe.com 48 • August 2016
Chemical Engineering World
CEW Features Technical Article
Der Antrieb is in control There must be appropriate interfaces for the vertical integration of sensors and actuators into control, management, and production planning systems, and high-quality data transmission must be ensured. NORD frequency inverters therefore monitor and transmit drive data and also collect information from externally connected digital and analog sensors and actuators.
T
he first and foremost prerequisite of intelligent process control – wherever the controller is installed and however it is connected (by cable or wireless, via Industrial Ethernet or Internet) – is accurate data from the field level. The components themselves must communicate their operating status in order to allow conclusions about what is happening in networked system segments. There must be appropriate interfaces for the vertical integration of sensors and actuators into control, management, and production planning systems, and high-quality data transmission must be ensured. NORD frequency inverters therefore monitor and transmit drive data and also collect information from externally connected digital and analog sensors and actuators. Moreover, they enable condition monitoring and predictive maintenance using software capabilities for efficient diagnostics. The inverters can, for example, calculate the state of the gear lubricant and indicate when an oil change is required. They can also autonomously monitor wear on the braking surface as well as the load situation for the entire drive train. Based on such data, operators can implement predictive maintenance, thus augmenting plant availability. Autonomous Removal of Obstacles The frequency inverters can utilize their versatile sensor interfaces to do much more than just pass on data to a central controller. These drives also react to changing process conditions according to their parameterization. They can implement closed loops based on their
50 • August 2016
integrated PI controller functionality. In metering applications, for example, NORD drives detect the fill level and control replenishment. In all kinds of process applications, networked drives ensure that glitches that occur will often not result in downtime with considerable costs. By monitoring the load situation, the on-board PLC of the inverter is able to detect blockages of pumps, screw conveyors, or agitators. If proper drive parameters are set for glitch scenarios, a NORD drive will, for instance, first attempt to remove a mechanical obstacle by reversing direction and by pulse operation. If this effectively resolves the blockage, the drive will then resume normal operation. If the problem persists, the inverter can submit an error signal to the control level and can possibly initiate a fallback procedure, e.g. have other networked drive units unlock a bypass. The PLC capabilities of these inverters significantly contribute to higher plant availability and lower service costs.
Application Development Made Easy NORD also facilitates application development, providing the userfriendly, free-of-charge NORD CON programming and parameterization software that supports drive-related functions according to IEC 61131-3, as well as the PLCopen motion control library. Customer-specific routines can be freely programmed in the text-based programming languages “Structured Text” or “Instruction List”. All driverelated functions can be implemented directly in the inverter PLC. Users therefore do not need to spend time and money on the development, verification, and validation of an application-specific firmware. Moreover, NORD CON enables remote access via Ethernet tunneling – for instance, from a notebook with a standard Ethernet interface –, which gives users very flexible remote diagnostics and maintenance options. NORD frequency inverters can also manage safety applications, notably for implementing Safe Stop 1 (SS1) and Safe
Figure 1: Smart drive systems increase manufacturing efficiency
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With our extensive knowledge and experience in the power transmission arena, we continuously innovate and launch new products, aimed at meeting the varied application needs of our customers. Our line of products for the Chemical & Pharmaceutical sector manufactured at our Chennai production facility in India, applying state-of-the-art technology, ensuring superior quality standards and matching the best cost/performance ratio. While the AS Series is most dependable and performing solution for all inline drive applications featuring unsurpassed Quality to Price ratio, the light-weight F Series ensures rugged and effective operations. Compact, and yet extremely powerful, are the units of the 300 series planetary drives that make them the ideal choice for all the severe duty applications where shock loadings and impacts are more the rule than the exception. Precision Planetary gearbox along with new range of AC Servomotors and servo drives along with Brushless DC Motors and drives is complete range of compact and flexible solution that are versatile and featuring control for high performance and unbeatable advantage in scalability. Welcome to the world of Bonfiglioli! Bonfiglioli Transmissions (Pvt) Ltd Survey No. 528, Perambakkam High Road, Mannur Village, Sriperumbudur Taluk • Chennai 602 105, Tamil Nadu www.bonfiglioli.com - salesindia.ins@bonfiglioli.com
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CEW Features
Figure 2: Up to 24 drives from NORD DRIVESYSTEMS per beverage filtration unit – distributed drive electronics reduce the necessary cabling and all but eliminate EMC issues
Figure 3: Highly intelligent drive family: NORD frequency inverters for control cabinet or motor mounting feature integrated PLC functionality
(Super Premium Efficiency), all of which are manufactured in-house. The IEC standard motors enable simple, easy-toservice, and economical drive concepts. In addition, drive systems from NORD combining a motor and an electronics unit achieve the highest level of system efficiency – an IES2 rating according to the current EN 50598-2 European Ecodesign standard.
Figure 4: All frequency inverters are 100% made in Germany – manufactured and tested at NORD Electronic Drivesystems in Aurich
Torque Off (STO). A library with these safety-related functions is available for free from the NORD website. It enables an evaluation of machine applications according to DIN EN ISO 13849 with the safety integrity software tool SISTEMA. State-of-the-art Decentralized Automation Distributed drive solutions for simple, low-cost, and efficient machine and system designs are still the fastestgrowing product segment for NORD. Drive systems based on the SK 200E line of frequency inverters are most in demand. They offer the same extensive functional range (including positioning, 52 • August 2016
on-board PLC, safety-related drive functions) as their SK 500E counterparts for control cabinet installation. The robust distributed units from NORD cover an exceptionally large performance range. This allows for versatile installations with decentralized process control of pumps, compressors, screw conveyors, etc., with motor outputs up to 22 kW. Moreover, NORD inverters feature high-performance microcontrollers and can control synchronous as well as induction motors. The company configures mechatronic drive systems based on three-phase induction motors and permanent magnet synchronous motors with efficiency ratings up to IE4
Author’s Details Jyoti Mishra Assistant Manager – Marketing NORD Drivesystems Pvt Ltd Email: marketing.in@nord.com Chemical Engineering World
Gear pumps for the chemical and polymer industry.
Boo
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The CHEM gear pump can be used for a wide range applications from low to high viscosity. It is well suited for high temperature, vacuum inlet conditions and high discharge pressure. Applications can range from liquid metering to basic transfer tasks. Pumps of this type can be supplied without heating, electrically heated or
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jacketed. The available materials of construction and design options provided Goodie International Pvt. Ltd. Plot no. 15, Sector 3, IMT Manesar, Gurgaon - 122050, Haryana Tel.: +91 124 42802 61 - 63
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CEW Features Technical Article
Alarm Management is A Continual Process Alarm management is a comprehensive process by which alarms are engineered, monitored, and managed to ensure safe, reliable operations. Alarms are considered to be a Layer of Protection (LOP) and are often used in Safety Integrity Level (SIL) analysis. The intent of these alarms is to warn operators of an impending abnormal situation, which can often have safety related consequences.
I
ndia is developing as a key global player in industrial and technology sector. Rapid industrialization has increased the hazard, risk and vulnerability of the industry and the environment. The calculus of industrial hazard is a blend of industrial systems, people and environments. It is, therefore, required to develop a strategic framework especially towards capacity building and integration with holistic environmental risk management within the broader system of multi-hazard risk reduction and mitigation. Good plant maintenance practices are absolutely critical in terms of plant production rates, safety, and alarm system performance. Ineffective alarm systems pose a serious risk to safety, the environment, and plant profitability. Too often, alarm system effectiveness is unknowingly undermined by poorly configured alarms. Static alarm settings cannot adapt to dynamic plant conditions, and many other nuisances result in alarm floods that overwhelm operators when they instead need concise direction.
how technologically advanced it might be. Operators should be engaged at every stage of the improvement plan, in part to ensure buy-in to the program, but also to capture their knowledge and insights into human limitations. Alarm management is a comprehensive process by which alarms are engineered, monitored, and managed to ensure safe, reliable operations. Alarms are considered to be a Layer of Protection (LOP) and are often used in Safety Integrity Level (SIL) analysis. The intent of these alarms is to warn operators of an impending abnormal situation, which can often have safety related consequences. It is important for the organization to be clear about their reasons for embarking on an alarm management project. These vary between businesses, but without clear agreement on the benefits sought, it is difficult to tailor an effective program to the organization’s needs. There are a number of common drivers:
• • • • • • •
Regulatory compliance Safety improvement Operator efficiency Insurance premiums Reduction of trips Increased production Reduced maintenance costs
The Alarm Management Model The lifecycle model is an excellent method of representing the overall process of alarm system management. It is an ongoing process that is suitable for new or existing systems. The overall structure of a successful alarm management process is fundamentally the same across industries and regardless of plant size. The model is built around five phases: philosophy, identification, alarm rationalization, alarm flood analysis, and operations and boundary management. Phase 1: Philosophy This phase sees the development of a sitespecific alarm strategy. With the landscape better understood, it is also important to
Experience has shown that industrial organizations should undertake alarm management and operations management as a single, combined effort in their drive towards optimization. These initiatives have consistent desired outcomes, and should be part of a larger program incorporating all the work processes and technologies necessary to achieve operational excellence. Human factors are, of course, crucial to effective alarm management. The operator is the most important link in the chain in any alarm system. They are the vital supercomputer, without which no system can be effective, regardless of 54 • August 2016
Figure 1: Layers of Protection in a Processing Plant
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CEW Features develop an alarm philosophy document (APD). The APD is an engineering document focused on all aspects of the alarm management system. This document should clearly outline key concepts and governing rules for the alarm strategy, such as what constitutes an alarm and what risk categories pertain to site operations. The philosophy should also outline roles and responsibilities and change management procedures and project goals, such as target alarm rates. This phase also includes site assessment results, outcomes of discussions with various stake holders that would help in understanding the state of the Alarm system at site and also the scope of improvement. As part of this phase, alarm data is collected from various sources, compared with industry standard guidelines to arrive at baseline for current system. These fundamentals will form a solid foundation for our alarm management improvement program. Phase 2: Identification and Elimination of Bad Actors Phase 2 is where the Alarm Management software is implemented. Once the strategy is clearly defined, the software tools can identify the bad actors so that they can be eliminated first. The correct tool will rapidly accelerate the return on the alarm management investment, particularly in the early stages. For example,
fixing just three alarms a week may equate to a 60% reduction in bad actors over a one-month period. Most of these easy wins will come from removal of nuisance alarms, replacing faulty sensors or changing on/off delays and dead band timings. This phase essentially never stops throughout the process, but a focus at this stage will not only drive clarity in the alarm system; it will also educate the stakeholders on what is required to maintain the alarm system going forward. Phase 3: Alarm Rationalization Alarm rationalization is not specifically about reducing the number of alarms, but rather more about the quality of the alarm by ensuring the design of the alarm is correct in the first place. The purpose of alarm rationalization is to determine the causes, consequences, and corrective actions for an alarm. There are different methods of rationalization, and more than one method may be used to solve alarming issues. Phase 4: Alarm Flood Analysis The analysis will help identify and detail common patterns and consistent areas of weakness, as well as chattering, redundant and consequential alarms. The information identified here, along with the previous rationalization phase, can be used to help define logic for more advanced alarm management techniques.
Phase 5: Operations and Boundary Management Optimizing performance through better operations management, determining boundary management and operating envelopes, as well as processes for shift handovers, concerning alarms, overrides, production targets and actual performance, takes the alarm improvement program to another level. It can also help develop action workflows based on the data captured and integrate these into the daily operations of the site – truly enabling plant optimization through alarm management. While the phases are broadly chronological, the model is flexible enough to accommodate a variety of levels of sophistication in existing strategies. Plants can simply begin at the phase that best reflects the current state of the process. The phases can be executed as and when required. This is crucial, because all sites have different commercial and resource constraints. The flexibility of this model allows any site, of any size, to choose the phases to execute based on their current level of alarm management maturity. Conclusion An alarm management program can significantly improve plant safety, reliability, and profitability, but will only succeed if deployed properly. By following the recommended life cycle methodology and avoiding common mistakes, operators will have an effective and successful alarm management program that will undoubtedly ensure plant personnel are more productive, making the plant and operations more reliable. By aligning the tasks of alarm and operations management within an overall scope of activities—addressed simultaneously as a single combined effort rather than as separate—industrial organizations can realize significant economies-of-scale in their drive towards optimization. Author’s Details
Figure 2: Alarm Management Model
56 • August 2016
Mr. Ulhas Deshpande Business Leader, Projects & Automation Solutions (PAS), Honeywell Process Solutions, India E: hpsmarketing@honeywell.com Chemical Engineering World
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Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite REFINERY Ferolite Ferolite Ferolite Ferolite Ferolite FERTILIZER Ferolite Ferolite Ferolite Ferolite Ferolite & POWER CHEMICALS Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite PUMPS Ferolite SEALING & Ferolite Ferolite PAPER FerolitePRODUCTS Ferolite Ferolite FOR COMPRESSOR Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite SHIPPING Ferolite & CEMENT Ferolite Ferolite Manufacturer of : Ferolite Ferolite Ferolite MARINE FOOD Ferolite Ferolite Ferolite Asbestos & Non Asbestos Gasket Jointing Sheets & Gland Packings INDUSTRIES Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Ferolite Add :- C-178. Site-1, Bulandshahr Road Industrial Area, Ghaziabad-201001 (U.P.) INDIA Telephones : +91-0120-4051500 (60 Lines); Sales : 2702655; Fax : +91-0120-2701002, 4051550 Ferolite Ferolite Ferolite Ferolite Ferolite email : dgmsales@ferolite.com, sales@ferolite.com, vp@ferolite.com Website : www.ferolite.com Asbestos & Non Asbestos Gland Packings
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ADVERTISE TO EXPAND your reach through INSIGHT INTO THE PHARMACEUTICAL AND BIOTECH INDUSTRIES
Capacity : Up to 300 m 3/hr. Head : Up to 140 m. 0 Temp : 200C to 150 C Size : 32 mm thro’ 150mm Working Pressure : 18 kg/cm.2 Materials : CI, CS, CF8M, CN7M, R-55 DIN 4136, CA6NM, CA15, Hastalloy grades, Special Alloy Steels & Non-Ferrous Materials. Pump Flanges according to DIN, ANSI, BS Stds.
For Details Contact
Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com
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KUMARS Forge & Valves Pvt Ltd Forging Ahead…….Creating Values
K
UMARS Forge & Valves Pvt Ltd (Formerly Kumars Autotech (Pune) Pvt Ltd) is a prominent manufacturer o f fo r g i n g s , m a c h i n e d c o m p o n e n t s , flanges, fittings and valves. Kumars has exclusively positioned company’s offering, single point solution for customer needs f r o m d e s i g n , d ev e l o p m e n t , fo r g i n g , heat treatment, machining and valve manufacturing. Kumars valves for application in Oil & Gas, Power, Petroleum, Chemical, Sugar and various process industries are also known to confirm to all global standards alongside being aesthetically admirable. Presently, KUMARS is a renowned brand for the uppermost quality and commended for the supreme critical forged valves comprising high pressure applications, special mater ials and special project necessities & applications. With a widespread knowledge of several steels like carbon steel, stainless steel, Alloy steels and exotic nickel steels like Duplex, Inconel, MOC Monel, Hastelloy, Alloy20 & many more, they are the most trusted name for forged valves, flanges and forgings. K U M A R S m a nu fa c t u r e s fo r g i n g s a n d machined products for various sectors i n c l u d i n g - Va l ve s , I n s t r u m e n t a t i o n , Au t o m o t i ve , D e fe n c e , C o n s t r u c t i o n , Mining, Agriculture, Power, Railways etc alongside with numerous customized forgings for prominent OEM's.
They are certified with ISO 9001 and OHSAS alongside being an IBR & TDC company. "KUMARS GLOBAL" possesses the essential experience, proficiency, financial forte, apparition and inclination to take up challenges & delivering all that goes into a quality product. KUMARS product portfolio comprises of: • Forged Valves: G a t e, G l o b e, C h e ck , B a l l , Y t y p e globe & Pressure Seal Pressure Class: 150# to 2500# • Forgings - Carbon steel, Stainless steel, Alloy steels and Exotic high nickel alloy steels. • Machined Components • Fittings – Socket weld, Screwed & Hex type Compression fitting. • Flanges – BLRF, SORF, WNRF, SW (Standard: ASME, SAE, JIS) • Forged & Machined Balls – Floating & Trunnion Contact Details: Kumar Autotech (Pune) Pvt Ltd Gate No 54/6, Biradawadi village, Chakan - Ambethan Road, Opposite Chakan Telephone Exchange, Chakan, Pune – 410501 Maharashtra, India Contact: +91- 02135 – 254600/ +91 – 9689891950 / 51 Email: kumarsautotech@rediffmail.com Website: h t t p : / / k u m a r s g l o b a l . c o m / index html
KUMARS scorching attitude, vehemence to lear n and honesty have netted the tr ust and confidence of var ied customers comprising many prominent comprehensive brands. 64 • August 2016
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Marketing Initiatives
DelVal Flow Controls Delivering ue, always!
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ependable, smooth and controlled f l ow o f f l u i d s t h r o u g h p i p e s i n a p r o c e s s p l a n t i s v i t a l fo r i t s ex i s t e n c e a n d c o n t i nu o u s o p e ra t i o n . To achieve this efficiently, DelVal Flow Controls offers high quality Ball Valves, Butterfly Valves and Valve Automation Accessories for the chemical process industry. The company was formed in 2006 as a joint venture with DelTech Controls LLC, USA. Located in Pune, India, DelVal has a large well-equipped manufacturing facility. Led by its vision, “We will build flow control products that will be installed in all plants world-wide as a preferred brand�, a team of over 100 engineers with excellent product design capabilities, robust manufacturing process knowledge come together to deliver a world-class Demanding applications in the process industr y world-wide are ser viced by a variety of Ball Valves and high-performance Butterfly Valves. DelVal ball valve program includes the floating ball design and the trunnion mounted ball design. The butterfly valve program includes the highperformance butterfly valve range with
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Marketing Initiatives
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Double Offset and the Triple Offset design. These valves are designed and certified to the latest API Standards. For the chemical process industry, DelVal offers resilient seated butterfly valves. A wide variety of materials for seats such as EPDM, Buna, Viton, Silicone, PTFE and PEEK are available. To complement these, disc materials in SS or with a variety of linings such as Nylon, PTFE and PFA ensure clean and contamination-free performance. The DelTorq Series 21 and Series 25 pneumatic actuators, DelMonitor valve automation accessories, complement the valve program and make DelVal the most comprehensive manufacturer in the world for flow control products and solutions for any process, in any
DelVal quality management system is cer tified for ISO 9001-2008. Butterfly and Ball Valves are certified to CE-PED Module H. Pneumatic Actuators are certified to CE-MD and ATEX Standards. The DelVal facility is certified to ISO 14001 for environment management and OHSAS 18001 for occupational health and safety.
DelVal believes that a good product is built by paying critical attention to the inputs that make the valve. Product designing and quality assurance process implemented meet stringent industry criteria. Each valve is tested for seat leakage and shell leakage and integrity as per approved international standards. Driven by its mission to “provide our customers with superior performance flow control products delivered through efficient people and processes”, DelVal valves are designed to incorporate design features that deliver benefits which few other manufacturers can match. DelVal engineers are aware of the critical costs when a valve fails in the plant. Therefore, to ensure that all DelVal products meet the demanding expectations of the industry, DelVal engineers conduct a wide range of product design validation and life cycle tests in-house. Fire-safe, cryogenic and fugitive emission tests are done in-house.
Contact Details: DelVal Flow Controls Pvt Ltd Gat No: 25, Kavathe, Post-Javale Khandala, Satara District, Maharashtra 412 801 Contact: +919922425418 E-mail: arunshiroor@deltechcontrols.com Website: www.deltechcontrols.com
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DelVal engineers work closely with the customer from selection to installation o f t h e va l ve a n d eve n s u b s e q u e n t l y. Over 100,000 DelVal products have been delivered since inception and the number of satisfied customers is growing in all parts of the world. Therefore, Delivering Value…always! Is an abiding way of life in DelVal.
For Details Contact
Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com
Chemical Engineering World
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Vacuum Technology With An Attitude: Reducing the Life Cycle Cost
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ife Cycle Cost is a Design Factor The principal factor in the design of the vacuum pumps is providing the end user the preeminent Life Cycle Cost solution. • Reduce the frequency of maintenance interventions • Reduce the period of the single intervention • Reduce the consumables • Improve reliability • Improve efficiency
Engineering support as a rule A range of factors determine performance in vacuum processes: Correct distr ibution of the vacuum is essential for achieving better performance and energy savings. While a 0, 1 bar pressure drop represents a 10% vacuum loss, the same pressure
drop corresponds roughly to a 0,014% pressure decrease in a usual 7 bar compressed air system. Therefore it is especially important to consistently size the vacuum distribution network. Experience has shown that installations with pipes of insufficient width lead to the use of a larger vacuum pumps capacity with considerable energy losses. The same applies to the vacuum tanks, which have to be specially designed and sized for any application. The vacuum plants must be designed according to case-specific requirements, and it is therefore vital that the manufacturer of the vacuum pumps advice the end user about the installation’s latent for supreme reliability and efficiency, thereby facilitating the end user to design the most suitable vacuum system.
We perfor m this ser vice as a regular procedure for every project. Every installation is a case history Any successful project starts from a good, solids basis. A vacuum process means driving particles, liquid and/or vaporous, to the vacuum pump. A preventive and accurate a n a l y s i s o f t h e p r o c e s s i s t h e r e fo r e essential to achieve good results. This methodology helps avert crude errors and leads to success. Engineer ing specialists, at Toshniwal have supplied vacuum pumps to several industr ial applications for over 60 years. Today, Toshniwal and par tners world-wide provide full assistance to their customers, from the process s p e c i f i c a t i o n s t h r o u g h o u t l ayo u t a n d installation, commissioning, regular operation, and long-term maintenance needs. Each application is exclusively researched and analyzed for the right selection and sizing of pumps and accessories. Finally, maintenance contracts give end users the prospect to advantage from extended warranties. Tur ning ever y installation into a case history for us and into a success story for our customers is our comprehensive objective. Contact Details: Toshniwal Instruments (Madras) Pvt. Ltd. 267, Kilpauk Garden road, Chennai - 600 010 Ph: 044-2644 8983 / 5626 E-mail: sales@toshniwal.net Web: www.toshniwal.net
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CEW Products Convoluted Bellows
Edge Welded (Diaphragm) Bellows
Bhastrik Mechanical Labs offers convoluted metal bellows in SS-304, 304L, 316, 316L, 316Ti, 321 and AM 350 and exotic metals including Hastelloy C-276, Inconel 600 and 625/625 LCF, and phosphor bronze. Bellows size ranges from internal dia 10mm to 600-mm, wall thickness from 0.10mm to 1.0-mm with single ply or multiple plies. Metal bellows are manufactured in U-shape and Toroidal shape by hydroforming, expanding mandrel forming and elastomeric forming methods. For details contact: Bhastrik Mechanical Labs Pvt Ltd Plot No: 95 & 96, 1 st Main Road Nehru Nagar Indl Estate, Kottivakkam Chennai 600 041 Tel: 044-43593702, 4359703 | Fax: 91-044-24540353 E-mail: admin@bhastrikbellows.com / sales@bhastrikbellows.com
Bhastrik Mechanical Labs possess the capability to manufacture nested ripple type edge welded bellows in SS and exotic metals like Hastelloy C276, Inconel 600, 625 and AM 350 of size ranging from 12-mm ID to 175-mm OD. Thickness of diaphragm varies between 0.1-mm and 0.3-mm. In some special cases Bhastrik Mechanical Labs have welded diaphragms as thin as 0.03-mm (30-µm) with ‘0’ wrinkles and distortion. The precision-formed diaphragms are edge welded by micro plasma/laser welding using special fixtures to prevent uneven stress build up. For details contact: Bhastrik Mechanical Labs Pvt Ltd Plot No: 95 & 96, 1 st Main Road Nehru Nagar Indl Estate, Kottivakkam Chennai 600 041 Tel: 044-43593702, 4359703 | Fax: 91-044-24540353 E-mail: admin@bhastrikbellows.com / sales@bhastrikbellows.com
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PFA-lined Magnetic Drive Centrifugal Pumps Sawant Filtech offers vacuum-resistant PFA-lined magnetic drive centrifugal pumps, Model MKPL magnetic drive chemical process pump and Model MKPL-S self-priming magnetic drive chemical process pump from CP, a Swiss company designed to DIN EN ISO 2858, 5199 and 15783 and compliant with EC Directives 2006/42/EC (Machinery) and 94/9/EC (ATEX). With their sealless design, the MKPL and MKPL-S magnetic drive pumps are ideal to meet the stringent requirements of chemical processing and a multitude of other industries. Made of pure SSiC (sintered silicon carbide) in robust design engineered for ceramics, the bearing assembly provides max reliability of pump operation. Plain and thrust bearings are secured with polygonal form-fit, self-centring anti-rotation devices. Even at high temperatures, the PFA-lined metal plain bearing carrier maintains a constant clearance between the impeller and casing. The MKPL and MKPL-S pumps come with either an open impeller for low NPSH or a closed impeller for high efficiencies. MKPL is designed for operating at up to +200 0C, the MKPL pump is built for safety in handling corrosive fluids in high tempera¬ture applications. Its connection dimensions and performance data conform to DIN EN ISO 2858, making the MKPL easy to retrofit into any installation to replace old pumps. The MKPL-S features an integral priming chamber in the casing. The MKPL-S can even readily pump entrained air in the suction line while running, thus increasing reliability of operation. This pump achieves suction lifts up to 8.5 m.
For details contact: Sawant Filtech Pvt Ltd 102/103 Ram Ashirwad Indl Estate, Bldg No: 2, Ram Mandir Road, Goregaon (W), Mumbai 400 104 Tel: 022-26764171, 26792602 | Fax: 91-022-26764452 E-mail: sawantfiltech@mtnl.net.in or Circle Readers’ Service Card 3
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Products CEW EtherCAT P Beckhoff combines ultra-fast EtherCAT communication and power supply (2 x 24 V DC/3A) in a standard 4-wire Ethernet cable. It enables direct power supply for both EtherCAT P slaves and the connected sensors and actuators in such a way that separate power lines can be eliminated, simplifying system cabling. This makes EtherCAT P the ideal sensor, actuator and measurement bus, providing advantages both for connecting small remote I/O stations in terminal boxes and for decentralised I/O components located throughout the actual process. For connecting sensors and actuators, users can integrate any of the wide range of well-established EP Box modules from Beckhoff in the new EPP versions for EtherCAT P. These include a variety of 4, 8 and 16-channel digital input box modules; 4, 8, 16 and 24-channel digital output modules; numerous 4, 8 and 16-channel IP 67 I/Os with combined digital inputs/outputs; as well as RS232 and RS422/RS485 serial interfaces. There are also new EPP Box modules for analog I/O quantities, such as ±10 V/0-20 mA, differential/absolute pressures, and data from resistance sensors, thermocouples and incremental encoders. For details contact: Beckhoff Automation GmbH & Co KG Huelshorstweg 20 33415 Verl, Germany Tel: +49 (0) 5246 963-0 | Fax: +49 (0) 5246 963-198 E-mail: info@beckhoff.com or Circle Readers’ Service Card 4
High-pressure Pumps High-pressure pumps are manufactured with Advanced Pump Technology. Their pumps are horizontal, simplex or triplex positive displacement plunger pumps. Their high-pressure equipment is time-and-cost-effective solution for cleaning, cutting, removing, descaling, testing, spraying, etc. Pump drive end assemblies are of rugged construction with heavy duty taper roller bearings. Pumps are designed to permit rapid and economical maintenance, particularly regarding plunger, packing and valves are manufactured to ensure accurate alignment on reassembly. Fluid can be accelerated to high velocities through a nozzle by the application of sufficient hydraulic high-pressure (HP). Hydraulic HP is proportional to the product of fluid pressure and the volume delivered. Fluid velocity is proportional to the pressure developed through a nozzle orifice. The impact of high pressure fluid jets can remove deposits which defy mechanical cutting tools, without any damage to underlying materials by correct selection of nozzles, accessories and power sources. Interchangeable conversion kits are available for all pump units so that the pressure/volume relationship can be altered to suit a particular operation without altering the pump speed. For details contact: SRS Pumps Chawl No: B, Pitch No: 3, Pimpal Galli Nr Hindustan Naka, Charkop, Kandivli (W) Mumbai 400 067 Tel: 022-28688422 E-mail: info@srspumps.net / srspumps@gmail.com or Circle Readers’ Service Card 5
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CEW Products Roots Vacuum Pumps
Liquid Ring Vacuum Pumps
The roots-type pumps belong to the group of positive displacement delivery pumps. Two symmetrical pistons having eight features, housed in the pump body, rotate in opposite direction with no contact neither between each other nor with the pump body, meshing continuously. The pistons are driven by a set of gears with synchronised rotation, which guarantees friction-free movement.
Toshniwal provides solution to your vacuum needs in manufacturing of liquid ring vacuum pumps that offer optimum performance and reliability. They offer minimal water consumption and an innovative impeller design that assure extremely quite operation and extending its life even under harsh condition, the most advanced manufacturing process, with the objective to reduce manufacturing time and shortening delivery time. Hydrotwin - PLC-controlled roots + LRVP package for high vacuum application with total liquid re-circulation capacity to 3,900-m 3/hr, max vacuum 2-mbar. Hydro sys - Centralized package vacuum units with total or partial water re-circulation. capacity to 3,500m 3/hr, max vacuum 33-mbar. It finds application in distillation, drying/material transfer/power and steel/food processing/paper/ general vacuum/textile, etc.
During rotation, a progressively growing space is created which corresponds to the suction stage: Phases 1 and 2, being gradually decreased, Phases 3 and 4, compressing the volume of gas. This cycle is repeated four times per each complete rotation of the drive shaft. For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 6
For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 7
Drum Pumps Shanbhag & Associates is the authorised, national distributor for the entire range of Lutz products. Lutz Pumpen GmbH & Co KG, Germany is the premier manufacturer of electric and pneumatic drum/container pumps in the world. The Lutz concept allows the complete pump (drive motor and pump tube) to be used in different containers and liquids as long as both components are approved for use in the liquids. Lutz drum pumps can handle liquids which are aggressive, flammable, thin, viscous, hot or cold, hazardous to ground water and the environment, and vary with respect to their density. The wide variety of liquids and container types/dimensions necessitates an extensive range of drum pump models. They are available in a variety of materials, equipped with electric/air motors adapted to the output requirements, for different voltages (AC/DC), explosionproof for hazardous applications, pneumatically operated, with the required delivery rate and a suitable sealing system. Added to this are pump tubes in varying lengths and wide range of accessories permitting, eg, adaptation to problematic containers or operating conditions. Pump tubes are available with centrifugal impeller or with eccentric screw principle constructions. Tube materials are in PP/PVDF/Alu/ SS-316 (Ti)/Hast-C. Tube drivers are available in electric (Flp/Non-Flp) and pneumatic options. Drum pumps can be offered in sanitary and non-sanitary constructions. For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E), Mumbai 400 093 Tel: 022-40365711 | Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 8
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Products CEW Cordless 3/8” Impact Wrench Ingersoll Rand offers the IQV20 W5132 3/8” Impactool. It has 750 Nm of nut-busting torque and 500 Nm of max reverse torque. It delivers up to 50 per cent more torque compared to the leading cordless 3/8” impact wrench. It matches the power capabilities of many pneumatic impact wrenches so technicians can get jobs done fast, with less tools. Technicians and operators can use the IQV20 W5132 3/8” and ½” Impactools to quickly loosen and tighten a variety of fasteners with four accurate power and control settings. The tool is available with a 3/8” or ½” square drive and four power and control settings. Each setting operates at max reverse torque so technicians don’t need to switch settings to remove a stubborn fastener. The four power modes for forward control include: full power, mid power, wrench tight and hand tight. In addition, the tool comes equipped with a shadowless 90 lumen Chip-on-Board (COB) LED task light that provides a 360-degree ring of light to the area that needs servicing. The light has four settings for high-, medium- and low-light environments, providing increased visibility and access, as well as an off mode. The 20-V battery is compatible with the Ingersoll Rand IQV20 Series battery system. For details contact: Ingersoll Rand India Plot No: 35, KIADB Indl Area Bidadi, Bengaluru, Karnataka 562 109 E-mail: Contact-India@irco.com or Circle Readers’ Service Card 9
Inverting Filter Centrifuges Heinkel offers the inverting filter centrifuge that is accepted and highly regarded in all application areas of the pharma industry. For products with a large proportion of free material <20 um and high filtration resistance, the centrifuge drum can be pressurised with a gas pressure of up to 6 bar in order to combine the process engineering advantages of centrifugation with the possibilities offered by differential pressure filtration. The residual moisture in hard-to-filter products can be reduced by a further 10-20 per cent in comparison with pure centrifugation. Pressure added centrifugation can also be used for drying solid matter to a residual moistness <1%. This drying method is used most importantly in situation where valuable, toxic or extremely small quantities of product are being processed with no transfer of solids between the filtration and drying apparatus. Centrifuging process can be regulated flexibly and adjusted automatically according to product properties. Homogeneous washing results through the even cake structure. Comparatively low consumption of wash medium and consequently low volume of wash filtrate to be processed. No manual emptying of the drum or opening of the process housings necessary. For details contact: HEINKEL Engg Pvt Ltd 209, 2 nd Floor, Block IV, Emrald Plaza Hiranandani Meadows Gladys Alwarys Road, Thane (W), Maharashtra 400 610 Telefax: 91-022-21730785 E-mail: sales@heinkel.in or Circle Readers’ Service Card 10
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CEW Products SS Magnetic Drive Centrifugal Pumps Sawant Filtech offers vacuum-resistant PFA-lined magnetic drive centrifugal pumps, Model MKP magnetic drive chemical process pump, Model MKP-S self-priming magnetic drive chemical process pump and MKTP magnetic drive chemical process sump pump from CP a Swiss company. The MKP, MKP-S and MKTP sealless pumps are ideal to meet the stringent requirements of chemical processing and a multitude of other industries. With their special design using an inverted drive configuration, the MKP, MKP-S and MKTP pumps require no plain bearing carrier. Depending on the pumped medium, they can handle fluids containing solids in concentrations up to 30 per cent with a particle size up to 1 mm. MKP is available in a variety of designs and configurations can be customised and tailored perfectly to each specific pumping application. Its connection dimensions and performance data conform to DIN EN ISO 2858. The MKP-S can even readily pump entrained air in the suction line while running, thus increasing reliability of operation. This pump achieves suction lifts up to 8.5 m. The MKTP is designed for efficiently emptying tanks that have no bottom drain. It pumps corrosive media safely, ensuring that no fluid or vapours emitted can escape into the atmosphere. This pump is available with a column length up to 4 m and can also be supplied with a double-walled jacketed discharge pipe. For details contact: Sawant Filtech Pvt Ltd 102/103 Ram Ashirwad Indl Estate, Bldg No: 2, Ram Mandir Road, Goregaon (W), Mumbai 400 104 Tel: 022-26764171, 26792602 | Fax: 91-022-26764452 E-mail: sawantfiltech@mtnl.net.in or Circle Readers’ Service Card 11
Process Control System Version 8.2 of Simatic PCS 7 offers individual, networked and reliable plant monitoring. Web systems can also be operated and observed over the Intranet/Internet. For this, operators can use extensive configuration possibilities for individual and secured online access to the operating and monitoring level of a production plant, enabling the implementation of benefits such as remote control room concepts. Simatic Process Device Manager supports plant-wide access to field devices. Diagnosis, maintenance, parameterization, configuration and commissioning can be performed by mobile terminals with standard browsers as well as by any optional computer within a system. The PC7 supports operators with a new range of search and visualization functions. The Operator Trend View tool depicts the process sequence in the form of trend graphs for a rapid overview. The group view visualizes existing measuring points, making operation faster and more intuitive for plant personnel. The new Logic Matrix allows the switching of interlock statuses in a production plant in compliance with the cause and effect principle. In mass data engineering has also been substantially extended: for instance technological engineering with function, system and layout plans and the relevant documents for PCS 7 projects. PCS 7 also offers integrated monitoring of all energyrelevant consumption data for a complete plant. The load management functions to control loads such as drives are a constituent part of the technology library and can be simply implemented. Software modules supply the faceplate of the Simatic PCS 7 user interface with operating and diagnostic data, generate messages and guarantee connection to the Simatic PCS 7 maintenance system. Siemens offers a Software Update Service for Simatic PCS 7. This also encompasses support for new operating systems such as MS Windows 10 and Server 2012. For details contact: Siemens Ltd 130 Pandurang Budhkar Marg, Worli, Mumbai 400 018 Tel: 022 39677000, 39677537 | Fax: 91-022-39677500 E-mail: bijesh.kamath@siemens.com or Circle Readers’ Service Card 12
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Products CEW Motorised Double Diaphragm Pumps The DELLMECO DME Series is an electro-mechanical double diaphragm pump. Dellmeco offers energy efficient electric geared motor as the driver for the double diaphragm pumps. The pump technology is especially designed for universal applications. The unique design concept and low energy consumption enable Shanbhag to combine high-tech with proven reliability and quality for the most demanding of customers. DME Series pumps housing is machined from PE and PTFE conductive blocks and also in aluminium, cast iron, AISI 316 industrial and AISI 316 L hygienic combinations; temperatures up to 1200C; dry-running, low shear, versatile fluid handling capability, smooth product transfer; constant flow rate against variable pressure and viscosity; withstands highly corrosive chemicals; long life fully enclosed diaphragms; abrasion resistance with their robust design; capacity up to 650 l/min without variable freqency drive (VFD) flow control; optional VFD flow control for process performance (from 35-70 Hz); wide range of optional accessories available; etc. For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E) Mumbai 400 093 Tel: 022-40365711 | Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 13
M Pumps Shanbhag & Associates is the authorised, national distributor for M Pumps of Italy, a unit of the Mischiatti Group, manufacturer of sealless, magnetic driven pumps. M Pumps is an ISO 9001 and ISO 14001 Certified company manufacturing to API 610 and 685 as well as non-API Pump Standards. These pumps are offered in centrifugal, peripheral, sliding vane, self-priming, centre-line mounted, inline and vertical pump versions. M Pumps manufactures these pumps in metallic, non-metallic and lined constructions. Typical applications are in oil and gas, chemical, pharma, industrial refrigeration, offshore platform, electronic and galvanising and nuclear plant areas amongst others. To safeguard the pumps Shanbhag also offer dry-running protection, temperature monitors on rear casing and ATEX Certification as options for many models. M Pumps are available in 26 designs with over 350 basic models. The wide range of pumps will allow Shanbhag to meet your exact process requirements. For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E) Mumbai 400 093 Tel: 022-40365711 | Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 14
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Chemtech World Expo 2017 Dates: 14 – 17 February 2017 Venue: BC&EC Mumbai, India Details: Platform to showcase services, technologies, innovations and current & future trends of entire value chain of process industry. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
Watertech India 2016 Dates: 15 – 16 September 2016 Venue: New Delhi Details: An event for water, wastewater and solid waste management products/technologies/services Organiser: Messe Frankfurt Trade Fairs India Pvt. Ltd. Contact: +91-22-6144 5900 Email: prashant.lade@india.messefrankfurt.com Website: www.watertechindia.com
Chemspec South East Asia - 2016 Dates: 30 Nov to 01 Dec, 2016 Venue: Queen Sirikit National Convention Center, Bangkok, Thailand Details: Exhibitions for the fine and speciality chemical industry Organiser: Mack Brooks Exhibitions Asia Ltd Contact: +66 (0) 2684 6894 Email: wendy@mackbrooks.com Website: www.chemspec-southeastasia.com SOMChE - 2016 Dates: 1 – 3 December 2016 Venue: Miri Marriott Resort & Spa, Malaysia Details: an established platform for chemical engineers from academia and industries to disseminate their latest research and to highlight new technologies. Organiser: Curtin University, Sarawak Malaysia Contact: +60 85 44 3939 Email: somche2016@curtin.edu.my Website: www.curtin.edu.my International Conference on Chemical Engineering
India Chem 2016 Dates: 1 – 3 September, 2016 Venue: Bombay Exhibition Centre, Mumbai Details: Event of chemicals and petrochemicals industry in India in its 9th edition Organiser: FICCI Contact: +91 22 2496 8000 Email: vishal.ganju@ficci.com Website: www.indiachem.com
Dates: 12 – 14 September, 2016 Venue: Phoenix, Arizona, USA Details: To encourage young minds and their research abilities by providing an opportunity to meet the experts in the field of Chemical Engineering Organiser: Conference Series LLC Contact: +1-650-618-9889 Email: chemicalengineering@conferenceseries.com Website: http://chemicalengineering.conferenceseries.com/
Powder & Bulk Solids India 2016
Petrochemistry and Chemical Engineering
Dates: 13 – 15 October 2016 Venue: BCEC, Mumbai, India Details: Event for mechanical Processing Technologies and Bulk Solids Handling Technologies Organiser: NuernbergMesse India Pvt. Ltd. Contact: +91 11 47168830 Email: priya.sharma@nm-india.com Website: www.powderbulksolidsindia.com
Dates: 05 – 07, 2016 Venue: Phoenix, Arizona, USA Details: The conference will cover advanced technologies in petrochemistry and chemical engineering Organiser: OMICS International Contact: 1-650-618-9889 Email: contact.omics@omicsonline.org Website: www.omicsonline.org KHIMIA 2016 Dates: 19 – 22 September 2016 Venue: Moscow, Russia Details: This event showcases products like raw materials for the chemical and petrochemical industry, and inorganic chemistry, refining and petrochemicals, fuels, etc Organiser: Expocentre Contact: + 7 (499) 795 3841, + 7 (499) 795 3845 Email: chemica@expocentr.ru Website: www.chemistry-expo.ru/en
74 • August 2016
Chemical Engineering World
Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.
CHEMICALS Resipol Adhesives proposes an expansion of synthetic organic chemicals manufacturing unit in village: Rajpur, district: Mehsana, Gujarat. The estimated cost of the expansion is ` 40-million. The current status of the project could not be ascertained. According to SEAC sources, the amanufacturing of existing products, 2.0-TPM benzyl alcohol, 1.1-TPM benzyl benzoate, 3.0-TPM benzoic acetate, 1.4-TPM sodium benzoate, 1.8-TPM sodium acetate will be discontinued and 300-TPM polyester resins (different grades) and alkyd resins (different grades), 90-TPM melamine formaldehyde resin and 85-TPM urea formaldehyde resin will be manufactured as new products. The plot area is approximately 6,033.00-sq m. Unit has proposed 2,000-sq m area for green belt development. Industrial effluent of 0.42-KLD after primary treatment will be evaporated in kettle type evaporator. Two DG sets each of 65-KVA will be provided. It was decided to recommend the project to SEIAA, Gujarat for grant of environmental clearance. Royal Wood proposes a 90-TPM phenol formaldehyde resin, urea formaldehyde resin, melamine urea formaldehyde resin and melamine formaldehyde resin manufacturing unit in village: Modvadar, district: Kutch, Gujarat. The current status of the project could not be ascertained. According to MoEF sources, existing products are 3-million sq m per month plywood, flush door, block board and veneer. The manufactured resin will be used for in-house consumption at the wood products plant. The project will come up on 11,603.62-sq m of existing land. The greenbelt area is 600-sq m. A base platform will be constructed for the resin plant; remaining will be MS structure. Eternis Fine Chemicals proposes an expansion of synthetic organic chemicals manufacturing unit from 42,200-TPA to 60,000-TPA in MIDC Kurkumbh, district: Pune, Maharashtra. The current status of the project could not be ascertained. According to MoEF sources, total land area is 100,400-sq m and built up area is 42,710-sq m. 33 per cent will be developed as green belt area. The project will entail: 1) capacity expansion of existing products and by-products; 2) addition of similar products and by-products; 3) introduction of new eco-friendly biomass boiler as replacement to furnace oil. Project involves manufacturing of fragrance from organic raw materials by chemical process like hydrogenation, esterification, Diels-Alder reaction, cyclisation, dehydrogenation, aldol condensation, etc, followed by distillation to match precise quality standards. By-products capacity will be augmented from 11,400-TPA to 20,000TPA. The estimated cost of the project is ` 1,050-million. The power requirement 12,000-KVA will be available through Government Electricity Board. Panoli Intermediates (India) proposes an expansion of its specialty chemicals manufacturing unit and a new 10-MW coal-based captive power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat. The estimated cost of the project is ` 100-million. The current status of the project could not be ascertained. According to MoEF sources, the total plot area is 15,480-sq m. The capacity of isomers and DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented from 200-TPM to 2,200-TPM, ortho anisidine/para anisidine from 100-TPM to 1,100-TPM, ortho nitro aniline/para nitro aniline from 300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a new product namely, 1,500-TPM derivatives Chemical Engineering World
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CEW Project Update of nitro phenol and a new 10-MW coal-based captive power project. 10-MW power requirement is to be met from MGVCL and 10-MW from the captive power project. The effluent will be treated in proposed effluent treatment plant. Saras Plywood Products is planning a 60-TPM urea formaldehyde resin manufacturing plant in New GIDC Gundlav, district: Valsad, Gujarat. The existing land area is 1.5 acres. The estimated cost of the project is ` 7.5-million. Kalyan Industries is the equipment supplier. The project is waiting for environmental clearance. Civil work will commence in 3 months. The project is planned for completion in this year. According to SEIAA sources, the company has proposed primary treatment plant followed by evaporator for treatment of industrial effluent and has also proposed a multi-cyclone separator. FMC India is planning an expansion of its chemical manufacturing unit at IDA Patancheru, district: Medak, Telangana. The estimated cost of the project is ` 17.5-million. As of September the project was waiting for the environmental clearance. According to MoEF sources, the plot area is 4.027 acres. The company proposes to manufacture 50-TPM of products as part of the expansion. Green belt on 33 per cent of the land area will be developed and maintained. Power requirement will be made available through SPCPDCL. The project will be completed within 2 years. Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312-sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40TPM yellow pigments and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products â&#x20AC;&#x201C; red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26 th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product. Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500-sq m of existing land. The project will entail expansion of single super phosphate capacity from 400TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550-TPD synthetic gypsum, 30-TPD Di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H 2 SO 4 and 0.3-TPD Sodium Tri 76 â&#x20AC;˘ August 2016
Polyphosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018. Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM Carbomazepin and 12-TPM Oxacarbomazepin. The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-m 3 /day) will be treated in the ETP comprising primary, secondary and ter tiary treatment. Treated effluent will be sent to CETP for fur ther treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator. Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat. The project is waiting for environmental clearance. RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date. MINING Metabluu Power, a sister concern of Minera Udyog India, is planning a 75,000-TPA iron ore mining project in village: Devikonda, district: Karimnagar, Telangana. The project is awaiting Government approval. PETROLEUM Indian Oil Corporation is planning a common user facility (CUF) for storage of petroleum products in Berhampur, district: Ganjam, Odisha. Single window clearance has been received. Land acquisition and land allotment is under progress. The project is planned for completion in 3 years from zero date. Chemical Engineering World
Book Shelf CEW Theory, Design and Applications Author/s: Price: Pages: Publisher:
G.K. Sahu 736 (Hardcover) New Age International Publishers
About the Book: This book, written with an applications-oriented approach, is divided into four parts. Part I covers the general aspects of fluid flow and pumps including the governing theories of fluid flow. Part II covers the design and construction of pumps and auxiliaries, drives etc. Part II presents pump selection criteria and procurement actions including fittings and maintenance requirements. Part IV includes miscellaneous items like key to symbols, conversion tables etc. for reference.
Pump Operation and Maintenance Author/s: Tyler Hicks Price: ` 565.00 Pages: 325 (Paperback) Publisher: McGraw Hill Education About the Book: This book was written to help every engineer, foreman, and mechanic charged with pump operation and maintenance to reduce costs. It can be used by personnel in every industry. Typical men who will find this book of much use include plant, mechanical, chemical, petroleum, marine sanitary, civil, irrigation, mining, power-plant, nuclear, and hydraulic engineers.
Hydraulics of Pipelines: Pumps, Valves, Cavitation, Transients Author/s: Price: Pages: Publisher:
J. Paul Tullis ` 3250.00 269 (Hardcover) John Wiley & Sons
About the Book: This comprehensive text/reference addresses all hydraulic aspects of pipeline design. Incorporates many real–life examples from the author’s experience in the design and operation of pipelines. Topics covered include basic equations necessary to pipeline design, how to conduct a feasibility study and perform economic analysis, design considerations for pumps and valves, how to suppress cavitation, hydraulic transients, trapped air, and methods of numerical solution. of governing equations (including applications to complex piping systems). Includes twenty–five tables for easy reference. Extensively illustrated.
Valve Selection Handbook Author/s: Price: Pages: Publisher:
R.W. Zappe ` 287.00 326 (Hardcover) Jaico Publishing House
About the Book: This is a definitive guide to valve selection. It covers the fundamentals of valve construction and application and analyses the different hazards and requirements of all types of industrial fluid flow situations. This edition expands the coverage of pressure relief values and ruptures discs and includes a new section on valve chatter which is a serious problem in installations such as atomic power plants where valve chatter could have catastrophic consequence to the safety of a plant. In addition, there is also information on performance of spring loaded pressure relief valves and a closer examination of valve selection with respect to rupture discs and explosion venting Chemical Engineering World
Handbook of Valves and Actuators: Valves Manual International Author/s: Price: Pages: Publisher:
Brian Nesbitt RS. 11,559.00 416 (Hardcover) Butterworth-Heinemann
About the Book: Industries that use pumps, seals and pipes will also use valves and actuators in their systems. This key reference provides anyone who designs, uses, specifies or maintains valves and valve systems with all of the critical design, specification, performance and operational information they need for the job in hand. Brian Nesbitt is a wellknown consultant with a considerable publishing record. A lifetime of experience backs up the huge amount of practical detail in this volume. • Valves and actuators are widely used across industry and this dedicated reference provides all the information plant designers, specifiers or those involved with maintenance require • Practical approach backed up with technical detail and engineering know-how makes this the ideal single volume reference • Compares and contracts valve and actuator types to ensure the right equipment is chosen for the right application and properly maintained August 2016 • 77
Ad Index CEW Sr. No.
Client’s Name
Page No
Sr. No.
Client’s Name
Page No
Inside Cover I
19
KSB Pumps
29
33
20
Kumars Autotech (Pune) Pvt Ltd
57
9
21
Mist Ressonance Engineering Pvt Ltd
11
Bonfiglioli Transmission Pvt Ltd
51
22
Nirmal Industrial Controls Pvt Ltd
78
5
Busch Vacuum India Pvt Ltd
45
23
Nord DriveSystems Pvt Ltd
6
C R I Pumps Pvt Ltd
35
24
Paharpur Cooling Tower
23
7
Chemlin Pumps & Valves Pvt Ltd
63
25
Rathi Transpower Pvt Ltd
43
8
Cole-Parmer India
59
26
Ravindra Heraeus Pvt Ltd
17
9
DelVal Flow Controls Pvt Ltd
37
27
Shanbhag & Associates
31
10
Ferolite Jointing Ltd
63
28
Shavo Technologies Pvt Ltd
39
11
Garlock India Private Limited
47
29
Suraj Ltd
61
12
Goodie International Pvt Ltd
53
30
Swastik Industrial Valves Pvt Ltd
61
13
Gujarat Fluorochemicals Ltd
49
31
SYP Engineering Co Pvt Ltd
21
14
Hi-tech Applicator
3
32
Uni Klinger Ltd
15
15
Horizon Polymer
5, 18 & 19
33
UNP Polyvalves
27
16
ImageGrafix Engineering Services Pvt Ltd
69, 71, 73, 75
34
Vac Enterprises
41
17
IPP Pumps (India) Pvt Ltd
59
35
Watson Marlow India Pvt Ltd
57
18
Kirlsokar Brothers Ltd
1
Atomic Vacuum Company (Exports)
2
Beda Flow Systems Pvt Ltd
3
Blackbuck
4
Chemical Engineering World
7
Inside Cover II August 2016 • 79
CEW Interview
“All in all GST is a welcome move” Over the last six decades, KSB Pumps Limited has grown with the philosophy to play a vital role in India’s development by equipping the diverse requirements of the pump markets. Rajeev Jain, has recently assumed his new role as the Managing Director, KSB Pumps Limited after his tenure in Indonesia. He shares his view on his new role, GST, end users market in India & company’s future plans to drive the growth of organization, in an exclusive interview with CEW. What was you experience during the tenure with KSB in South East Asia prior to assuming this new role? How do you compare the business environment in S.E Asia as compared to India in terms of available and future market opportunities and challenges? South East Asia is a growing Region with a lot of opportunities. The emerging economies of Indonesia, Thailand, Malaysia, Vietnam offered a lot of growth opportunities for KSB; and we were able to increase our business substantially in the last decade. I had a great opportunity to be in the region to experience the diverse culture of each country in the region and which has helped me a lot to shape up my thinking and also my respect for the different cultures. India, in that respect is different, as it is a more mature market! When I say this; I refer to the variety of Industries; the variety of markets and variety of local Chemical Engineering World 80 • June August 2016 2016
and multi-national manufacturers, and the vast geography too! So obviously, customers are rapidly becoming more sophisticated and differentiated, and hence manufacturers must be agile enough to keep pace! Recently, the long awaited One Nation One Tax has received heads up from both upper and lower houses of Parliament and is likely to be implemented. In your view, how will this impact the market dynamics for the pumps and valves manufacturers in the country in terms of both opportunities as well as the challenges? For us, from the business point of view, this is a very positive change and we hope it will bring a lot of efficiency improvement in our administration. We expect the business to be easier and simpler. The challenges will be on how fast we can adapt to this system and implement it smoothly.
Implementation of GST will attract lot of interest of foreign companies to the Indian market and also provide a major boost to the Make in India campaign launched by the Government. What kind of business trends do you foresee in the near future in your business domain? With the “Make in India” Campaign, we definitely see that there would be increase in investment in this sector. KSB has already committed with an investment of almost 230 Crores; wherein, we are building a totally new facility for 100% indigenous manufacture of pumps for Nuclear and Super Critical Power plant applications. As markets become more diverse and customer segments more narrowly defined, engineered product companies are developing increasingly complex offerings that provide integrated product-andservice solutions. Sales and Marketing teams, therefore, must be able to Chemical Engineering World
Interview CEW understand these offerings and how they drive value for the customers’ businesses.
improve our cost competiveness of goods and services in the International markets.
It’s a transition from “Art to Science”; and five commercial topics are bound to offer companies significant opportunities to differentiate themselves in the new environment: Sales Force Effectiveness; Channel Management; Pricing and Profitability; After Sales and Human resources and IT enablers. Superior performance in the above areas will distinguish the winners in this highly competitive market!
How are the end user markets evolving globally & in India for consumption across – hydrocarbon & chemical processing, water & wastewater treatment, infrastructure, power generation and other key industry verticals? At present we see Water and Wastewater markets to be attractive and offers opportunities across the world.
Though there are significant number of small and medium scale pumps and valves manufacturers, the industry is dominated by major players. In your view, could GST be a game changer for the SMEs and how would this possibly change the market dynamics? All in all GST is a welcome move!! GST will be a game changing reform for Indian economy by developing a common Indian market and reducing the cascading effect of tax on the cost of goods and services. It will impact the Tax Structure, Tax Incidence, Tax Computation, Tax Payment, Compliance, Credit Utilization and Reporting leading to a complete overhaul of the current indirect tax system. There are various benefits such as Cost Benefit being one! In addition, it would have a better compliance and revenue buoyancy replacing the cascading effect [tax on tax] created by existing indirect taxes. Tax incidence for consumers may fall lower transaction cost for final consumers. And last but not the least, apart from making the taxation very simple and transparent in character, it would
The Oil and Gas and Mining markets are a bit subdued. Power Generation and Industry are sluggish, except for the nuclear supercritical business which offers some opportunities. Of all these, which are the fastest growing segments that would drive the demand of pumps and valves in India and how is KSB planning to continue to maintain its position in the Indian market? Water and Waste Water markets are bound to improve. For…As we know, India’s fragile and finite water resources are depleting while the multi-sectorial demands for water from sustained economic growth (over 8%) is driving the increased demand for water through coupled dynamics between increased energy and consumption. Exponentially increasing demand for water due to population growth and agricultural use, if left unchecked. Climate change and extreme climate variability are further likely to accentuate these numbers. In the future higher usage in the domestic and industrial domains is likely as the pace of economic development grows. Even in the Water and Waste water sector, Global water companies such
GST will be a game changing reform for Indian economy by developing a common Indian market and reducing the cascading effect of tax on the cost of goods and services. It will impact the Tax Structure, Tax Incidence, Tax Computation, Tax Payment, Compliance, Credit Utilization and Reporting leading to a complete overhaul of the current indirect tax system. Chemical Engineering World
as Veolia Water, Suez de Lyonnaise (Degremont) and VA Tech Wabag, Nalco, GE Betz-Dearborn etc., have established a presence in India with many projects initiated or underway worth several billion Euros; only to signal what potential this segment is going to offer and will auger well with the pump industry at large and KSB in particular! Additionally, other segments which currently offer opportunities are the energy Segment – mainly in the Nuclear and Supercritical power generation arena and FGD business which is emerging and will to offer some opportunities in the near future. Along with this, Solar pumping is a growing domain in the Indian Market. With a good monsoon this year, we are hopeful that the upstream industries and the Agriculture Segments will also get a Philip and auger well for the Industry. Globally, the manufacturers are embracing the trends of Digitsation & Industrie 4.0 which is slowly catching up in India too amongst the big players. How are pumps and valves manufacturers responding to this changing demand and what are the challenges that need to be addressed? Please share the details on the work KSB has carried out in this space so far. Yes Industrie 4.0 is bound to catch vogue of the Indian manufacturing sector by the turn of this decade / mid next decade! Industrie 4.0 disrupts the current value chain and requires companies to rethink the way they do business. They need to drive the digital transformation of their business to succeed in the new environment. Five pillars will be critical for this transformation: first, companies need to build digital capabilities. This comprises factors such as attracting digital talent and setting up crossfunctional governance and steering. Second, companies need to enable August 2016 • 81
CEW Interview collaboration in the ecosystem. This requires getting involved in the definition of standards and cooperation across company borders through alliances, strategic partnerships, and cooperation in communities. Third, managing data as a valuable business asset will be important in securing crucial control points. Fourth, companies need to manage cybersecurity end to end to protect digitally managed shop-floor operations and proprietary data. Lastly, companies need to implement twospeed systems/data architecture to differentiate quick-release cycles from mission-critical applications with longer turnaround times. To leverage these multiple opportunities, companies need to embark on a digital transformation journey: a continuous, long-term effort is needed to successfully navigate the changing industrial environment of Industrie 4.0. We at KSB in India have taken our baby steps in this direction, first, by pursuing simpler e-commerce and marketing automation initiatives to start with; and intend to be abreast in this morphing digital arena; as we also see our markets mature to this concept! Presently, with five manufacturing facilities, KSB is among the top manufacturers in India. How do you plan to lead the growth of company in India and what are the plans for the future? The breadth of KSB India’s product portfolio addresses the needs of myriad customers... KSB in India has been; and continues to be a trendsetter pumps for virtually all conceivable applications through her Technological leadership and solid German heritage. These include pumps for customers from basic domestic water, to supply and consumption of water in commercial buildings and offices including that for HVAC purposes and firefighting. Moving towards Industry, KSB pumps are a heart of the process! They reliably transport 82 • August 2016
With the “Make in India” Campaign, we definitely see that there would be increase in investment in this sector. KSB has already committed with an investment of almost ` 230 Crores; wherein, we are building a totally new facility for 100per cent indigenous manufacture of pumps for Nuclear and Super Critical Power plant applications. fluids ranging from Industrial water to acids to viscous and solid laden liquids and abrasive solvents with ease. In the Refinery and Petrochemical sectors, cryogenic and explosive media is handled with great finesse. In the Power sector, be it a Conventional or a supercritical or a Nuclear Power plant, we save energy while helping the nation to generate more. And to keep our fields green, our pumps romance the life giving element- water, with great panache. As mentioned above, KSB has its strength that it covers all the market segments with its products. This is very significant at a time when some markets are not doing so well and it gives us this flexibility to focus on other segments. We are at present putting a lot of focus on our Standard business, and also the aftermarket business. We hope to grow our business substantially in these areas and we are also planning in to add some new products to fuel our growth.
which are evolving in India and where KSB have a strong and proven presence worldwide. KSB in India is a part of the Global Manufacturing Network of the KSB Group; and due to her cost advantages, is also poised, not only to be a formidable Exporter in the Asia Pacific Region, but also to other group companies in the World in the coming years. KSB in India is indeed a “One Stop Shopping Centre” when it comes to delivering value to the customers with reliable pumping solutions to what-so-ever or how-so-ever the application may be! India is a promising market for KSB and we also are gearing up to tap the opportunities it offers and to remain “Ahead of Time … all the time”.
We are also cautious and optimistic in the Solar Pumping arena! While we are closely observing the central governments initiatives in this direction; we are simultaneously gearing ourselves with products; including introducing suitable products top address this need. KSB in India has been and will continue to support the “Make in India” philosophy. To this, we are investing heavily in a brand new and an ultramodern manufacturing facility near Pune, to take care of the future demands and indigenous supply of critical pumps for the of the Super Critical and Nuclear Power Stations, which were partly or fully imported. As mentioned earlier too, we are also looking at the FGD markets Chemical Engineering World