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Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
EDITORIAL
Editor Editorial Advisory Board Contributing Editors
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Mittravinda Ranjan (mittra_ranjan@jasubhai.com) D P Misra, N G Ashar, Prof. M C Dwivedi P V Satyanarayana, Dr S R Srinivasan, R B Darji, R P Sharma Bernard Rapose (bernard_rapose@jasubhai.com) Mahesh Kallayil Arun Parab, Shankar Joshi
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NEWS Industry News
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Technology News
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Sealless Magnetic Drive Pumps - Pradeep Narayan Dhole, Technical Director, Mascot Dynamics Pvt. Ltd.
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Selection of Pumps for Liquefied Petroleum Gas - Vinod Shenoy, Engineering Manager - Mechanical, Aker Solutions
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Bearings in Centrifugal Pumps - Nilesh WargantiwarGeneral Manager- Sales & Marketing, NRB Industrial Bearings Ltd.
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Instrumentation on Production Platform - Santosh Shanbhag , Sr Engineering Manager (Instrumentation), Aker Powergas Pvt Ltd.
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FEATURE
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MARKETING INITIATIVE Advanced service functions for machinery and equipment Boost productivity with anti-sloshing
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PRODUCTS
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EVENTS
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PROJECT UPDATE
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BOOK SHELF
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AD INDEX
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INTERVIEW “HRS is a technology driven company and that differentiates us from most of the other companies who are predominantly fabricators” -V. Gokuldas, Managing Director, HRS Process Systems Ltd.
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Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.
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Chemical Engineering World
Vacuum Systems by GEA Solution that delivers low operating cost GEA offers complete range of Vacuum Systems backed by over a century of experience in design and construction of vacuum systems for Refinery, Petrochemical, Fertilizer, Chemical, Pharmaceutical, Steel and Water Treatment Industries. GEA’s Vacuum Systems result in lower cost of operations. It can be used for suction flows from 10 -2,00,000 m3/h and is suitable for 0.01 mbar (abs). It is highly reliable in operation with very low wear and tear and minimum maintenance. Available in a range of material of construction, it is resistant to fouling. It is designed to be driven either by water vapor or product vapor. If you wish to have a Vacuum System that helps you drive down operating cost, write to us at sales.india@gea.com
CEW Industry News Unrivalled accuracy in level sensors used for non-invasive level measurement CeramTec has developed a drip chamber level sensor solution which draws on the company’s unparalleled materials expertise to deliver superior measurement accuracy and performance in medical applications. Designed in response to the needs of medical device manufacturers as well as CE and FDA regulations, the innovation provides a level of measurement accuracy crucial in so many medical devices, including haemodialysis machines and other liquid/ blood handling applications. Featuring ultrasonic technology, the level sensor can easily distinguish between liquid and foam, unlike capacitive sensors, helping to ensure that the presence of non-liquid materials does not interfere with the accuracy of measurements. For flexible chambers of approximately 20mm diameter the level sensor is designed to clip firmly onto the chamber and can be easily removed as required. The level sensor can be suspended from the chamber or alternatively, mounted to the machine via screw fitting and subsequently positioned against the chamber. Furthermore, it has been specially engineered to ensure continuous operation in temperatures of up to 105°C and can even withstand up to 130°C. Finally, the level sensor is designed to be easily cleaned with most commonly used medical cleaning agents and is sealed to IP67. For rigid chambers, a derivative of this level sensor has been made that dry couples to the chamber and can transmit through most plastics, glass and even aluminium. This design utilises the electronics and sensing elements from the sensor, which can then be housed in a mount that is available in a wide range of dimensions and can be tailored to meet individual customer requirements. Because of the compact nature of the level sensors elements, multiple levels can be monitored as close as 4mm apart, giving continuous feedback to the machine which can then be used to control pump speed.Richard Miles, Business Manager at CeramTec, explained: “Increasingly our level sensor technology and custom design capabilities have been called upon to solve level sensing problems associated with tight spaces, complex geometries and challenging materials where the safe and reliable operation of the machine with no nuisance fault alarms ensures medical staff can concentrate more on their patients and supporting their needs. Our new standard level sensors ideally complement our existing sensor range to offer great versatility in non-contact applications where safety cannot be compromised.
Covestro achieves a breakthrough in research Covestro has scored a research breakthrough for the use of plantbased raw materials in plastics production: aniline, an important basic chemical, can now be derived from biomass. The materials manufacturer achieved this by collaborating with partners on the development of a completely new process, initially in the laboratory. Until now, only fossil raw materials had been used for the production of aniline, which plays an important role in the chemical industry and is used as starting material for numerous products. 8 • June 2017
Following its success in the lab, Covestro plans to further develop the new process together with partners from industry and research. The first step is to upscale the process in a pilot plant with the ultimate goal of enabling the production of bio-based aniline on an industrial scale. That would be an unprecedented achievement in the chemical industry. Unprecedented achievement About five million metric tons of aniline are produced annually worldwide; the total volume has been increasing by an average of about five percent every year. With a production capacity of about one million metric tons, Covestro is among the leading producers. The company requires aniline as a precursor for rigid polyurethane foam, a highly efficient insulating material used in buildings and refrigeration systems. “The market is showing great interest in ecologically beneficial products based on renewable raw materials,” said Covestro Chief Commercial Officer Dr. Markus Steilemann. “Being able to derive aniline from biomass is another key step towards making the chemical and plastics industries less dependent on fossil raw materials and market fluctuations. With this, we are pursuing our vision of making the world a brighter place.” “The process currently under development uses renewable raw materials and produces aniline with a much better CO2 footprint than that manufactured with standard technology,” said Covestro project manager Dr. Gernot Jäger. “This also enables our customers to markedly improve the CO2 footprint of their aniline-based products.” And the reactions would take place under milder conditions. The ecological aspects of the process are also being thoroughly evaluated by external institutes. 100 percent of carbon from biomass The industry currently derives aniline from benzene, a petroleum-based raw material. But industrial sugar, which is already derived on large scale from, for example, feed corn, straw and wood, can be used instead. The newly developed process uses a microorganism as a catalyst to first convert the industrial sugar into an aniline precursor. The aniline is then derived by means of chemical catalysis in a second step. “This means one hundred percent of the carbon in the aniline comes from renewable raw materials,” explained Jäger. Covestro is working with the University of Stuttgart, the CAT Catalytic Center at RWTH Aachen University, and Bayer AG to further develop the process. “This interdisciplinary, motivated team combines all the needed expertise at a very high level and is the basis for continued success,” said Jäger. The long-term research project will receive funding for a period of two and a half years through the FNR (Fachagentur Nachwachsende Rohstoffe e.V.), a project agency of Germany’s Federal Ministry of Food and Agriculture. Covestro is already using renewable raw materials in a number of different products. A hardener for coatings that the company developed is one example: up to 70 percent of its carbon content is derived from plants. And CO2 is also increasingly being used an alternative raw material. Used in place of petroleum, CO2 accounts for up to 20 percent of the raw materials used in a precursor for flexible polyurethane foam that Covestro began producing in 2016. The company is also researching and developing many more products based on CO2. Chemical Engineering World
CEW Industry News TechnipFMC Signs Agreement with Pall to Supply Slurry Oil Filtration Systems for Fluid Catalytic Cracking Units
knowledge in sustainability and boast a much stronger joint innovation platform. This will enable the development of new products in order to deliver superior returns and drive shareholder value.
LONDON, PARIS, HOUSTON, June 5, 2017 — TechnipFMC (NYSE and Euronext: FTI) announced today that it has signed a cooperation agreement with Pall Corporation to market, design and supply proprietary Slurry Oil Filtration Systems for Fluid Catalytic Cracking (FCC) Units.
“This is the perfect deal at the right time. Clariant and Huntsman are joining forces to gain much broader global reach, create more sustained innovation power and achieve new growth opportunities,” said Hariolf Kottmann, CEO of Clariant. “This is in the best interest of all of our stakeholders. Peter Huntsman and I share the same strategic vision and I look forward to working with him.”
Based on Pall technology, the filtration systems are used by refiners to remove catalyst fines from slurry oil, an FCC main fractionator bottoms product. The clarified oil can be blended into fuel oils that must meet stringent particulate requirements. It can also be used as a feedstock for plants that produce premium products such as carbon black and anode grade coke. The agreement combines TechnipFMC ‘S global strength in FCC technology with Pall’s expertise in the development of specialty filtration systems and fabrication of advanced filter media. "As a major licensor of FCC technology, TechnipFMC is pleased to offer filtration systems which will help refiners meet increasing environmental regulations and improve the value of their supply chain," said Stan Knez, Senior Vice President, Onshore Process Technology for TechnipFMC. The associated activities will be managed by TechnipFMC Process Technology’s center in Houston, Texas (USA), which has significant refining technology experience. The center is part of a global network of centers which look after the company’s expanding portfolio of onshore process technologies in petrochemicals, refining, hydrogen and syngas, polymers and gas monetization. With its FCC alliance partner, Axens, TechnipFMC has licensed 61 grassroot FCC units and performed more than 250 revamp projects.
Huntsman and Clariant to Combine in Merger of Equals Mumbai, India - Huntsman Corporation (NYSE: HUN) and Clariant (SIX: CLN) announced that their Boards of Directors unanimously approved a definitive agreement to combine in a merger of equals through an all-stock transaction. The merged company will be named Huntsman Clariant. On a pro forma 2016 basis, the combination of both companies will create a leading global specialty chemical company with sales of approximately $13.2 billion, an adjusted EBITDA of $2.3 billion and a combined enterprise value of approximately $20 billion at announcement. The combined entity will benefit from each other’s strengths. It will have a significantly improved growth profile in highly attractive end markets and geographies. Huntsman Clariant will leverage shared 10 • June 2017
Peter R. Huntsman, President and CEO of Huntsman, commented: “I could not be more enthusiastic about this merger and look forward to working closely with Hariolf Kottmann, a man I have admired and trusted for the past decade. We also look forward to a close association with his immensely talented colleagues around the world. Together, we will create a global leader in specialty chemicals with a combined balance sheet providing substantial financial strength and flexibility.” Value Creation The new company will accelerate value creation for shareholders through a more robust combination of technology, products and talent. The combined company expects to realize more than $3.5 billion of value creation from approximately $400 million in annual cost synergies. The full synergy run-rate will be achieved within two years of closing. These synergies will be realized by reducing operational costs and improving procurement. The targeted synergies represent roughly 3 percent of total combined 2016 revenue with one-time costs up to $500 million. There will also be additional cash-tax savings. Corporate Governance The combined company, incorporated in Switzerland, will be governed by a Board of Directors with equal representation from Clariant and Huntsman and will follow Swiss Corporate Governance standards. Hariolf Kottmann, current Clariant CEO, shall become Chairman of the Board of Huntsman Clariant. Peter Huntsman, current Huntsman President and CEO, will become CEO of Huntsman Clariant. Jon Huntsman, founder and Chairman of Huntsman, shall become Chairman Emeritus and board member of Huntsman Clariant. The merger enjoys strong commitment from both Clariant and Huntsman family shareholders. The company will be listed on the SIX Swiss Exchange and the New York Stock Exchange. Huntsman Clariant will use IFRS, and beginning in Q1 2018 will report in USD and will start filing 10Qs and 10Ks consistent with SEC requirements. Timing The transaction is targeted to close by year end 2017, subject to Clariant and Huntsman shareholder approvals, regulatory approvals and other customary closing conditions. Clariant and Huntsman are confident that the required regulatory approvals can be obtained in a timely manner. Chemical Engineering World
CEW Industry News Shell Lubricants Unveils Its New Global Positioning ‘Together Anything Is Possible’ Mumbai, India – Shell Lubricants, the global market leader in finished lubricants, with CII -IL today organised “Empower” – an introduction to its new global direction for its B2B sectors, as a partner to its allied industries. The event also served as a platform to discuss how the different stakeholders from the industry can come together and help reduce the total cost of ownership and enhance profitability. Highlighting the message of “Together anything is possible”, Shell introduced the concept of total cost of ownership with an aim to inspire customers by addressing the efficiency challenges and help them towards achieving their day-to-day ambitions. In addition to Mumbai, the launch will take place across clusters in India including Delhi, Pune, Bengaluru, and Chennai. Mumbai served as the venue for the first leg of the launch series with a special focus on construction, mining and the fleet industries. The event witnessed participation from eminent industry leaders including L&T, Afcon, Cargo carriers India Ltd., Ambey Mining, Allcargo Logistics, Baska Bombay Carriers etc. and Industry associations such as CII Institute of logistics. As part of its renewed focus on creating greater customer interaction, the event highlighted the importance of lubricants to counter the challenges faced by relevant sectors and assist them to achieve significant reduction in operational cost. The impact of Shell’s products and services in delivering Total Cost of Ownership can be assessed by the example of Construction company Al-Watanyiah United Engineering & Contracting. The company which operates in remote locations in mountainous and desert regions in Oman could extend Oil Drain Intervals of its heavy equipment and save USD $172,000 by switching from non-Shell engine oil to Shell Rimula R4 X 15W-40. Shell’s product and services could increase equipment availability and productivity, extend component life, reduce maintenance downtime and cut lubricant and spare-part consumption. Speaking on the occasion, Mr. Steve Reindl – Global B2B Marketing Head, Shell Global Lubricants said, “As a part of our new focus on building a greater collaboration with our customers, Shell Lubricants undertook a Global study to understand the current lubrication practices of businesses in Shell’s six priority B2B sectors across eight markets: Brazil, Canada, China, Germany, India, Russia, UK and US. Our Study helped us reveal that Companies recognise that effective lubrication represents a significant financial opportunity, but there is a lack of understanding about how lubrication can impact the TCO of their equipment. Hence, we are aligning our Global outlook to reach out to our customers better, offer our people and expertise to ensure they can save smartly.” Delivering the inaugural address Ms. Mansi Tripathy, Country Head of Shell Lubricants India said, “India’s growth story is today a global example of the opportunities that make India an exciting market to be in. Sectors such as Construction, Infrastructure and Mining are fundamental to India’s growth. While the Lubricants industry holds key significance in the business operations of its allied industries, it is necessary for sectors to perceive the contribution of lubricants as an enabler of efficient macro 12 • June 2017
operations. We are hence trying to create an ecosystem and dialogue with our customers to help them understand TCO and how Shell can be a trusted partner in their journey to achieve the same.” Lauding the campaign Mr. K V Mahidhar, Executive Director of CIIInstitute of Logistics said, “India is an emerging logistics hub and fleet management is a key aspect to ensure smooth functioning of the sector. Today, one of the key challenges of the Fleet sector in India is effective driver retention along with a constant check on per mile return on cost. Understanding ‘Total Cost of Ownership’ and how it impacts business hence becomes critical for a sustained business growth. With Shell Lubricants’ initiative, I am hopeful that the knowledge barriers prevailing due to a lack of understanding of Total Cost of Ownership and improving operational efficiency will be addressed.” Speaking at the occasion, Neeraj Bhatia, Chief Marketing Officer, Shell Lubricants India, “We have always ensured that all our initiatives and services help our customers in solving some of their most critical business problems. Collaborating with our OEMs to deliver greater results has been our aim and we have worked towards offering not only products and services that help achieve this, but also design special initiatives. Our renewed global brand positioning ‘Together Anything is Possible’, is aimed at keeping our customer’s best interests at heart, thereby bringing together our people, products and services under one umbrella to power progress together.” On the lines of the campaign, Shell’s global survey revealed that only one of three companies has correct lubrication management procedures in place. With only 52% considering lubricants product performance, there is a lack of understanding about how lubrication can impact the reliability and productivity of the equipment. Moreover, there is lack of expertise along with knowledge barriers in these sectors, with only 33% of the companies conducting regular staff training. Shell hopes to address this with its “Together Anything is Possible” brand alignment.
RIL becomes the second largest producer of Paraxylene (PX) globally Mumbai, India: Reliance is pleased to announce the successful and flawless commissioning of the last crystallization train (Train 3) of the Para-xylene (PX) complex at Jamnagar. This plant is built with state-of-the-art crystallization technology from BP which is highly energy efficient. With the commissioning of this plant, RIL’s PX capacity has more than doubled making it world’s second largest producer of PX with about 11% of global production. Pursuant to installation and mechanical completion of the entire PX complex in the previous quarter, Reliance commissioned second phase of PX comprising of second crystallization train (Train 2), Trans-alkylation and Aromatic Extraction units at Jamnagar in April 2017. Train 3, which was at an advanced stage of commissioning, has now been successfully started. Chemical Engineering World
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CEW Industry News New Immobilized Lux® Chiral LC/SFC Selector from Phenomenex Delivers Broad Enantioselectivity Torrance, Calif. – Phenomenex Inc., a global leader in the research and manufacture of advanced technologies for the separation sciences, expands its Lux chiral LC/SFC column family with new immobilized Lux 5µm i-Amylose-1 and Lux 3µm i-Amylose-1 media. During the manufacturing of Lux immobilized media, a chemical crosslinking is formed between the polysaccharide and silica support, resulting in a robust column that can withstand a wide range of strong solvents including DMSO, THF, Ethyl Acetate and DCM. This robustness allows for potential increases in enantioselectivity as new strong solvent systems can provide more mobile phase options during method development. It also allows scientists to keep samples dissolved in strong solvents like DMSO/DCM. With the addition of the new Lux i-Amylose-1 and previously introduced i-Cellulose-5 media, Phenomenex now offers two immobilized polysaccharide chiral stationary phases (CSP) in analytical and preparative formats. These two robust chiral options combine with six Lux coated chiral stationary phases (Amylose-1, Amylose-2, Cellulose-1, Cellulose-2, Cellulose-3 and Cellulose-4) to deliver a wide and complementary range of enantioselectivity for even the most difficult chiral separation projects under normalphase, reversed-phase, polar-organic or SFC separation modes. “Amylose tris (3, 5-dimethylphenylcarbamate) is one of the most popular polysaccharide CSPs in use today for enantiomeric separations,” explains Simon Lomas, strategic marketing manager for Phenomenex. “The addition of an immobilized version of this popular phase adds versatility and extends the possible uses of the product.” The new Lux 3µm i-Amylose-1 is ideal for LC/SFC analytical work and chiral screening, while the larger diameter Lux 5µm i-Amylose-1 can be used for analytical and purification work as it is available in pre-packed Phenomenex Axia™ preparative columns. Primary applications for this new phase include small molecule pharmaceuticals and their impurities as well as chiral pesticides in the environmental and agricultural markets. Phenomenex continues to expand its Lux chiral media offering, which now contains eight different Lux Medias, to meet these needs. The company also offers free chiral screening services with greater than 90 percent success rates from its PhenoLogix application development group, along with over 2,000 chiral applications online that are easily searchable by compound structure or name at www.phenomenex.com/tools. “Our Lux chiral columns are known for their separation power, seamless scalability and reproducibility,” said Lomas. “We are extremely excited to offer these versatile new chiral selectivity, along with strong solvent robustness, to give customers greater chiral separation success rates.” Commenting on the decision to choose the SMART Build solution, Per-Ola Svahn, technical manager, Skanska, said, “We are excited 16 • June 2017
to partner with Hexagon to work together toward Skanska’s vision of a new level of construction, where we will move toward an integrated construction process.” Mattias Stenberg, Hexagon PPM president, said, “We are looking forward to our partnership with Skanska Sweden. Through our partnership, we can strengthen HxGN SMART Build to create valuebased, field- and office-tested innovations that will greatly impact construction productivity and processes on projects around the world.” HxGN SMART Build is an end-to-end construction management solution for the AEC market that connects and simplifies all construction phases, driving the completion of projects safely, on time and on budget.
Hexagon PPM Partners with Skanska on HxGN SMART Build Collaboration accelerates strategic development of digital construction technologies HUNTSVILLE, Ala., June 14, 2017 – Hexagon PPM, the world’s leading provider of enterprise engineering design software and project control solutions, has partnered with Skanska Sweden to leverage the power of HxGN SMART Build for one of Sweden’s most prominent construction companies. Skanska will use SMART Build to consolidate all elements of its estimation, design, planning, scheduling, pre-construction and construction processes into one easy–to-use, powerful cloud platform. Implementing SMART Build will enable Skanska to aggregate, manage and make sense of 3D, 4D and 5D project data to deliver better, more predictable project outcomes. As changes occur in the project data, the downstream impact can be identified and suitable options adopted. The partnership with Hexagon ultimately will allow Skanska to realise its 2020 corporate vision of using digital construction technologies to improve productivity, profit margins and overall client satisfaction. This initiative aims to deliver significant benefits for both organisations, with Hexagon PPM working with Skanska to accelerate the strategic development of the SMART Build solution. Skanska’s validation of existing functionality and input into the product roadmap will support creation of the next-generation construction management platform, benefiting the global construction market. The collaboration involves the delivery of two parallel work streams over the next 12 months: •
The integration of SMART Build with Skanska’s existing inhouse-developed estimating and cost control application.
•
A series of non-live and live project deployments of the SMART Build product suite including its integration with Hexagon robotic total stations to support digital site layout. Chemical Engineering World
CHEMICAL & PHARMA INDUSTRY
CEW Industry News Successful interpack 2017 with new owner and new technologies-Romaco enters a new era Romaco took advantage of the recent interpack 2017 to show a total of 15 machines not only to industry professionals but also to its new owner, the Chinese Truking Group. Seven innovations and the launch of a new product line attracted numerous visitors to the exhibition stand. interpack 2017 marks the beginning of a new era for Romaco. Just two days before the Dusseldorf fairground opened its doors, Deutsche Beteiligungs AG (DBAG) announced the sale of the Romaco Group to the Chinese Truking Group in Changsha. The new owners, among them Truking founder and Chairman Yue Tang, took the opportunity to pay a two-day visit to the Romaco booth at interpack. “After our intensive negotiations, it was a good chance to get to know each other better in an informal setting – and for Romaco to show itself off at its best in the presence of the new owners”, emphasised Paulo Alexandre, CEO Romaco Group. Innovations for the pharmaceutical process chain The Romaco Group exhibit at interpack 2017 comprised 15 different machines, including three packaging lines and nine standalone units for manufacturing and packing pharmaceutical solids. The launch of four new machines in the corporate industrial design underlined the supplier’s key role within the Group with its very broad portfolio of seven brands. In addition to the new Noack NBP 950 blister machine and Promatic PCI 915 intermittent motion cartoner, the Siebler STF 120 tube filler also made its debut at interpack. The KTP 590X, the youngest addition to the successful KTP series, was premiered by Romaco Kilian. This single-sided rotary press for bi-layer and effervescent tablets was sold to a Korean pharmaceutical manufacturer directly at the exhibition. The laboratory scale VENTILUS® V 5 from Romaco Innojet with the IHD 5 hot melt device, which is now available for the first time in a GMP design, was a further innovation in the area of processing technology. Several selected classics like the Noack 960 blister line, the Macofar MicroMaxX 18 aseptic powder filling machine, the Kilian KTP 720X and STYL’ONE Evolution tablet presses and the Innojet VENTILUS® V 100 were also presented by Romaco. Four of the exhibition machines were configured with Remote Assist, Romaco’s Industry 4.0 technology, for demonstration purposes. This new remote maintenance generation uses smart glasses for virtual communication between the machine operator and Romaco’s service technicians. Promising results Yue Tang, Chairman of the Truking Group was thoroughly impressed: “The diversity of Romaco technologies at interpack is an inspirational experience. The synergetic effects of the brands are instantly apparent to visitors to the trade fair and the potential created by Romaco’s system solutions for the global pharmaceutical industry is easy to see.” 18 • June 2017
“It was an interpack with the focus on content”, concluded Paulo Alexandre, CEO Romaco Group. “More than three quarters of the people we spoke to at our booth were new or existing customers, and the dozens of talks we had and the negotiations we engaged in were output orientated and targeted.” Kilian and Macofar sales representatives each signed deals with customers from Asia and North Africa directly during the interpack week. The new STF 120 tube filler from Romaco Siebler was sold to a German pharmaceutical manufacturer even before interpack began. The MicroMaxx 18 was acquired by a customer in Spain prior to the exhibition. The Noack 960 also changed hands only a few weeks after it finished. This blister line will soon be on its way to Mexico.
Doosan Heavy Industries & Construction Boosts Power Industry Productivity with Intergraph Smart® Construction Dynamic work package planning solution helps leading Korean EPC improve management of construction information HUNTSVILLE, – Korea’s Doosan Heavy Industries & Construction (DHIC) has selected Intergraph Smart® Construction to boost productivity during the delivery of power projects across five continents. DHIC was seeking a construction quantities management solution using 3D technology that would improve construction information management, specifically the millions of details and numerous complex variables it handles. Smart Construction impressed DHIC with its ability to combine information from various sources such as 3D models to create accurate work packages containing detailed construction steps, quantities and work hours. Additionally, Smart Construction’s 4D capabilities helped DHIC to verify best construction sequence of the scheduled work package to optimize labor productivity. “Smart Construction allows us to achieve better construction material management of our projects,” said Young Geun Lee, DHIC’s Engineering Innovation team leader. “It provides us with access to the most accurate information, such as construction quantities, to make more informed decisions.”Mattias Stenberg, president of Hexagon PPM, said, “We are pleased that Smart Construction has helped DHIC to improve the accuracy of the information available, which allows for better management of construction material so projects are delivered on-time, on-budget and in the safest and most efficient manner.” Smart Construction helps construction planners more efficiently plan and manage fabrication and construction projects, resulting in enhanced safety, increased quality and improved productivity. Using current information from various sources such as 3D models, 2D engineering tools, materials management, project controls and scheduling systems, Smart Construction ensures that accurate and timely decisions can be made on the most up-to-date information needed for optimized construction planning and execution. Users can view/filter 3D models and drawings with enhanced 4D animation to verify the construction sequence with powerful new preconfigured filters and selection rules for a 3D model. Chemical Engineering World
CEW Industry News Nuberg to Execute 228 TPD Caustic Soda Plant Project in Egypt New Delhi, India, Egypt- Nuberg, a leading global EPC & LSTK company for specialty chemicals has been chosen by Egyptian Petrochemicals Company (EPC) as a single-point solution company, from concept to commissioning, for caustic soda-chlorine plant in Alexandria, Egypt. The project envisions setting up a turnkey project having production capacity of 228 TPD with a provision to expand it to 342 TPD in future. The plant will be based on new generation state-of-the-art bipolar membrane cell technology (Bi-Chlor) from INEOS Technologies, UK which is widely sought out by caustic soda manufacturers for its best in class power consumption, longevity, low capex/opex and environmental considerations. The plant will produce caustic soda, chlorine, hydrogen and other chlorine derivatives. Chlorine produced shall be used as a raw material in existing EDC/ VCM plant for PVC production. The contract signing ceremony took place at hotel Hilton Green Plaza in Alexandria, Egypt in the presence of the dignitaries from both the companies. The contract was signed by Mr. AK Tyagi, MD, Nuberg and Chemist Gaber A. Hassan, Chairman, EPC. Sharing his happiness on winning the contract, Mr. A K Tyagi, MD, Nuberg said, "We are thankful to Egyptian Petrochemicals Company for entrusting our turnkey project engineering capabilities and our EPC services and solutions for its caustic soda plant. We are excited to partner with INEOS Technologies once again, strengthening our relationship with them even further." Chemist Gaber A. Hassan, Chairman, EPC said, "The caustic soda plant is of great importance to our company in specific and to the petrochemical sector in general. I would like to highlight that this project is among the chain of projects that will be executed by our company in near and far future to promote the petrochemical field in Egypt. I would like to congratulate Nuberg on being awarded this order and I am confident that Nuberg has the experience and the expertise to execute an excellent plant in cooperation with the licensor INEOS Technologies." Role of INEOS Technologies will be of process licensor and will supply technology know-how and state-of-the-art electrolyser commissioning services. Caustic soda produced in the plant will be supplied mostly to the markets of Europe, Asia and Africa. Caustic Soda has applications in various industries such as hydrocarbons, paper, chemicals and soaps & detergents industry. Nuberg's scope of services includes basic & detailed engineering, supply, civil and equipment installation, commissioning of plant and start-up for new bipolar electrolyser as a turnkey project. Nuberg, which is the biggest EPC Company for chlor-alkali industry in the UAE, is among world's leading EPC companies for caustic soda-chlorine plants, offering a comprehensive single-point solution to caustic soda manufacturers across the world. Nuberg has successfully executed 20 • June 2017
turnkey projects not only for chlor-alkali industry but also for other chemicals and speciality chemicals such as sulfonate, anisole, sulphur bentonite, sulfuric acid, hydrogen peroxide, calcium chloride among many others.
BASF is All Set to Develop a New Fungicide with Sumitomo Sumitomo chemical, a Japanese company is collaborating with BASF to bring about a change in the lives of farmers. The collaboration will enhance a new technologically driven fungicide which will act as a compound for the farmers. The collaboration will put into use the technical knowledge of both the companies to create one advanced product, a novel fungicidal compound that can be used extensively for farming. This compound has shown high proficiency in controlling major plant diseases. It is also effective against many diseases which had developed resistance against available fungicides. Sumitomo Chemical representative director and senior managing executive officer Ray Nishimoto said: "Together with BASF, we will be able to provide more growers with the opportunity to experience the benefits of this new fungicide, which will play an important role in the resistance management of serious plant diseases. The fungicide is expected to protect the regions where the options are limited or the fungicides are less efficient. Farmers have always wanted to grow and supply healthy and sustainable crops to the increasing demand for food. The strategic cooperation between BAST and Sumitomo Chemicals demonstrates that both the companies are committed towards investing into the agricultural industries so that there is growth and development in that business. Once both the companies receive their regulatory approvals from the authorities, the unique technology will be commercialised globally.
Linde could be world’s larg est supplier of Industrial Gases American company Praxair has convinced Linde, a German company to make a move that would make them global leaders in the supply of industrial gases. The combined company will be named Linde and will have a market value more than US $70 billion. The company will be based out of Ireland with corporate offices in Danbury, Connecticut and Munich, Germany. It will be governed by a 12 member board with equal representation from Linde and Praxair. According to the agreement, Linde shareholders will receive 1.54% shares in the new company and Praxair will receive one share in the new company. The new Linde will be listed on both, New York Stock Exchange and the Frankfurt Stock Exchange. All the regulatory approvals will be completed in 2018. Chemical Engineering World
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CEW Industry News Chemical Industry to be empowered, growth to $226 billion by 2020 The union minister of state for Commerce and Industry, Nirmala Sitharaman has come out with great news for the Indian Chemical Industry. The domestic chemical industry is expected to grow to $226 billion by 2020. There has been a decline in the chemical exports of 7.8% from $12.66 billion in 2014-2015 to $11.67 billion in 2016 which is in terms of value, but when it comes to the volumes, it has shown a remarkable growth of 7.51%. The global chemical industry is estimated at $43 trillion, with Indian chemical industry accounting for $147 billion in 2015. The budget of 2017-2018 will put into use the new Trade Infrastructure Export Scheme which will help the exporters to reduce their transaction cost and be competitive globally; also it will help in reducing the corporate tax for MSME’s by 5% in a way boosting the industry. The domestic chemical industry which is the 3rd largest producer in Asia and 12th in the world is the key constituent of Indian economy. India is the fourth largest producer of agrochemicals. The Basic Chemicals and Dyes Export Promotion Council (Chemexcil) has played a key role in promoting exports of the products in its basket by showcasing the capabilities of Indian chemical industry to the world, expressed Smt. Nirmala Sitharaman.
Mr. Milind Khadilkar took over the responsibilities as Director – Finance of KSB in India with effect from 6th June, 2017. A qualified Chartered Accountant and armed with a Master’s Degree in Commerce from Pune University, Milind has a vast experience spanning over 3 decades. 53 year old Milind’s career graph has always been on the rise since his first assignment with AF Fergusson in 1987. Ever since then his experience and success with organizations such as Tata Motors, Fujitsu ICIM, UB Engineering; Apollo Tires; Virgo Engineers; Godrej GE Appliances; Rohan Builders; UMW Dongshin Motech Pvt. Ltd.; and also a 6 years international assignment with Ali & Abdul Karim Group of Companies, Muscat has got him to where he is, today! Prior to joining KSB, since April, 2012 he worked with Wilo Mather and Platt Pumps Pvt. Ltd. as Vice President - reporting to the Managing Director and leading a team of 40 members. During his over 30 long years of Industry experience, Milind has handled myriad functions including Finance and Accounts, 22 • June 2017
C o n t r o l l i n g a n d B u d g e t i n g , Au d i t s , L e g a l & S e c r e t a r i a l Compliances, IT Systems, Cor porate Restr uctur ing, Fund Raising, ERP Implementation – SAP and ORION, Formulation of Group Administrative, Financial and Control Policies, HR Administration and Procedures including manuals of delegation of author ity, and also suppor t to procurement and sales development and growth. He has conducted Management and Audit Committee and Board of Directors and Shareholders Meetings. He has also overseen and completed all the formalities in respect of setting up of a Wholly Owned Subsidiary in USA; during one of his past assignments. T h e va s t ex p e r i e n c e a n d s h r ew d bu s i n e s s a c u m e n t h a t Milind br ings with him, is bound to, not only safeguard, but als o c ons olidate and improve the ex is ting str o n g p o s itio n of KSB in India. Today, from its 6 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, with great aplomb!
LANXESS water treatment technologies for pulp manufacturing Zellstoff Stendal, par t of the Amer ican-Canadian Mercer Inter national Group, is the largest and most cutting-edge manufacturer of NBSK (Nor thern Bleached Softwood Kraft) market pulp in Central Europe. With their outstanding properties – especially their high tensile strength and high degree of whiteness – these pulps are used, for example, for high-quality printing and copying paper, wallpaper bases, household paper such as paper tissues and kitchen roll, filter paper and a range of other specialist papers like silicone base paper. Wood elements such as bark and lignin that are not used for pulp production are incinerated in boiler plants. A combined heat and power process in this case generates heat energy that is used as process steam and electricity. Located in the north of SaxonyAnhalt, the plant generates enough power to cover its own needs and also feeds a large part of the renewable energy generated into the public electricity grid. More than 50,000 cubic meters of water are needed every day for pulp manufacturing in Arnsberg, and this is treated using reverse osmosis and ion exchange resins. The Lewatit MonoPlus S 100 and Lewatit MonoPlus M 600 grades are used in the multistep process, while Lewatit MonoPlus SP 112 H and Lewatit MonoPlus MP 500 are used in the mixed bed. Chemical Engineering World
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CEW Technology News Siemens India Wins First Cyber Security Contract for Power Plan Automation Siemens India has bagged its first order in the cyber security category for power plant automation from the Mumbai based completely owned CLP India Pvt.Ltd, subsidiary of CLP Holding Limited. Siemens will implement a Cyber Security Solution for their power plant automation at Paguthan, Gujarat. The Cyber Security Solution being implemented by Siemens Ltd. will support CLP India’s efforts to bolster cyber security at its power plant by detecting threats and minimising the risk of advanced cyber-attacks. The solution detects analyses and raises alarms of the threats that move laterally from Information Technology to Operations Technology network. Prashant Jain, head, power generation ser vices, Siemens Ltd, said, “In today’s digitalised world, power plant automation systems require robust and resilient delivery systems. Given the increasing frequency of cyber-attacks, it is very important to obtain a precise picture of the cyber security level of the plant and its associated instrumentation and control systems. Protective measures can then be implemented to remedy any deficiencies detected.” The complexities of power and modern energy are growing. Hence, a large number of power plant systems are connected through internet of things. When things are more on the internet, it is exposed to more security vulnerabilities due to meagre number of connected systems and lack of high level security available in simple devices. Siemens is an established global leader when it comes to advancement of digitalisation across a wide variety of industries. It has established a critical cyber security solution for power, infrastructure and industrial control system. These solutions provided by Siemens accords with the international standards such as NERC (North American Electric Reliability Corporation cr itical infrastr ucture protection) and VGB, the European technical association for power and heat generation.
South Korean chemicals firm, Songwon, to open pilot plant in Gujarat Songwon, a South Korean speciality chemicals company has launched a new pilot plant in Panoli in Gujarat. The company attempts to strengthen the organisation’s overall speciality chemicals development capability. The new pilot plant is built on Songwon‘s Indian site with all the necessary main unit operations. It is equipped with the most up-to-date technologies and materials for producing wide range of chemicals for broad spectrum of applications. The new pilot 24 • June 2017
plant will be immensely supported by the Songwon’s strong local R&D team in Panoli to reinforce the organisation’s position in the existing areas of business. The R&D team will be assisted by central technology innovations centre located in Maeam, Korea. “Technology and product innovation is at the core of Songwon’s business strategy. With our high-quality manufacturing expertise and strong R&D, we have already earned a solid reputation in the industry. This new facility will play an important role in ensuring that Songwon can continue developing new industrial technologies to meet evolving market needs and make it possible for us to reliably supply customers with innovative products for testing and approval,” said Giacomo Sasselli, leader operations, Songwon. Headquartered in Ulsan (South Korea), Songwon Industrial Co is a leader in the development, production and supply of specialty chemicals. The second largest manufacturer of polymer stabilisers worldwide, Songwon operates group companies all over the world, offering the combined benefits of a global framework and readily accessible local organisations.
HPCL, Mittal to invest $ 3 billion in setting petchem complex in Bhatinda. Lakshmi N Mittal and their state-owned par tner Hindustan Petroleum Corporation Limited (HPCL) are all set to invest $ 3 billion in setting up a petrochemical complex at their Bhatinda refinery in Punjab. HPCL-Mittal Energy Ltd. (HMEL) a joint venture between HPCL and Mittal Energy Investments Pvt.Ltd., Singapore, plans to set up an up to 1.7-million tonne naphtha cracker unit to produce basic raw material that goes into making of plastics. The plant which will initially start at 1.2 million tonne naphtha cracker will be expandable upto 1.7 million tonne later. This will be HPCL's first petrochemical plant in Northern India. The company has refineries in Mumbai and Visakhapatnam. HPCL and steel baron Mittal are equal partners in the Bhatinda refinery in Punjab. HPCL and Mittal Investment Sarl hold 48.94 per cent stake each in HMEL while the balance is with financial institutions. HMEL had also plans to expand Bhatinda refinery capacity further to 10 mt, but Surana did not speak on the same. HPCL is investing Rs 45,000 crore by 2020 for expansion of its Mumbai and Visakhapatnam refineries as well as augmenting its marketing infrastructure. The investments will also help the company produce "products confirming to Euro VI" emission specification, HPCL Chairman and Managing Director M K Surana said. Chemical Engineering World
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CEW Features
Sealless Magnetic Drive Pumps Sealless magnetic drive pumps give total containment of the pumped process liquid, which in an industry where there are tightening environmental constraints on plant operation and increasing health and safety requirements, offer real advantages of reliability and safety to users. This paper, describes the key design features of magnetic drive pumps as well as the potential failure modes and the protective systems and design features that can be put in place to monitor and protect the pumps in a Chemical, Process & Petrochemical plants. As with any piece of machinery, magnetic drive pumps have an operating envelope where their use is to be recommended. The factors which determine efficient and reliable magnetic drive pump application are described (such as power, head, flow, fluid cleanliness, NPSH available, fluid properties etc.) and the data presented upon which the criteria were determined.
1.1 A brief history
T
he 70-year evolution of magnetics and associated drive technology has led to the availability of high quality, high integrity, economical zero leakage pumps that comply with ISO, ANSI and API design standards and offer significant advantages over equivalent mechanically sealed designs. The hydraulic coverage of such designs is comparable to sealed pumps Magnetic drive sealless pumps are widely used in the chemical, process, petrochemical, pharmaceutical and other industries for a wide variety of liquids, they are particularly suited to liquids that are toxic, pungent, hot or corrosive as the complexity usually associated with a sealing system for such liquids is completely eliminated. Magnetic drive pumps are also now quickly gaining acceptance in the hydrocarbon processing industry where absolute safety, integrity and reliability are key factors behind rotating machinery selection. 1.2 Key design features Basic design The magnetic drive pump can be viewed as three parts. The hydraulic (casing
28 • June 2017
and impeller), the supporting shaft and bearing system and the magnetic drive. The hydraulic end is fundamentally the same as a traditional centrifugal pump and as such invokes energy into the pumped liquid. At the rear of the casing, a non-magnetic containment shell is used to completely contain the liquid being pumped. This shell is rated for the same design conditions as the pump casing and is part of the pressure boundary. Inside the containment shell, the impeller is mounted to a shaft that is supported on journal bearings which are lubricated by the pumped fluid. Attached to the shaft is an inner rotor which usually consists of a ring of permanent magnets or in some cases a torque ring, similar to that of an electric motor rotor. Correspondingly around the outside of the containment shell is an outer magnetic ring. This ring of magnets is either directly mounted on a motor shaft or is supported by some form of external bearing assembly. The outer magnet ring is rotated by a standard electric motor. The principle of
operation is that as the outer magnetic ring is rotated by the electric motor, magnetic flux is transferred through the non-magnetic containment shell to the inner magnet ring or torque ring, thus causing the shaft and impeller to rotate. [See Fig. 1]
Simplicity One of the key features of this design of pump is that it completely eliminates the need for any form of dynamic sealing device. This in turn reduces the number of potential leak paths and also removes the need for any ancillary support systems that are associated with more complex dynamic sealing systems. Because there are no mechanical seals, there are fewer potential leak paths, no complex seal systems are necessary, they have fewer working parts and maintenance is simple. Zero leakage No fugitive emissions, no odours and no monitoring is required with such a system. No loss of product to atmosphere Chemical Engineering World
CEW Features By replacing the inner magnetic ring with a torque ring (similar to the squirrel cage rotor of an induction motor) the operating temperature of the coupling can be further increased to 450 o C without the need for any form of ancillary cooling system.
High pressure capability As there are no dynamic sealing devices in the magnetic drive pump, high system pressures can be easily catered for. High pressure designs suitable for system pressures in excess of 185 Bar have been manufactured and successfully applied. Typical duties in this area include crude oil jet mixing, sampling and hydrocarbon condensate applications.
Figure 1:
means inherent safety when pumping hazardous liquids. Usually a single, fully trapped controlled compression gasket forms the static seal between the casing and the containment shell and is designed in such a way that blow out is not possible.
coefficient of thermal expansion. It is chemically inert and extremely abrasion resistant. These factors make SIC the first choice material for the internal bearing system, although in some cases carbon and other materials are utilized.
Extended mean time between failure (MTBF)
Magnetic Coupling
Magnetically driven pumps, because of their robust design and the fact that they have no mechanical seals (the principal cause of pump failure), will generally operate
for
long
periods
without
maintenance. This means that costs of maintenance and lost production are kept to a minimum and that overall life costs are reduced significantly. Internal bearings bearings)
(silicon
carbide
Silicon Carbide became the standard magnetic drive pump bearing material in the 1980s. This material is one of the hardest materials available, has high thermal conductivity and a very low 30 • June 2017
The introduction of high energy magnetic materials in the early 1980s has considerably increased the amount of power transmitted by the magnetic coupling. Current magnetic couplings usually feature one of two types of magnetic material – Neodymium iron boron or Rare earth samarium cobalt. Neodymium has the higher energy product but has a lower operational temperature threshold and therefore tends to be used on pumps featuring plastic construction. Samarium Cobalt, whilst having a lower energy product is able to cope with higher operational temperatures and features in metallic magnetic drive pumps which have the ability to operate with process temperatures up to 315 oC. Both materials are capable of operation at sub-zero temperatures.
Temperature capability Low temperature to minus 100 o C and high to 450 o C pumps are available. 2) Environmental Considerations The Environment Agencies have basic rules for the oil, gas, chemical and pharmaceutical industries which include minimizing fugitive releases of liquid and gaseous materials at the design stage, with a priority on environmental protection and a formal leak detection and repair program. It is calculated that approximately 10% of fugitive emissions in refineries and chemical installations are from sealed pumps. MDPs completely eliminate fugitive emissions and odours by their zero leakage design. Because there are no emissions there is no requirement to monitor them. Plastic lined, non-metallic magnetic drive pumps feature non-metallic containment shells and thus the eddy currents associated with a metallic containment shell are reduced to Chemical Engineering World
ws o l nF
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CEW Features zero and therefore efficiencies are comparable to a mechanically sealed pump. The restriction with using a non-metallic containment shell is that temperature and pressure capability is reduced when compared to a metallic shell. High performance polymers and other materials are slowly gaining acceptance and it is likely that these will, in time, provide higher pressure and temperature capabilities.
adoption of the product and this has been especially true of magnetic drive pumps.
•
Carcinogenic
•
Flammable
•
Lethal
The first magnetic drive pumps based on the widely specified API 610 standard were introduced in the 1980s. Recognising the need for a sealless pump specification for heavy duty services in refineries and related industries the American Petroleum Institute introduced the API 685 standard in 2000.
•
Expensive fluids
•
Fluids containing dissolved solids (i.e. Caustic)
•
Fluids containing H2S (sour water)
• • •
Heat transfer fluids (cold and hot) High vapour pressure liquids Toxic
•
Fluids presenting sealing difficulties
•
Liquids that regulated
3) Health and Safety Considerations To handle hazardous liquids and gases safely, particularly where the plant operates under pressure, the whole of the containment system needs to be built to a high standard. There are detailed codes for pipework and pressure vessels, but there is less information about mechanical seals, although these are widely regarded as the weakest link in many containment systems. Magnetic Drive pumps by design are leak free and therefore odour free meaning operators have less exposure to the process liquids. Liquids are contained within the pump which has a design pressure rating equal to or in excess of the pipework, pressure vessels and other ancillary equipment. The extended mean time between failures (MTBF) means fewer repairs, therefore less handling and decontamination and disposal requirements. MDPs therefore can contribute to a cleaner, safer working environment.
4) Overview of API 685 Standards (5 & 6) 4.1 Background The petrochemical, oil & gas industries have always tended to wait for technology to be proven before 32 • June 2017
This provided further credibility for the technology and resulted in acceptance of MDPs by some of the world’s largest oil companies who now see the opportunity to reduce maintenance and monitoring and to protect both their employees and the environment. 4.2 Parameters API 685 (2000) recommends the use of the standard for sealless services that exceed the following limits:
have
emissions
4.3 Examples A few examples of some of the typical liquids that API 685 pumps have been used for are: •
Hydrocarbons
•
Sour water
•
Aromatics (Benzene, Xylene, Toluene)
•
Anhydrous hydrofluoric acid
•
Hydrofluoric acid
•
Discharge pressures greater than 275 psig (1900kPa)
•
Caustic
•
Alkylate
•
Suction pressures greater than 75 psig (500kPa)
•
Methyl Mercaptan
•
Pumping temperature greater than 300oF (150oC)
•
Aromatics (Benzene, xylene, toluene)
•
Methanol
•
Rotational speed greater than 3600 rpm
•
Olefins
•
Naptha
•
Rated total head greater than 400 ft. (120m)
•
Sulphuric Acid
•
Amines
Maximum impeller greater than 13 inches (300mm)
•
Isobutane
•
5) Why Pumps Fail API recognizes that below these limits purchasers may wish to consider sealless pumps that may not comply with API 685 for process services. API does not give guidelines on when a sealless pump should be considered but they are especially suited for applications with the following characteristics:
5.1 Pumps fitted with mechanical seals It is estimated that 80% of pump break downs are due to mechanical seal failure resulting in pumped liquid escaping to atmosphere, or to the sealing system in the case of double seals. The remainder are due to bearing failure or gasket leaks. Mechanical seal failures can be caused by: Chemical Engineering World
CEW Features •
Running dry
•
Loss of seal flush/cooling or barrier fluid on double seals
• •
Shaft misalignment or bent shaft Shaft deflection caused by operating at low or high flow
•
Wear of seal faces
•
Failure of elastomers – due to heat or incompatibility with fluid
•
Gasket failure
•
Faulty installation of seals
•
Bearing failure
•
Excessive vibration, low NPSH
•
Hang up caused by crystallisation
5.2
Magnetic drive pumps
The failure modes of MDPs are somewhat different from their mechanically sealed equivalent. Gasket failure is virtually unknown, and drive bearing failure is not usually catastrophic as it is with sealed pumps. In many cases a non-spark phosphor bronze “bump ring” is fitted so that in the event of bearing failure the outer magnet ring runs against this and not the thin walled containment shell hence limiting the damage.
Although MDPs have an extended MTBF, they may fail occasionally and experience shows that this is usually due to process upsets such as running dry, running with a closed suction or discharge valve, cavitation/vapour in the pump or high flow overload. The extent of damage can vary from internal bearing failure to damage of magnet rings and potential breach of containment shell.
Shaft deflection is not usually an issue with MDPs, as the overhang from the closest bearing is very short – unlike mechanically sealed pumps. Consequently, there is little deflection and little damage to the impeller and renewable rings.
5.3 Pump protection In most cases the pump can be protected using an inexpensive power control monitor. This simple device monitors the actual power absorbed and will cut out the pump if it falls below a predetermined value or above its upper set limit. Soft start devices and inverter drives often have this feature. This method has eliminated most of the catastrophic failures experienced by some users in past years. An alternative or additional method of pump protection that can applied to metallic MDPs is to use a temperature measuring device located on outside of the containment shell.
10 Neck Ring [Front] 10A Neck Ring [Back] 50 Coupling Washer 60 Impeller 70 Front Thrust Washer 80 Back Thrust Washer 90 Bush Holder 100 Bush 130 Thrust Pad 170 Casing Gasket 170B ‘O’ Ring 200 Containment Shroud 220 Rear Bush Housing 360 Coupling Nut 370 Inner Magnet Ring Figure 2: 34 • June 2017
390 Support Gasket 410 Casing 430 Coupling Housing 440 Bump Ring 510 Outer Magnet Ring Bearing Housing 610 620 Drive Shaft 670 Front Cap 680 Back Cap Labyrinth Seal [Kit] 700 700A Sec. Containment Seal 860 Shaft Sleeve 890 Breather 5020 Race **** Fixings [Kit]
the
A rise in temperature indicates a reduced cooling effect of the magnetic drive cooling and bearing feed stream thus signaling a potential issue with operation. [See Fig 3] 6) Reliability It is reasonable to assume that if a pump does not have mechanical seals, then it will be more reliable and magnetic drive pumps certainly have an extended MTBF – estimated at 2 to 3 times that of an equivalent mechanical seal pump. 7) Secondary Control or Containment The purpose of a Secondary Control system is to control any leakage that Chemical Engineering World
CEW Features
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The Journal of Materials & Equipment for the Process Industries
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A Secondary Containment system is able to contain any leakage that may occur. Once contained safely, the leaked product should have a means of being drained away from the Secondary Containment area in a safe and controlled manner.
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CEW Features
Selection of Pumps for Liquefied Petroleum Gas The process industry has a market for a wide variety of pumps. Most of the standard needs are met by conventional centrifugal pumps. However, some applications limit the choice of pump type and LPG is a perfect example of this.
L
PG is generally a mixture of propane and butane of varying composition. It is significantly lighter and less viscous than water, which makes it harder to seal and prevent pump slippage. The design for the storage, transportation, and pumping of such liquefied gases is the key success factor to handling this media. It is unique as it can be transported and stored as a liquid but when released it will vaporize and burn as a gas. It can easily be changed from either liquid state or gas state. When liquefied, LPG is always at its boiling point at normal temperature. The slightest drop in pressure or least addition of heat will cause it to boil and give off vapor or gas. This characteristic becomes critical when considering the transfer of LPG from one tank to another. It is very volatile in nature compared to such stable fluids as water. It is this volatility that makes LPG difficult to pump. LPG properties Constituents
Propane (C3H8) / Butane (C4H10)
Boiling point
- 42 deg. C to 0 deg. C
Melting or - 188 deg. C Freezing point
Case 1: High capacity / moderate net positive suction head available (NPSHA) LPG terminals involve unloading of propane and butane from large ships. Unloading is achieved with the ship’s own unloading pumps which are located within the ship. It is critical to unload these fluids in the shortest possible time to avoid the high costs incurred through ship idling charges. For this reason, booster pumps were required to reduce the unloading time and thereby the operational costs. The pump configuration for this had to be considered in terms of capacity and number, for which there were two options. The first was to use pumps of a lower capacity and intermediate storage for propane and butane. The second was to increase the number of pumps such that an appropriate pump model could be easily procured. The latter option was selected as storing propane and butane called for high pressure bullets or spheres, which were immediately ruled out. Thus, by increasing the number, the pump capacity was lowered to widen the spectrum of possible choices in the market. The required pump capacity and head were specified as follows.
Specific gravity 0.495 to 0.601 (at 25 deg. C) The basic intent of this article is to focus on the challenges faced when pumping LPG since, as explained, it is quite different from handling other fluids. In certain cases, it is possible to use a compressor to transfer LPG but this article is restricted to pumps. The concepts discussed will be illustrated by a few cases from a greenfield LPG terminal project being executed by Aker Solutions in Asia. 40 • June 2017
Q (flow) = 800 m3/h H (head) = 300 mlc (meter liquid column) NPSHA = 7 mlc Though this appeared to be a straightforward application, most pump manufacturers could not offer a suitable model for this duty in spite of a reasonable value of NPSHA. Vertical pumps and other rotary pump options were also explored without any success. The differential
head was viable but rotary pumps were limited by low capacities and vertical pumps would have been too expensive. Finally, one manufacturer proposed an API 610 centrifugal pump model (between bearings) with a BB2 configuration for this service, as they had supplied such pumps for a similar application in the past. The BB2 configuration consists of an impeller or two supported on either side by antifriction bearings. Such pumps were commonly used in the hydrocracker and sulphur recovery units executed by Aker Solutions recently. Case 2: Medium capacity / no NPSHA The net positive suction head required (NPSHR) is the minimum inlet pressure required at the pump inlet to avoid excessive cavitation. The NPSHA must be greater than required (NPSHR) to prevent pressure from dropping below the liquid’s vapour pressure at any region in the pump suction area. If the inlet pressure is lower than the vapour pressure, bubbles will form in the liquid. As the bubbles travel through the pumping chamber to the higher discharge pressure region, they will collapse. This causes pressure spikes, resulting in noise, vibration and damaged hardware. In the first case, a pump model was available as the NPSHA was not a significant challenge. However, some other cases from the greenfield project that were peculiar due to varying capacity and NPSHA are given below. = 400 m3/h Q H = 150 mlc NPSHA = 0 mlc As the horizontal centrifugal pump and other rotary pumps would not have been suitable for zero NPSHA, the automatic choice for this capacity and NPSH limit Chemical Engineering World
CEW Features was the vertical barrel type multistage centrifugal pump. These pumps develop differential heads up to 700 mlc. The pump consists of a vertically suspended shaft with a series of impellers at the base of the shaft. Typically, the first stage impeller can be designed for low NPSHR requirement. The inlet and outlet of the pump are located above grade and the pump is installed on a mounting plate. The drain and vent connections are located on the top of the plate for such pumps. The pump manufacturer can easily set the depth of the pump to meet the NPSH criteria. Thus, the pump has to be located inside a pit. Though these pumps are expensive and difficult to maintain, it is one of the best choices available for such services based on Aker Solutions’ extensive past experience. Case 3: Low capacity / flooded NPSHA When liquefied gas is transferred from one tank to another, as the liquid level drops, the vapour above expands and its temperature and pressure drop. Immediately, the liquid begins to boil creating vapour bubbles. The liquid entering the intake pipe carries some of these gas bubbles with it. Each restriction in the intake piping drops the pressure of the liquid-vapour mixture, causing the vapour bubbles to expand and causing more boiling and the formation of more vapour bubbles. Vapour has an adverse effect on both pump life and performance. The vapour bubbles prevent liquid from completely filling the pumping chamber cavity, which results in reduced pump capacity. The LPG terminal currently being executed involved applications such as transfer, bottling and unloading. Some of these are reviewed below, with low capacities but with flooded suction.
Q = 5 m3/h H = 200 mlc NPSHA = flooded After a few rounds of discussion with 42 • June 2017
potential suppliers of horizontal and vertical centrifugal pumps, it was concluded that the most cost effective solution for the above service was a rotary positive displacement pump such as the sliding vane type pump. For the given duty conditions, these pumps are highly efficient compared to centrifugal pumps, which are not economical for low flow and high head applications. A sliding vane pump consists of a slotted rotor attached to a rotating shaft. Vanes are fitted in the rotor slots and freely slide in and out during operation. An eccentric cam profile is machined into the liner, forming the pump chamber. As the rotor turns, the vanes slide out of the slots and ride along the liner. At the intake port fluid is drawn into the pumping chamber which is formed by rotor and liner surfaces. A volume of fluid, trapped between two vanes, is pushed along the pumping chamber. At the outlet port, the vanes slide back into the vane slot and the fluid is squeezed out through the discharge piping. Another option available for similar services is a regenerative turbine pump or a side channel pump with multiple stages (for high differential head). The turbine construction provides a smooth continuous flow through the pump case resulting in high efficiency. The side channel pump has become indispensable in LPG applications with capacities upto 35 m3/h and 350m head. There are some manufacturers who offer these pumps with a magnetic coupling as well. Aker Solutions has had positive experiences with such pumps on a butanediol project in South East Asia. When started, the pump begins to function as a displacement pump due to its selfpriming characteristics, but once the side channels are completely filled with liquid, the pump works as a centrifugal pump. Due to the centrifugal effect, the fluid is collected in the outer region of the side channel as well as the wheel cells, where it forms the liquid ring responsible for its
self-priming characteristic. On the inside, the gas is concentrated. The side channel pump with variable vapour pressure is significantly less vulnerable to cavitation compared to radial centrifugal pumps. This is due to the lower specific speed, which enables these pumps to handle LPG and other media close to its boiling temperature. These pumps are commonly used for propane and butane transfer and tanker unloading applications, as well as propane cylinder filling and bottle filling. Summary As can be seen from the three cases above, each service for the LPG terminal was unique in terms of capacity and fluid characteristic. There was a specific choice of pump type for each of the duty conditions encountered during execution. It is vital that the difference between LPG and conventional media is fully understood when specifying pumping equipment. In simple terms, an explosive liquid being pumped at its boiling point needs to be handled with greater care than a less complex liquid far away from its vapour pressure. Regarding the pumping equipment, there is a set of criteria that the user or specifier ought to consider as fundamental to the long-term trouble-free operation and ownership. Primarily, the most crucial factor is the vapour pressure of the liquefied gas
Author’s Details
Vinod Shenoy Engineering Manager - Mechanical Aker Solutions Mumbai Chemical Engineering World
CEW Features
Bearings in Centrifugal Pumps A bearing is a machine element that constrains relative motion to only the desired motion, and reduces friction between moving parts.
P
umps operate by creating low pressure at the inlet which allows the liquid to be pushed into the pump by atmospheric or head pressure. Net Positive Suction Head (NPSH) available is the absolute pressure at the suction port of pump and Net Positive Suction Head (NPSH) required is the minimum pressure required at the suction port to save the pump from Cavitation. Hence NPSH available must be greater than the NPSH required for a healthy Pump operation and prevent Cavitation. The highest point of Efficiency in pump is the “BEST EFFICIENCY POINT” (BEP). The Pump is operated between 80 & 100 % of BEP. Increased hydraulic Impeller loads can be result for pump flow rate below BEP. Cavitation and Increased Vibration can result from Pump operating above BEP. The other important parameter called Net Positive Suction Head (NPSH) is required for the better performance and avoids cavitation. The most common phenomenon, cavitation, takes place when fluid pressure is less than the vapor pressure. It develops small vapor bubbles which causes unbalanced flow and pressure on the impeller Ieading to Impeller damage, shaft deflection and increased bearing loads. Bearing Load classified into Axial Load and Radial Load determine the basic rating life of Bearing, expressed as the number of revolutions before the fatigue occurs on the bearing components like Rolling elements or raceways. The Axial Load acting on the Bearing is the sum of the forces arising from Change in the direction of the fluid flow, hydraulic pressure and the changes in axial load be due to changes in the flow conditions in and around the impeller. If balance holes become plugged with debris or due to wear, pump-out vanes clearance change the magnitude and direction of the Axial load which can deviate from its calculated value. The hydraulic loads depend on 44 • June 2017
pump operating conditions like fluid suction pressure, size of impeller & casing. The Radial load depends on the design of the pump casing, and is designed for even distribution of velocity and pressure acting at the impeller. The BEP factor during pump operation is very crucial for magnitude and direction of the Radial Load. The bearing types applicable are Single Row Deep Groove Ball Bearing, Angular Contact Ball Bearing Double Row, Single Row Angular Contact Ball bearings, Universal Match Pair. Ball Bearings like radial bearings are suitable for small & medium pumps due to their low friction and high speed capability. Single Row Angular Contact Ball Bearings with contact angle of 40 degree provide higher pump operational reliability due to high axial load carrying capabilities. These bearings operate with a reduced clearance or light preload, giving better positioning accuracy of the shaft. Cylindrical roller Bearings with their design features like separable component are used as nonlocating radial bearings. NU type for axial displacement due to thermal expansion of the shaft is preferred and tight housing fits are used to overcome impeller imbalance. The Spherical Roller bearings are used for high radial and axial load applications. Where Axial Load is in either direction needs to be taken care Universal match pair Single Row Angular Contact Ball Bearings are to be used. In larger with slow rpm pumps Spherical Roller, Cylindrical Roller , Taper Roller and Spherical Roller Thrust Bearings are to be used. The increased misalignment can be taken care by Spherical Roller Bearing and Spherical Roller Thrust Bearing, while moderate and low misalignments can be taken care by Single Row Deep Groove Ball Bearing followed by Angular Contact ball Bearing, Cylindrical roller Bearing. The Right bearings provide better performance, speed capability, quiet running and longer
service life. The Bearing Root cause Failure Analysis which concludes the factors like contamination, wear, misalignment, corrosion or lubrication or sealing failure. Bearing lubrication plays a major role to separate the rolling and sliding contact surfaces within the bearing components, besides providing corrosion protection and heat transfer agent for the Bearing. The viscosity and viscosity index i.e. kappa (k) value determine the effectiveness of film formation and surface separation between the rolling contact surfaces. Other important factors such as Bearing internal clearance, cage material and operating temperature are also to be considered. Proper Selection of Cages for the application depends upon the speed, temperature and lubrication. For harsh operating conditions and demanding service conditions, machined brass cage will be most suitable. The use of polyamide cage is limited to temperature of 100deg for optimum service life and avoids premature bearing failure. Rolling Bearings to be handled carefully with correct method of mounting for increased bearing performance and preventing premature failure. Few areas like Shaft and Housing Seating Dimensions for straightness and abutments for perpendicularity. Most of the pump applications need an interference fit, hence depending on the size /type of the bearing mechanical (Cold Mounting) or thermal (Hot Mounting) methods must be adopted.
Author’s Details Nilesh Wargantiwar General Manager – Sales & Marketing NRB Industrial Bearings Ltd.
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CEW Features
Instrumentation on Production Platform The article describes the instrumentation requirements of three critical and front end sections – Wellheads, Flowlines and Manifolds, and Separator - of a production oil & gas platform.
T
he hydrocarbons are believed to be formed by thermal conversion of organic matter trapped in sedimentary rocks from Jurassic era. The process is lengthy and not fully understood. The essential factors needed for oil and gas to evolve, to accumulate in a reservoir is known with a degree of uncertainty.
• ■Produced water treatment • ■Fuel gas In this article, we will restrict to the critical and front end section of the production platform up to the separator section. The Instrumentation requirements of these 3 sections will be described in this article. 1. Wellheads
Drilling is very expensive especially offshore and it is essential that suitable exploration surveys should be undertaken before drilling begins. One well does not make an oilfield, far more must be found before oil operator can decide whether it is profitable to exploit the strike. A number of appraisal wells are drilled and samples taken for lab analysis. If appraisal wells indicate the field is big enough to be of commercial value then drilling of development wells begin. Due to enormous cost of offshore platforms the most economical way to develop an oil field usually involves drilling a large number of wells from a single structure using a technique called deviated drilling. Depending on type of reservoir several layers of strings of tubing will be inserted in to well bore and cemented in place to provide passage for oil and gas to flow to surface. The oil and gas flow to surface needs careful regulation at surface and cluster of valves and fittings is known as Xmas tree (see Figure 1).
The term wellhead is used to describe the top section of the well located onboard the platform. Commonly referred to as the wellhead area this is where the well terminates and flow of oil or gas production can be controlled by series of valves.
A typical offshore production platform consists of the following sections: • • • • • • •
■Wellhead Area ■Flow line & Manifold area ■Separation ■Metering ■Gas Compression/dehydration ■Gas Export ■Oil Stabilisation
46 • June 2017
Whether the well is single or dual completion the valve arrangement is similar for each string. The first valve within the tubing string of a well is located at a depth of approximately 600 meters below the platform. This valve is known as the sub surface safety valve (SSSV) or downhole safety valve (DHSV) and is controlled from the surface and hence the term surface controlled subsurface safety valve. These valves play a vital part in well isolation and because of their importance are only operated when needed. Subsurface valves are actioned close at the higher end of the platform shutdown hierarchy e.g. High Gas or confirmed fire situations. When referring to a production well, topsides valves comprise the following in order of fluid flow. A. Lower Master Gate Valve (LMGV): This valve is manually operated and as with the subsurface valve is only operated when needed. The valve will be function tested periodically but this will involve partial closure and re-opening only.
Obliviously a partially open or stuck closed LMGV will have serious consequences on the production rates available. B. Upper Master Gate Valve (UMGV): This valve is remotely operated and is used when the occasion demands such as when production from a well is required to be stopped immediately. This situation can arise when a production cutback is required by closing in selected wells or when production stop is required and all wells are closed in. All upper master valves or selected upper master valves can therefore be closed within matter of seconds. Downstream of UMGV the well effectively divides in to three paths or routes normally referred to as: • Production or active side is the route for reception of well fluids. • Non-active or kill side of the tree whereby wellhead pressures can be monitored and kill fluids can be injected into well in order to stem or kill the flow. • Swab connection is the connection provided at the top of Xmas tree vertically above the well stream through which access can be gained to the wellbore. C. Active Side – Production or Flow Wing Valve: This valve is used to isolate the well fluids from the associated well flowline (which in turn leads to production and test manifolds). D. Non Active Valve or Kill Wing Valve: This valve provides access/isolation to the wellhead and is used when injecting kill fluid or monitoring the well. Chemical Engineering World
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CEW Features and manifolds it into various hydraulic actuated valves. The WHCP opens and closed the wellhead valves on signals from the main control room. The ESD logic is translated by a series of isolation and dump valves. A series of hydraulic accumulators are usually fitted to provide security of supply. The output from WHCP is divided into 2 discrete systems. • Sub surface safety valve operating system • Wellhead operating system The differences between two systems is that SSSV is usually controlled at a higher pressure due to distance and downhole pressures and any returns are routed back to a calibrated tank on the HPU. The wellheads valves return their fluid directly to the HPU main storage tank.
Figure 1: Well head & Xmas Tree Source: Schlumberger Oilfield Glossary
E. Swab Valve: The swab valve allows well service operations through the well service lubricator. Xmas trees and their associated valves are designed to withstand the maximum pressures that can be met. Typically 5000 and 10000 psi rated tress and valves are installed as required. 1.1 Interface with Other Systems The wellhead valves indicated in section 1.0 are generally supplied by the drilling/ Xmas tree vendor as part of the drilling package. Engineers at APG integrate the signals from the above valves with the platform Control/Safety system or Wellhead Control Panel (WHCP) based on the control philosophy of the platform. 1.2 Wellhead Control Control of the downhole safety valve (DHSV) is by way of hydraulic line that is run and strapped to the production string. The platform valves can be either 48 • June 2017
pneumatically or hydraulically actuated valves are controlled by a wellhead control panel (WHCP) that is in turn supplied by a hydraulic power unit (HPU 1.3 Hydraulic Power Unit (HPU) The HPU normally supplies hydraulic power to operate the wellheads valves through a control panel. • Surface controlled sub surface safety valves • Hydraulic upper master valves • Hydraulic wing valves The HPU can also supply hydraulic pressure for subsea riser valves and remote wellheads. The HPU is a closed loop system using either mineral based hydraulic fluid for surface operations or glycol based fluid for subsea operations. The cleanliness level of the hydraulic fluid is usually high. The HPU can supply hydraulic power at several levels using air and electric driven pumps as required by the volumes pumped.
1.5 Production Choke Purpose of Choke The production of oil or gas from a well is controlled by a variable valve referred to as choke which is either mounted directly on the upper part of the Xmas tree or in close proximity to the wellhead. The choke is located on the production flowline downstream from all other shutdown valves. The purpose of the wellhead choke is to provide precise control of flow and pressure, tight shut-off and high degree of reliability and resistance to wear and tear. Since the choke is the first stage of control over the well flow, it is essential that it is correctly sized for the required operating conditions from the outset. The choke is generally referred to as Multiple Orifice Valve (MOV) by virtue of its capability to interchange the trim internals to achieve
1.4 Wellhead Control Panel (WHCP) The WHCP receives the hydraulic power
a multiple range of operating conditions The means of control is by two discs each having 2 holes of the same diameter. Chemical Engineering World
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CEW Features The flowlines normally do have additional tappings in order to facilitate injection of chemicals as required. Typical examples are scale inhibitor to prevent calcium carbonate scales and methanol injection to prevent hydrate formation. Also installed on the flowlines are the various instrument tapping’s that are used to communicate pressure and temperature indications of the well fluids to the control room. Further there is provision for sampling monitoring of flowline contents. Individual well flowlines are routed to either a production manifold or a test manifold. See Figure 2 for a typical Wellhead Oil and Xmas Tree Source 2.1 Production Manifold The production manifold is designed to accommodate the total production from all the wells and once the individual flows are combined in the manifold they pass on to main separation train. Where each flowline terminates at the manifold there will be valve isolation available plus a non –return valve in order to prevent flow reversal back along the individual flowlines.
Figure 2: Well head & Xmas Tree Source: Schlumberger Oilfield Glossary
One disc referred to as back disc is kept stationary by means of locating pins and other disc referred to as front disc is rotated through 90 degrees to expose a portion of the flow area.
and cavitation and hence metallurgy of the valve is very important and should be taken care during section of the valve.
Choke valves are fitted with calibration bands in 64ths of an inch or in oilfield language ‘bean size’
Flowlines are installed in order to transmit fluids to or from the wellheads. On the production side of the well the production flowlines is used to transmit the well fluids to the production or test manifold, the production flowline will normally include a choke for controlling the amount of fluids passing forward to the manifolds.
The choke is likely to encounter three types of conditions which are prevalent to all used equipment used in flow control. These are erosion, corrosion 50 • June 2017
In event of problems arising within the system i.e. effective boxing in of the manifold at both ends, then the manifold can be depressurized to the flare system through a blowdown valve and then drained for maintenance. 2.2 Test Manifold
2 Flowlines and Manifolds The test manifold is designed to accommodate individual wells by routing them to a test separator. This is required so those individual wells can be tested in order to ascertain their flow and what the composition of the fluids is. As with production manifold, the test manifold has facility to be depressurized Chemical Engineering World
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CEW Features • • • • • •
Figure 3: Production Separator and Instrumentation Source: Oilngasprocess
and drained. 3. Separator A separator is a vessel in which a mixture of fluids, which are not soluble in each other, can be segregated. On offshore installations, separators are used to segregate gas from liquids or one liquid from another such as water from oil. For separator of gas and liquid, the separator is referred to as a two phase type. For separation of gas, oil and water, the separator is referred to as three phase type.
5.
6.
7.
Gas off-take flowmeter - This measures the volume of the gas flowing from the separator in both the flare or recompression mode.
8.
Level Indicating Controller and LCV - The LIC monitors the level and modulates the LCV to control the level at the set point
9.
Oil outlet Line - This line which has the LCV in it, leads the oil to the next link in the process train which could be a lower stage of separation, storage or transfer pumps
3.1 Separator Instrumentation Within the limits of design and construction all separators have the same basic Instruments & Controls and are as follows: 1.
Pressure Transmitters - Monitors the pressure in the separator with remote indication in the central control room.
2. Temperature Transmitters - Monitors the temperature in the separator with remote indication in the central control room 3.
4.
Pressure Safety valve - Relief valves are installed on each separator, one in service and other isolated. Manual blowdown line - This gives the facility to manually depressurize the separator, the gas being routed to the flare system.
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Gas outlet line - This is split into two streams- the gas to the recompression and treating section and gas to flare system. Pressure Indicating Controller and PCV - These two Instruments control the separator pressure. The PIC monitors and modulates the PCV as required
■Low level shutdown ■High level alarm ■High level shutdown ■High pressure shutdown ■High pressure relief valves ■In order to give added safety by preventing gas blow-by between separators, a shutoff valve is fitted to the pipework connecting the vessels. This valve is designed to close on a low level being detected in the upstream vessel or a high pressure being detected in the downstream vessel. Should either or both of these conditions be detected, then excessive pressure from an upstream vessel will not be communicated to a lower rated pressure vessel.
Regardless of what function is being monitored the sequence for alarm and shutdown is the same. The first notice is the alarm allowing the operator to take corrective action. If no corrective action is taken or action is ineffective, further deterioration occurs and a shutdown results. All level, pressure or temperature separator shutdowns normally result in the closure of all producing wells upper master gate (surface safety valve) and flow wing valves
10. Drains - This gives the facility to manually drain down the separator through the closed drain system A typical production three phase crude oil separator together with its associated instrumentation and control system is shown in Figure 3. 3.2 Separator Controls All Separators are fitted with the following protection facilities: • ■Low level alarm
Author’s Details Santosh Shanbhag Sr Engineering Manager (Instrumentation) Aker Powergas Pvt Ltd Email: Santosh.Shanbhag@ akersolutions.com Chemical Engineering World
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Advanced service functions for machinery and equipment B&R fur ther expands mapp Technology framework B&R continues to expand its mapp Technology software framework. The new mapp Tweet function allows a machine application to send information via text message or email. The increased intelligence boosts machine availability.
Automated text messaging
Fast maintenance response times
The new software block mapp Tweet allows a machine application to send text messages and emails trig-gered by specific events. Set up with just a few clicks, mapp Tweet can easily be connected to other mapp components. This enables the mapp AlarmX component, for example, to automatically notify a maintenance technician when an alarm requires immediate action. mapp Tw e e t c a n s u p p l e m e n t t h e m e s s a g e with addi-tional infor mation, such as troubleshooting instructions that allow the technician to quickly and efficiently resolve the cause of the alarm. This is an effective way to achieve a targeted reduction in machine down-time.
If the ser vice technician isn't on site, t h ey c a n q u i ck l y c o n n e c t v i a B & R ' s remote maintenance solution in order to run diagnostics, adjust parameters and resolve the error – all in a matter of moments. The solution utilizes the latest IT and secur ity standards and allows for significant savings with low investment costs. B & R c o n t i n u e s t o ex p a n d i t s m a p p Te c h n o l o g y s o f t w a r e f r a m e w o r k . Functions are now available for sending automatic notifications that enable advanced maintenance concepts.
About B&R B&R is an innovative automation company with headquar ters in Austria and offices all around the world. As a global leader in industrial automation, B&R combines state-of-the-art technology with advanced engineering to provide customers in vir tually ever y i n d u s t r y w i t h c o m p l e t e s o l u t i o n s fo r machine and factor y automation, motion control, HMI and integrated s a f e t y t e c h n o l o g y. W i t h i n d u s t r i a l fieldbus communication standards like POWERLINK and openSAFETY as well as the powerful Automation Studio s o f t w a r e d eve l o p m e n t e n v i r o n m e n t , B&R is constantly redefining the future of automation engineering. The innovative spirit that keeps B&R at the fo r e f r o n t o f i n d u s t r i a l a u t o m a t i o n i s driven by a commitment to simplifying p r o c e s s e s a n d ex c e e d i n g c u s t o m e r expectations.
Contact Details: B&R Industrial Automation
Corporate Communications t +43 7748 6586-0 press@br-automation.com B&R-Strasse 1, 5142 Eggelsberg, Austria Website: www.br-automation.com Chemical Engineering World
June 2017 • 53
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Boost productivity with anti-sloshing Transpor t liquids faster without spills With B&R's industrial transport system, it is now possible to transport liquids quickly with no spills. SuperTrak is the only system on the market to offer anti-sloshing technology. This technology suppresses the formation of oscillations on free sur faces to prevent liquids from spilling over container edges during transport.
No spills from open containers The term slosh is used to describe the behavior of liquids in moving containers. Specially designed move-ment profiles p r eve n t t h e d eve l o p m e n t o f p o s i t i ve feedback loops on the surface of the liquid so that it remains calm dur ing transpor t. This minimizes downtime and increases productivity when handling open containers.
sophisticated anti-sloshing technology also prevents the formation of air bubbles a n d fo a m . T h e d o w n t i m e o t h e r w i s e required to allow the liquid to settle is reduced drastically or eliminated entirely for a substantial improvement in packaging line productivity.
Higher production speeds
As the only system on the market, SuperTrak offers anti-sloshing technology that suppresses the formation of surface o s c i l l a t i o n s t o p r ev e n t l i q u i d s f r o m spilling during transpor t.
Minimizing oscillations on the surface of liquids is par ticular ly impor tant in the packaging industry. The better you are able to control sloshing, the faster the products can be transpor ted. B&R's
About B&R B&R is an innovative automation company with headquar ters in Austria and offices all around the world. As a global
leader in industr ial automation, B&R combines state-of-the-ar t technology with advanced engineering to provide customers in vir tually ever y industr y w i t h c o m p l e t e s o l u t i o n s fo r m a c h i n e and factory automation, motion control, HMI and integrated safety technology. With industrial fieldbus communication standards like POWERLINK and openSAFETY as well as the powerful Automation Studio software development environment, B&R is constantly redefining the future of automation engineering. The innovative spirit that keeps B&R at the forefront of industrial automation is driven by a commitment to simplifying processes and exceeding customer expectations.
Contact Details: B&R Industrial Automation
Corporate Communications t +43 7748 6586-0 press@br-automation.com B&R-Strasse 1, 5142 Eggelsberg, Austria Website: www.br-automation.com 54 • June 2017
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CEW Products Pneumofore TPN Series pump provide the ultimate vacuum of 0.5-mbar with high capacity required for centralized vacuum system. TPN Series guarantees the highest performance compared to other small on-board single stage oil lubricated vacuum pump and this TPN pumps are ready to use machines designed for easy installation and trouble-free integration into industrial process. Design and efficiency of mechanical parts guarantee low power consumption and provide added value in terms of sustainability and reduced operation cost. The closed-loop lubrication circuit ensures negligible coolant consumption prevents air and environment contamination with harmful substances and reduces maintenance requirement. Therefore, TPN Series vacuum pump offer best return of investment and low life cycle cost.Features air cooling system through an aluminum radiator and electric fan thermostat for operating without cooling water. No coolant consumption thanks to the closed-loop lubrication circuit and high efficiency separation element. Coolant separator and recovery for clean air exhaust without treatment. Durability and efficiency guarantee by the special aluminum alloy vanes that ensure constant performances even after tens of thousands of hours of operation. They are ready-touse machines that can be easily and directly connected to the vacuum plant and the power supply without foundations. Limited footprint thanks to the compact layout designed to minimize the space needs. It has direct coupling between motor and air end to avoid energy losses. It has a sound-proof cabin to reduce noise impact. Fully automatic operation: intake valve regulated by safety vacuum switch, coolant temperature control, thermostat and auxiliary control switches. Control panel complete with main power switch, easy to operate. For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 1
Case Packer Machine The machine is a combination of auto case erector with pick and place top load mechanism. This fully automatic machine from auto erection to filling and final taping system occupies relatively less space in comparison with combination machine of separate auto case erection and filling machine. Optional top and bottom taping attachment based on customer preference. The machine works on the principle of pick and place method using specially designed vacuum suction systems. Grippers are used to hold containers and bottles if they are not suitable for lifting through vacuum. All moving parts are covered with safety limit switch interlock and the machine is fitted with optional beam sensors. HMI will display trouble-shooting procedures and fault indications to minimise down time and pneumatic components are designed for easy access and replacement without disturbing main wiring system to reduce down time. In semi automatic case packer there will not be automatic case opening/case erector. The person should hold the manual open box. For details contact: Foreview Engg and Technology Pvt Ltd PAP-R-251, TTC MIDC, Nr Golden Garage Rabale, Navi Mumbai 400 701 E-mail: marketing@foreviewengg.com / foreviewengg@gmail.com or Circle Readers’ Service Card 23
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Products CEW Spiral Wound Gasket Spiral wound gaskets are special semi-metallic gaskets of great resilience; therefore they are suitable for applications featuring heavy operating conditions. SWG manufactured by spirally winding a V-shaped metal strip and a strip of non-metallic filler material, the metal strip holds the filler, providing the gasket with mechanical resistance and resilience. SWG can be reinforced by an outer centering ring and/or inner retaining ring, The outer centering ring controls the compression and holds the gasket centrally within the bolt circle. The inner retaining ring increases the axial rigidity and resilience of the gasket and acts as a heat and corrosion barrier eliminating turbulance between the gasket inner diameter and the flange bore so avoiding erosion of the flange faces. For details contact: Norton Gaskets Pvt Ltd Works No: 66-B Nehru Nagar Indl Estate 2nd Link Road, Kottivakkam Chennai 600 041 Tel: 044-24540095 E-mail: nortongaskets@gmail.com or Circle Readers’ Service Card 3
Mass Flow Controller The mass flow meters and controllers consist of a metal body with a straight throughflow path. Two sensors are encased with stainless steel and protrude inside this bore; one is designed as a heater and the other as a temperature probe. The working principle is based on King’s Law of the Ratio between the mass flow and the heater energy. That means the higher the flow, more energy is required to maintain the chosen ∆ T. Features direct inline measurement principle; usable for virtually every kind of gas or gas-mix; mass flow measurement and control for a wide scope of applications; compact and robust design; IP65 for full product range; sensor made of stainless steel; no inlet pipe required; measurement without moving parts; customised adjustable multi-functional display: actual flow, totaliser with memory and reset, alarm, setup and much more. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448558, 26448983 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 4
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CEW Products Peeler Type Centrifuge Shiv Shakti Process Equipment Pvt Ltd offers horizontal peeler type centrifuge. Full opening housing gives complete access to the entire processing area, which allows for ease of maintenance, inspection, cleaning and validation. Clean room installation is possible with separation of the processing area from the mechanical components, which is achieved with a through the wall designInclined chute facilitate cake discharge, which is easily accessed for cleaning and validation.Feeding of the slurry across the entire length of the basket ensures uniform cake thickness. There are several possibilities for control systems from completely manual to fully automatic with a local operator interface and the possibility of plant networking. For details contact: Shiv Shakti Process Equipment Pvt Ltd 407 Shivam Chambers Next to Sahara, S V Road Goregaon (W), Mumbai 400 104 Tel: 022-26788480 Fax: 91-022-26798284 E-mail: sales@shivshaktiequipments.com or Circle Readers’ Service Card 5
Air-cooled Compressors Sauer Compressors presents the BREEZE WP323LM Basic air compressor. This three-stage air-cooled compressor generates a flow rate of 420 m³3/h with a final pressure of 40 bar (g) and a power consumption of 90 kW. It is one of four medium pressure models from a newly developed compressor Series for industrial applications. The BREEZE Series is based on a flexible modular system consisting of several crankcases with three to five cylinders. Thanks to its nine cylinder/piston combinations, the Series covers a wide output range and meets numerous customer requirements. The air-cooled compressors from the new BREEZE Series offer other innovations too, including the CubeCooler concept, which is being used for the first time. Block coolers arranged radially around the fan enable the recooling temperatures to be reduced by a third. A protective cover comes as standard and has an integrated gauge panel, ensuring outstanding usability with the highest safety standards. The protective cover covers the hot parts of the machine while still allowing easy access to the components relevant for maintenance. The industrial compressors from the BREEZE Series are generally very low noise, robust and compact. In addition to the BREEZE Series of medium pressure compressors up to 40 bar (g) and high pressure compressors with final pressures up to 500 bar (g), the modular system also opens up the option of booster versions with inlet pressures of up to 16 bar (g) as well as special gas-tight designs for gases such as helium, natural gas and hydrogen. For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.koester@sauercompressors.de or Circle Readers’ Service Card 6
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Products CEW Hybrid - LRVP Toshniwal, leaders in vacuum engineering for over 70 years, now provide further solutions to your vacuum needs. The most advanced manufacturing technology in liquid ring vacuum pump has now created as improved Liquid ring pump 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 is with the objective to reduce manufacturing times and shortening delivery times. 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 7
Combo Deduster + Metal Detector Combo Deduster + Metal Detector HS 30 consist of vertical deduster bottom and top integrated with digital metal detector. The deduster is provided with frequency and voltage (power) control insuring effective dedusting and deburring. The entire dedusting settings are controlled from the metal detector. The inlet can be rotated through 3,600 and hence the same can be used for right or left outlet of compression machine conveniently. The system is designed to ensure ease for cleaning and the entire deduster assembly can be dismantled and assembled within minutes without any tools. For details contact: Technofour Electronics Pvt Ltd Gat No: 3 (PT), 5 (PT), 243 (PT) Kasurdi (Kheba) Khed Shivapur-Saswad Road Post: Khed Shivapur Tal: Bhor, Dist: Pune Maharashtra 412 205 Tel: 02113-305200, 305246 Fax: 91-02113-305250 E-mail: pcssales@tepl.co.in teplinbox@gmail.com or Circle Readers’ Service Card 8
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CEW Products Compressor Control Sauer Compressors offers a new range of controls for fully automated monitoring and control of compressor functions. The first model is the Sauer ecc 4.0 – a control for universal use in all compressor Series for applications in the naval, shipping, offshore and industrial fields The software has been completely developed by Sauer Compressors, which enables it to be adapted precisely to the relevant requirements. Certain features can be added and customised for specific projects. The design of the Sauer ecc 4.0 follows an intelligent modular principle tailored to the compressor type and version. The modular system can be configured over various expansion levels - from the economical basic version through to complete monitoring of all measured values in the fully-featured version. The Sauer ecc 4.0 can connect up to twelve compressors, communicating via all standard interfaces. In terms of Industry 4.0, the control can be integrated into higher-level systems. The new control is operated using a 7” colour touch screen display. The latest generation resistive touch screen display is extremely robust and can be operated wearing gloves. Users benefit from the user-friendly intuitive menu system and step-by-step instructions in 30 languages. All relevant parameters are visible at a glance, represented visually by pressure gauges and texts. In case of faults, the control provides detailed alarm and fault messages including remedial suggestions. A numerical keypad allows easy adjustment of values. Operator login is based on direct code entry. For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.koester@sauercompressors.de or Circle Readers’ Service Card 9
Powerful Conveyor Drives Hoist functions and the STO and SS1 safety functions according to EN 61800-5-2 are included by default. By integrating geared motors that are produced in-house into the drive system configuration, NORD is able to supply complete solutions from a single source to system engineers and operators of warehousing, distribution center, intralogistics or baggage handling facilities. Interfaces for all common fieldbuses and Industrial Ethernet protocols are supported. Plug connectors for power, sensors, and communication lines ensure particularly fast and error-free installation and maintenance. The size 2 frequency inverters complement the smaller drive size and motor starters launched earlier in 2017, which cover a large part of all intralogistics drive applications in the 0.55 to 3 kW range. A video clip (http://nord.click/vq7g) shows the extensive functional features of the NORDAC LINK series, the comfortable and flexible control options, and the especially easy commissioning of these field distribution systems. For details contact: NORD Drivesystems Pvt Ltd 282/2, 283/2, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC II Pune, Maharashtra 411 057 E-mail: marketing.in@nord.com / Muthusekkar@nord.com or Circle Readers’ Service Card 10
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Products CEW Flare Fittings Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers flare fittings in SS, brass, carbon steel, alloys, etc, in size range from 1/8 to 2 inch piping; NPT, ISO/BSP and SAE threads. Excellent threads constructed to ensure leak-proof and reliable systems. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in or Circle Readers’ Service Card 11
Instrumentation Pipe & Weld Fittings Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization. Excel Metal & Engg Industries offers instrumentation pipe and weld fittings in SS, brass, carbon steel, alloys, etc, in size range from 1/8 to 2 inch piping; NPT, ISO/BSP and SAE threads; according to ASME B31.1 and B31.3. All threads are protected with a cap. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane, Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in or Circle Readers’ Service Card 12
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CEW Products Oil-free and Gas-tight Piston Compressors Sauer Compressors has enhanced its already extensive portfolio with a broad range of oil-free and gas-tight piston compressors for compression of air and a variety of gases. With the enhanced product range, Sauer is opening up a variety of new markets and applications, including compression of SF6, oxygen, CO 2 , H 2 and various special gases such as refrigerants, Argon, ammonia and more. The HAUG Sauer range includes entirely oil-free and completely dry running compressors. Oilfree compressors are suitable for processes and applications with high demands on gas purity and process quality. Since gas treatment and filtration after the compressor is simple or not required at all, oil-free compressors can reduce operating costs and risks significantly. HAUG compressors grant high reliability, both in continuous operation and operations with long standstills, frequent interruptions and cold starts. The compressors remain gas-tight even at maximum suction pressures of up to 20 bar, practically eliminating the risk of environmental contamination due to leakage. The air-tight design of HAUG compressors with its magnetic coupling includes a built-in overload protection. If the compressor is running with too high a load or discharge pressure, the magnetic coupling “slips” and the compressor is safely shut down and stopped. The modular compressor-concepts allow for high customization to meet the individual demands of a wide range of operations. Energy efficiency can be adjusted in accordance with the requirements of the application, thus the compressors reduce operating costs significantly. For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.koester@sauercompressors.de or Circle Readers’ Service Card 13
Standardized Chemical Pump with Magnetic Coupling KSB Pumps Ltd offers Magnochem pumps in India. These standardized chemical pumps with magnetic coupling are suitable for handling aggressive, toxic, explosive, valuable, flammable, malodorous or harmful fluids in the chemical, petrochemical and general industries. Magnochem - horizontal, seal-less volute casing pumps in back pull-out design with magnetic drive confirms to ISO 2858 / ISO 5199. Magnochem pumps are Atex compliant also. Its broad range of variants offers excellent flexibility. Pumps are optimally designed for excellent energy-efficiency and offers maintenance-free long life. Magnochem pumps are available in 26 different sizes and are designed for 40 bar operating pressure and have capacity to pump liquid up to 300 cu meters per hour at head of 150 meters. To cater to wide range of applications; hydraulic components of Magnochem are available in different grades of SS and it can withstand fluid temperature between -90 and +300oC.
For details contact: KSB Pumps Ltd Mumbai-Pune Road, Pimpri Pune, Maharashtra 411 018 Tel: 020-27101241 E-mail: bipin.kode@ksb.com or Circle Readers’ Service Card 14
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Products CEW Turbine Blowers/Exhausters Indovac offers turbine blowers/ exhausters a tailor-made solution for desired applications. It works dynamic compression by transforming flow energy into pressure energy. The features are compact and vertical shaft design integral silencer and suction mask, free of wear and tear maintenance by non-contact operation. The pumping medium is not contaminated. Available in 40-1,000 m3/hr capacity, vacuum up to 300-500 mbar single and double stage in suction operation and pressure up to 400-500 mbar in pressure mode. It finds application in plastic industry, air pollution monitoring equipment, aeration, pneumatic conveying, industrial vacuum cleaners, waste water treatment, measuring medical and laboratory equipment, etc. For details contact: Indovac Pumps & Engg Co 21 Anand Raj Indl Estate Sonapur Lane, B/h Asian Paint Off LBS Marg, Bhandup (W), Mumbai 400 078 Tel: 022-25664937, 65062751 Telefax: 91-022-25664917 E-mail: indovac@yahoo.co.in or Circle Readers’ Service Card 15
Pilot/Mini Spray Dryers AVM pilot/mini spray dryer is an excellent choice for laboratory testing, small-scale powder production requirements. These plants are designed for an evaporation capacity ranging from 3-60 kg/hr. AVM pilot spray dryers are complete skid-mounted packaged plants, comprising air heating section, spray chamber, cyclone separator, bag filter liquid pumping system, liquid atomisation system, air circulation blowers and control panel with instruments.AVM offers pilot/mini spray dryers with variety of configurations. For details contact: New AVM Systech Pvt Ltd AVM House, 3B+3 Part, 1/3 Akurdi Indl Estate Opp: Ador Welding Ltd D-1 Block, MIDC, Chinchwad, Pune, Maharashtra 411 019 Tel: 020-27459986, 27459987 Fax: 91-020-27459988 E-mail: avmtechnologies@vsnl.net or Circle Readers’ Service Card 16
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CEW Products Warehouse Management System
Metal Detectors
Warehouse management system is easy to use. It is user-friendly software with all required features to manage inventory in warehouse effectively. All warehouse owners always look for software which gives fast data entry and is easy report generation. Their WMS Inventory Software system is designed keeping your specific requirements for inventory management software in mind. It is complete online warehouse inventory control software with fast data entry facility.
Metal detector detects metal in a filled bag when the bag passes through its electromagnetic field. When metal is detected in the bag passing through the metal detector, the same is rejected by the bag rejection system ahead of the metal detector. Such bags slide down the non-driven roller conveyor. Metal-free bags are transferred to the next system without any stoppage.
For details contact: Sundaram Technologies F-339 Raghuleela Mega Mall Boraspada Road, Kandivli (W) Mumbai 400 067 Tel: 022-42661121 E-mail: info@makesure.org
For details contact: Jasubhai Engg 64/a, GIDC Indl Estate, Phase 1 Vatva, Ahmedabad Gujarat 382 445 Tel: 079-49003636, Fax: 91-079-25831825 E-mail: mhd-sales@jasubhai.com or Circle Readers’ Service Card 17
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Shrinkwrap Machine After completion of filling, capping and labelling, product containers are being fed automatically to lane divider and start moving in a single lane form on the collating table in a matrix form. Required container pack matrix formation is being done by collation through a pneumatic pusher, which after completion is transferred forward for the web sealer position. Immediate after proposed matrix enters into web sealer, the welding bar activates to complete the wrap and the pusher returns to prepare the next collation of product. As the welding bar ascends, the pusher advances to transfer the new collation into the welding position, at the same time displacing the previously wrapped collation on to continuously moving shrink tunnel conveyor.Once proposed wrapped matrix enters the shrink tunnel chamber, re-circulated hot air causes the wrap to shrink and tightly conform to the contours of the contents. Once the pack comes out of the hot chamber, air cooling is used to tighten sleeve wrap to achieve a strong, secure pack ready for stacking on pallet or a placing on a shipping carton. In semi-automatic shrinkwrap machine the pusher mechanism will be manual and respective specification and feature changes For details contact: Foreview Engg and Technology Pvt Ltd PAP-R-251 TTC MIDC Nr Golden Garage Rabale, Navi Mumbai 400 701 E-mail: marketing@foreviewengg.com or Circle Readers’ Service Card 19
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Products CEW Solar Pump Grundfos Pumps India Pvt Ltd (Grundfos India) offers Smart Solarz, a solar pump for domestic use. It is lightweight, easy to install and the wet parts of the pump are made of food grade engineered polymers to ensure that it is corrosion-free. The Smart Solarz also has intelligent features like protection against dry run and level controls. The pump has a 150-W/24-V BLDC motor. Smart Solarz is best suited for houses and buildings, which have a ground floor and max of two additional floors, especially in areas where the power supply is poor or not available. It operates with solar panels of 250-W/36-V (open circuit). It can be used for water pumping from sump to overhead tank as well as in greenhouses, lawns, gardens, solar powered fountains and for feeding livestock. For details contact: Grundfos Pumps India Pvt Ltd 118 Rajiv Gandhi Salai, Thoraipakkam, Chennai 600 097 Tel: 044-45966800, Fax: 91-044-45966969 E-mail: salesindia@grundfos.com / serviceindia@grundfos.com or Circle Readers’ Service Card 20
Pumps and Compressors Blackmer offers ML Series pumps ideal for liquid-terminal operations that require highcapacity product transfer, top or bottom loading/unloading and blending at the rack. ML Series pumps offer tremendous self-priming and high-suction capabilities that enable them to clear tanks of product more effectively and efficiently than competitive models. ML pumps can handle fluid viscosities from 30 to 500,000 ssu (1.0 to 108,000 cS) with flow rates up to 600 gpm (136 m3/h) and at operating temperatures as high as 400°oF (206°oC). Blackmer also offers its STX Series pumps ideal for loading and unloading corrosive and non-corrosive liquids – sulfonic acids, specialty chemicals, solvents, latex paints, liquid sugars and vegetable oils – that are not compatible for use with cast iron pumps. These pumps offer the best combined characteristics of sustained high-level performance, energy efficiency, trouble-free operation and low maintenance costs. S Series screw pumps from Blackmer with or without external timing gears and bearings, Blackmer S Series pumps are self-priming double-ended positive displacement pumps that offer outstanding performance in the most demanding liquid-storage terminal applications. Blackmer twin and triple screw designs provide complete axial balancing of the rotating screws and their timing technologies eliminate metal-to-metal contact with the pump. S Series pumps are also ATEX-certified for use in explosive or dangerous environments. In addition, Blackmer HD Series reciprocating gas compressors will provide quiet, efficient transfer of a wide range of liquefied gases. HD Series compressors also have been designed to handle the vapour recovery of gases that are common in terminal applications. The vapour recovery aspect of this application captures vapours before they are released in the environment, allowing terminals to be more environmentally responsible and compliant while ensuring the most complete product transfer possible. For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass, Sanneerkuppam Chennai 600 056 Tel: 044-26271020, 25271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 21
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CEW Products Dust Density Meter
Anti-crane Collision Switch
DDM is an on-line pollution monitoring system manufactured by Tanaka Electric Lab Co Ltd, Japan. It continuously detects and indicates the dust density in the exhaust gas discharged from industrial chimney or stack. DDM adopts reliable light scattering method for continuous detection with high sensitivity and without any bothersome adjustments. Remote fibre optic detector and built-in air purge facility ensure long time maintenance-free operations. This model has been specifically desigened for keeping in mind the environmental conditions.
Electronic Switches (I) Pvt Ltd offers anti-crane collision system for two overhead cranes on the same rail. With these units, the two cranes on the same rail will never collide with each other and thus the damage caused due to collision can be saved. Laser alignment tool is provided for perfect alignment of sensor unit and reflector. The reflected beam will be packed up by the receiver when both the cranes come closer. When the two cranes come within the range, the moving crane will be stopped immediately. This range can be adjusted for single set point, as required. For two set points, one can be adjusted to get an alarm and another can be set to stop the crane at required distance
For details contact: Toshniwal Sensors Pvt Ltd E 19/20, Indl Estate, Makhupura Ajmer, Rajasthan 305 002 Tel; 0145-2695536, 2695482 Fax: 91-0145-2695006 E-mail: info@tspl-india.com
For details contact: Electronic Switches (I) Pvt Ltd Plot No: K-11, MIDC Area, Ambad Nashik, Maharashtra 422 010 Tel: 0253-6697701, 6603954, Fax: 91-0253-2380918 E-mail: electronic.switches@gmail.com or Circle Readers’ Service Card 22
or Circle Readers’ Service Card 23
On-line Chloride/Sulphate Analyzer Mettler Toledo Process Analytics offers an on-line instrument for direct measurement of corrosive ions found in power plant water and steam.Chlorides and sulphates cause pitting and stress corrosion in expensive power plant components such as turbines and boilers, leading to extensive maintenance and unplanned shutdowns. Monitoring these ions at low ppb levels has therefore been identified as key measurements in power plant chemistry. The Mettler Toledo Thornton 3000CS Analyzer provides on-line, trace-level chloride and sulphate measurements for corrosion control. The 3000CS uses microfluidic capillary electrophoresis, an ionic separation technology, to provide an alternative to expensive off-line methods such as ion chromatography and inductively coupled plasma. The unit features semi-automatic calibration and an intuitive touchscreen interface, allowing operation without the need for extensive training. Mettler Toledo’s Intelligent Sensor Management technology in the analyzer provides diagnostics that predict when maintenance or replacement of consumables will be required. For details contact: Mettler Toledo India Pvt Ltd Process Analytics Solutions Amar Hill, Saki Vihar Road Powai, Mumbai 400 072 E-mail: akash.trivedi@mt.com. or Circle Circle Readers’ Readers’Service Service Card Card 24 24 or
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Products CEW Internal Gear Pumps EnviroGear Pumps offers its G Series Internal Gear Pumps designed with only two moving parts and operate equally well in both directions while providing a positive, non-pulsating flow. This innovative design also provides multiple inlet and outlet positioning, a single end-clearance adjustment and easy drive-end access for ease of maintenance and adjustability. Interchangeable with 95% of the internal gear pumps on the market, G Series pumps allow easy equipment upgrades with no piping, driver, coupling, flow rate and baseplate changes. The pump casing can also be easily rotated for multiple liquid porting positions, making these pumps simple to install into existing internal gear pump applications.EnviroGear G Series pumps are available in cast iron, carbon steel and stainless steel. They are extremely reliable, durable and cost-effective for challenging industrial applications involving both thin and highly viscous liquids up to 431,000 cSt. G Series pumps deliver flow rates up to 500 gpm (114 m3/hr) and are offered with both packing and mechanical seal options. They are available in 1.5- to 6-inch port sizes. Offering the shortest product lead-times in the industry with world-class application and technical support, EnviroGear is your complete solution for liquid transfer needs that involve internal gear pumps. For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass, Sanneerkuppam Chennai 600 056 Tel: 044-26271020, 25271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 25
Screw Pumps Blackmer offers its S Series Twin Screw pumps that are ideal for transferring bitumen from tankers to the distant tank-farm facility. Traditionally used as a cement binder for hot-slab paving, liquid bitumen must be handled at very high temperatures in order to keep it at a workable viscosity. However, even at high temperatures liquid bitumen can be an extremely viscous and shear-sensitive product. Therefore, shipyard operators and tanker owners demand a pumping technology that has been specifically designed to transfer highly viscous liquids over great distances. Realizing the importance for pumping equipment that feature the design and performance characteristics required for transferring highly viscous liquids, Blackmer offers its S Series Twin Screw models for these marine applications. S Series pumps feature a compact design composed of two sets of opposed screws that engage during operation to form a sealed cavity with the surrounding pump casing. The pumped liquid is moved axially as the screw shafts turn, allowing the liquid to be steadily and constantly conveyed to the center of the pump where the discharge port is located. This method of operation guarantees that the liquids are transferred with high efficiency and nearly pulsation-free, which are crucial considerations when transferring highly viscous liquids over great distances. Other features that make Blackmer S Series pumps ideal for use in marine applications include self-priming, compact design for convenience, ability to run dry for short periods, high suction lift and constant flow rates despite varying conditions. Blackmer offers its S Series Twin Screw pumps in a With Timing Gear (WTG) configuration that has a double-suction design with no metal contact between the hydraulic components and automatic axial balancing. They are low noise and nearly pulsation-free with little fluid agitation or emulsified shear, making them ideal for use with corrosive and non-corrosive, low or high viscosity, and clean or abrasive liquids. For details contact: Dover India Pvt Ltd 40 Poonamallee Bypass Senner Kuppam, Chennai 600 056 Tel: 044-26271020, 26271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 26
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CEW Products Helical Ribbon
Capacitance Level Transmitter
Helical ribbon impellers are designed for axial and overall mixing in laminar floor. Such an impeller can be designed with an additional inner helix or auger used to pumping in the opposite direction. This is needed for the mixing of high viscosity materials. These impellers can also have one or two start helix. The quality of the final mixed products in these applications is very critical. Wall scrapers can be mounted on the impeller blades to improve heat transfer and homogeneity in sticky products.
Capacitance level transmitter works on the principle of change in capacitance value, due to change in liquid level. Here the liquid acts as the dielectric, the probe and tank wall as electrodes. The change in capacitance value is converted to 4-20 mA analogue output. It is available for conductive as well as non-conductive liquids. PTFE sleeve is provided to the electrodes for better insulation and to withstand high temperature.It finds application in diesel tank, solvent tank, STP tank, water tank (RO, DM, soft, raw), acidic and alkaline tank. For details contact: Filpro Sensors Pvt Ltd 130, 10 th Cross, Petechennappa Indl Estate Kamakshipalya, Magadi Main Road Bengaluru, Karnataka 560 079 Tel: 080-23286463 E-mail: sales@filprosensors.com
For details contact: FEDA Inc B-37 Maruti Indl Estate Plot No: 59/1/2/3, Phase 1, GIDC, Vatva Ahmedabad, Gujarat 382 445 E-mail: ashok.chaurasia@gmail.com or Circle Readers’ Service Card 27
or Circle Readers’ Service Card 28
Reverse Osmosis Membrane Elements The reverse osmosis (RO) membrane elements in LANXESS’s Lewabrane® line of products are spirally wound, thin-film, composite membranes. They filter out undesirable substances from water, such as salts, pesticides, herbicides, viruses, bacteria and particulates. The product line includes elements for all the main RO applications, including desalinating seawater, brackish water and low-salinity water. Leading fields of application include the production and treatment of drinking water, but also the treatment of process water, other industrial water, and wastewater. Among the most important applications for RO membranes are the treatment of process water for power plants and the generation of ultrapure water in the microelectronics sector. Another area of application for RO membranes is the production of drinking water from both brackish water and seawater. This method is used on a large scale in cities and municipalities and on a small scale in restaurants, hotels and on cruise ships. The membranes lower the salt and particle content of the water and are often combined with ion exchange resins to form a highly efficient and very powerful demineralization system. Lewabrane® membrane elements chemistry depends on a strongly crosslinked polyamide layer that displays high resistance to chemical cleansers, higher rejection of complex salt mixtures and a low surface charge, which reduces the tendency toward fouling. For details contact: LANXESS India Pvt Ltd LANXESS House, Plot No: A 162-164 Road No: 27, MIDC, Wagle Estate Thane (W), Maharashtra 400 604 Tel: 022-25871000 E-mail: s.prakash@lanxess.com
or Circle Readers’ Service Card 29
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Products CEW Dosing & Metering and Industrial Metering Pumps SRS Pumps offer qualitative range of plunger type dosing and metering pumps, and industrial metering pumps. These pumps are positive displacement pumps and in each cycle of operation displace a particular amount of fluid. The pumping action is created by the reciprocating motion of a plunger. As per the requirements of the customers, SRS Pumps offer their assortment of plunger metering pumps and industrial metering pumps in different models. These pumps have two parts such as drive-end mechanism and the liquid-end mechanism. It can be distributed in simplex, duplex or multiple heads for handling various chemicals with a common motor to facilitate the whole operation. Each head is independently connected and the capacities of each head are also independently adjustable. It can achieve flow rates up to 10,000-LPH and delivery pressures up to 500 kg/sq cm. 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 30
Rotary Screw Air Compressors Ingersoll Rand offer new models to its line of R-Series oil-flooded rotary screw air compressors, which provide a more energy-efficient solution for customers with high capacity air requirements. The RS200 to RS250 models rotary screw air compressor will reduce energy cost by approximately 10 per cent for large manufacturing facilities. The RS200 to RS250 models are available with the new, state-of-the-art singlestage airend or the two-stage airend that increases airflow by up to 16 per cent. The new fixed-speed models are 10 per cent more efficient compared to legacy products, while the variable speed option is up to 35 per cent more efficient compared to the industry average. At the core of every Ingersoll Rand next generation R-Series compressor is an airend that is specifically designed to improve overall system efficiency. In addition to the enhanced single-stage airend, the RS200 to RS250 models are also available with the new two-stage airend. Each compressor comes standard with Progressive Adaptive Control (PAC) Protection, VShield technology, floating coolers and Ultra Coolant. These features help keep equipment running efficiently and maximize uptime for facilities that are manufacturing around the clock. All Next Generation R-Series air compressors are equipped with Xe-Series controllers, which allow easy, intuitive access to, and control of, the compressed air system. The Xe145 controller has built-in performance analysis and graphical trending, as well as built-in sequencing for up to four compressors. For details contact: Ingersoll Rand India Plot No: 35, KIADB Indl Area, Bidedi Bengaluru, Karnataka 562 109 E-mail: airsolutionsindia@irco.com or Circle Readers’ Service Card 31
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CEW Products Weir Diaphragm Valves
Gas Chromatographs
Cipriani Harrison’s Weir diaphragm valves are made from bar stock / forging and cover a range of sizes from ½” to 1”. These valves are made as per the ASME BPE specifications. All the elastomers used for the diaphragms (Viton, EPDM, PTFE, Buna) are FDA approved. USP Class VI Grade rubbers are also available on request. The standard surface finish of the valve is 0.4 Ra and 0.2 Ra available on request. Cipriani Harrison’s diaphragm valve utilises a patented new diaphragm design called hygieniseal.
Developed around key innovations driven by customer needs, including user-installable instant connect injectors and detectors, unique and patented solutions to conserve helium carrier gas while running analysis, and optimised and miniaturised electronic components, the compact Thermo Scientific TRACE 1300 Series GC is extremely fast, easy to use, and delivers high lab productivity at a much reduced cost of ownership. The new high-capacity TRACE 1310 auxiliary oven has multi-valve, multi-column capacity and enables the use of up to four conventional detectors simultaneously
For details contact: Cipriani Harrison Valves Pvt Ltd 1901, GIDC, Phase IV Vallabh Vidyanagar, Vitthal Udyognagar, Gujarat 388 121 Tel: 02692-235082, 235182, Fax: 91-02692-236385 E-mail: info@harrisonengineers.com
For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi ‘C’ Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494, Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com
or Circle Readers’ Service Card 32 or Circle Readers’ Service Card 33
New Drive Electronics The new NORDAC LINK Series of field distribution systems affords operators and installers of conveyor systems considerable savings through standardization, plug and play, efficient operation, a high level of service and ease of maintenance. All sensor, communications and supply lines can be easily connected via coded plugs that only fit the appropriate slot. The manufacturer supplies these new frequency inverters and motor starters configured to customer requirements. They are available with optional safety features, application-specific parameterization and sensor interfaces as required in addition to support for all standard bus systems. Maintenance switches, key switches and direction switches provide for very flexible direct user access to every single axis. As part of standardized LogiDrive units- along with IE4 synchronous motors and bevel gearboxes in three sizes – Featuring PI controllers and an integrated PLC, they can carry out logical sequences and take care of process control on their own. The PLC can monitor the drive system, evaluate sensor data and independently assess the state of the system. A fully operational solution for predictive maintenance based on PLC data analysis is currently in development at NORD and will soon be commercially available. For details contact: NORD Drivesystems Pvt Ltd 282/2, 283/2, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC II Pune, Maharashtra 411 057 E-mail: marketing.in@nord.com / Muthusekkar@nord.com or Circle Readers’ Service Card 34
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Plastasia 2017 Dates: 08-11 July 2017 Venue: Pragati Maidan, New Delhi Details: This event has built a reputation as the ideal place to discover the latest innovations in plastics, live demonstration/s, share ideas and most importantly secure orders. Today, Plastics has become omnipresent and an integral part of day-to-day activities. For details contact: Organiser: Triune Exhibitors Pvt Ltd Email: info@plastasia.in Website: http://www.plastasia.in/ Contact No.: 080 - 43307474 India Machine Tools Show Dates: 28-31 July 2017 Venue: Pragati Maidan, New Delhi Details: IMTOS a biennial event showcases path breaking ideas and innovation in machine tools, material handling and automotive technology. The show witnesses participation from over 500 companies every year.. For details contact: Organiser: K & D Communications Ltd Email: kandd@engimach.com Website: http://www.kdclglobal.com/ Contact No.: 079-26460624 ENGIMACH Dates: 06-10 December 2017 Venue: Helipad Ground, Gandhinagar, Gujarat Event: The ENGIMACH showcase engineering products and services, heavy and light machines, machinery equipment and accessories, tools and parts, technological devices and products, engineering tools and allied products and services. It is the most trusted machines and tools show that exhibits latest products and services, latest innovations and technologies and is known to attract visitors around the world. It is an ideal event that witnesses the best buyer and seller partnership and is a dynamic platform. For details contact: K & D Communications Ltd 3rd Floor, Kailash-A, Sumangalam Society Above HDFC Bank, Opp: Drive-In Cinema Bodakdev, Ahmedabad, Gujarat Waste Technology India Expo Dates: 18-20 January 2018 Venue: Bombay Convention & Exhibition Centre, Mumbai Event: Waste Technology India Expo is a 3 day event in Mumbai. The waste management and recycling exhibition will have solutions for managing and recycling of different kinds of waste, both solid and liquid, generated in industries, cities, homes, etc, to ensure clean surroundings. This event showcases product from air and water management, environment and waste management industries. For details contact: Virtual Info System Pvt Ltd 231 Mastermind-1, Royal Palms Mayur Nagar, Aarey Milk Colony Goregaon (E), Mumbai Chemical Engineering World
China (Shanghai) International Chemical Technology & Equipment Fair Dates: 23-25 August 2017 Venue: Shanghai New International Expo Centre (SNIEC) Event: The event will showcase wide variety of chemical technology and equipment associated with this field. Thus event like this will organize wide variety of workshops, seminar presentation and open forum questionnaires with the help of it the exhibitors will showcase products and services like pumps, compressors, thermal process, instrumentation, control, automation techniques, chemical industry apparatus and also regarding plants associated with this field. In addition to this the event will cordially invite all the eminent and distinguished exper ts associated with this field. For details contact: Organiser: Guangzhou Zhenwei International Exhibition Co Ltd Contact: Tel: + 86 (0)20 83953253
China Adhesive Dates: 23-25 August 2017 Venue: Shanghai World Expo Exhibition And Convention Center Event: China Adhesive is not only an event for adhesives industry but for all these related industry like package, construction materials, wood, windows, textile, aerospace, electricity, coating and decoration. The exhibition is expected to attract more than 300 exhibitors to display the latest products and technologies. Over 15,000 professional visitors from more than 20 countries and regions will attend the exhibition. For details contact: Organiser: CCPIT Sub-Council of Chemical Industry Contact: Tel: + 86-10-64288748
China International Chemical Industry Fair Dates: 30 August - 1 September 2017 Venue: Shanghai World Expo Exhibition and Convention Center, Shanghai, China Event: This fair is an international fair that has created enough space for the petrochemicals and processing, basic inorganic chemicals, basic organic chemicals, agrochemicals, fine and specialty chemicals, new chemical materials, chemical equipment and engineering products, chemical control apparatus and instruments and other chemical services. The fair allows the exhibitors to enter the Chinese market and discover new business traits and prospects. Through his fair, the exhibitors can penetrate through Chinese economy and develop new business ideas and solutions. For details contact: CCPIT Sub-Council of Chemical Industry Building 16, Block 7, Hepingli Dongcheng District, Beijing, China June 2017 • 71
CEW Project Update
New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.
CHEMICALS M Chemicals proposes an expansion from 10-TPM to 35-TPM of its synthetic organic chemicals manufacturing unit in GIDC Sachin, district: Surat, Gujarat. The estimated cost of the expansion is ` 12-million. The current status of the project could not be ascertained. According to MoEF sources, EIA report has been prepared by Aqua-Air Environmental Engineers. The existing plant manufactures 10-TPM 6-Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid. The expansion entails addition of new products namely, 25-TPM G-Salt, R-Salt, Amido G-Acid, Aniline 2,4 DSA, Aniline 2,5 DSA, Para Nitro Chloro Benzoyl Sulphonic Acid, Sulfo Tobias Acid, Para Cresidine Ortho Sulphonic Acid, Schaffer’s Acid, Broenner’s Acid. Total plot area is approximately 1,650-sq m, out of which, 300-m 2 has been used for green belt development. 5-KLD effluent will be treated in-house ETP and 10-KLD effluent will be sent to common MEE of MEPL for evaporation.
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.
Mamta Texdyes (Samba) proposes a synthetic organic chemicals manufacturing unit in GIDC Sarigam, district: Valsad, Gujarat. The project is spread over 2,250-sq m. The estimated cost of the project is ` 32-million. The current status of the project could not be ascertained. According to SEIAA sources, Eco Chem Sales Services is the environmental consultant. The proposed products are 200-TPM sulphur black grains, 300-TPM sulphur black liquid and the by-products are 250.1-TPM sodium thio sulphate crystal and 47.12-TPM sodium chloride salt. 700-sq m area has been proposed for green belt development. Industrial waste water will be treated in primary and tertiary treatment plant and treated waste water will be discharged into CETP Sarigam.
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 ascer tained. 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 20,000-TPA. The estimated cost of the project is ` 1,050-million. The power requirement 12,000KVA will be available through Government Electricity Board.
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 manufacturing of existing products, 2.0TPM 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:
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 ascer tained. 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, or tho anisidine/para anisidine from 100-TPM to 1,100-TPM, or tho 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 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.
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Project Update CEW 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, 40-TPM yellow pigments and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products – 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 2SO 4 and 0.3-TPD Sodium Tri 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 Chemical Engineering World
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-cu m/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further 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. Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7-million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal/kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha. June 2017 • 73
CEW Book Shelf Centrifugal Pumps: Design and Application Authors : Val S. Lobanoff, Robert R. Ross Price : USD 15.16 Pages : 640 (Hardcover) Publisher : Gulf Professional Publishing About the Book : Centrifugal Pumps: Design and Application, Second Edition focuses on the design of chemical pumps, composite materials, manufacturing techniques employed in nonmetallic pump applications, mechanical seals, and hydraulic design. The publication first offers information on the elements of pump design, specific speed and modeling laws, and impeller design. Discussions focus on shape of head capacity curve, pump speed, viscosity, specific gravity, correction for impeller trim, model law, and design suggestions. The book then takes a look at general pump design, volute design, and design of multi-stage casing. The manuscript examines double-suction pumps and side-suction design, net positive suction head, and vertical pumps. Topics include configurations, design features, pump vibration, effect of viscosity, suction piping, high speed pumps, and side suction and suction nozzle layout. The publication also ponders on high speed pumps, double-case pumps, hydraulic power recovery turbines, and shaft design and axial thrust.The book is a valuable source of data for pump designers, students, and rotating equipment engineers.
Pumps Authors : G.K Sahu Price : USD 7.58 Pages : 320 (Hardcover) Publisher : New Age International About the Book : This book, written with an applicationsoriented approach, is divided into four parts. Part I cover 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 III 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. Various aspects of pumps have been explained in systematic detail, starting from basic concepts and going on to industrial applications. The exposition is well illustrated with diagrams and solved examples. With all these features, this is an invaluable book for practicing engineers and designers. Mechanical engineering students would also find it extremely useful.
Pumps Author : Jaico Publishing House Price : USD 7.58 Pages : 196 (Hardcover) Publisher : Wiley-VCH About the Book: Pumps are the most widely used machines in the various spheres of industry. Many processes depend on the transport of liquids or transfer of energy through liquids. To convey these liquids, pumps are required in a variety of design. This edition of Pumps has been completely revised to give a far more comprehensive overview of the wide range of pumps available, together with their applications. Most of the information provided is intended to be of a general nature rather than that of specific products. 74 • June 2017
Automation Made Easy: Everything You Wanted to Know about Automation--and Need toAsk Author: Peter G Martin and Gregory Male Price: USD 89.00 Pages: 218 (Hardcover) Publisher: International Society of Automation About the Book : After a quick glance at the plant floor, it is very easy to see the industrial automation industry interoperates with other functions within the enterprise. Trying to keep up with changing technologies, however, is never easy and the industrial automation environment is no exception. Whether you are a student just starting out or are a top-level executive or manager wellversed in one domain, but have limited knowledge of the industrial automation industry, it’s easy to find yourself adrift in this evolving industry. That is where this easy-to-read book comes in; it provides a basic functional understanding in the field of industrial automation. In an effort to understand this industry, the authors break down the barriers and confusion surrounding the technical details and terminology used in this converging field. They provide an introductory-level approach, covering most of the major industrial automation topics, such as distributed control systems (DCSs), programmable logic controllers (PLCs), manufacturing execution systems (MESs), and so on. You may even learn a recipe or two. This book is ideal for executives, business managers, information technologists, accountants, maintenance professionals, operators, production planners, just to name a few, and provides an in-depth but easy overview for people new to the field who want to quickly educate themselves. Chemical Engineering World
Ad Index CEW Sr. No.
Client’s Name
Page No
Sr. No.
Client’s Name
Inside Cover I
14
Premium Transmission Ltd
17
Page No
1
Atomic Vacuum Company (Exports)
2
Busch Vacuum India Pvt Ltd
27
15
Prima Equipment
39
3
Chemlin Pumps & Valves Pvt Ltd
49
16
Rasaii Flow Lines Pvt Ltd
29
4
Cole-Parmer India
45
17
Rathi Transpower
43
5
Dover India Pvt Ltd
31
18
Ross Process Equipment Pvt Ltd
11
6
GEA Process Engineering (India) Pvt Ltd
5
19
Sahajanand Valves Pvt Ltd
47
7
Hi-tech Applicator
3
20
Sandvik Asia Pvt Ltd
23
8
Horizon Polymer Engineering Pvt Ltd
6&7
21
Sulzer India Pvt Ltd
33
9
ImageGrafix Engineering Services Pvt Ltd
57, 59, 61, 63
22
Suraj Ltd
47
10
Jay Water Management Pvt Ltd
15
23
SYP Engineering Co Pvt Ltd
21
11
KSB Pumps Ltd
9
24
Uni Klinger Ltd
41
12
Machbow Products
49
25
UNP Polyvalves (India) Pvt Ltd
19
13
Mist Ressonance Engg Pvt Ltd
35
26
Vac Enterprises India
45
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CEW Interview INTERVIEW
“HRS is a technology driven company and that differentiates us from most of the other companies who are predominantly fabricators” “HRS has been at the forefront of thermal processing technology in the chemical process and food processing industry. We have continued with our passion for innovative heat transfer solution and developed solution for pharma sector whereby they have huge cost advantage and product recovery, chemical process industry for value added solutions, energy saving units for fertilizer segment, amongst host of other solutions,” Says V Gokuldas, Managing Director, HRS Process Systems Ltd. In an interview with Chemical Engineering World, he further discusses evolving chemical process equipment market in India, HRS’ journey so far, future plan and much more. Where does HRS Asia stand today since the company commenced its Journey? HRS Asia started its operation in 2003 from Pune, providing innovative heat transfer solution to the industry. Beginning with the modest turnover of Rs. 50 million, HRS today is Rs. 880 million company. We have established state-of-the-art manufacturing facility and cater to a host of application in the chemical process and food processing sectors. We have also launched innovative 76 • June 2017
product and solutions to these industries in course of our journey. HRS reference today is a host of blue chip companies in chemical, agro chemical, pharma, steel, cement, beverages, fruit processing and such varied industries. What are the key thrust areas for HRS Asia? HRS has been at the forefront of thermal processing technology in the chemical process and food processing industry.
We have continued with our passion for innovative heat transfer solution and developed solution for pharma sector whereby they have huge cost advantage and product recovery, chemical process industry for value added solutions, steel industry for innovative products in cokeoven and by-product plant, energy saving units for fertilizer segment, aseptic and hygienic solutions for nutraceuticals and food processing sectors, amongst host of other solutions. We are committed to Chemical Engineering World
Interview CEW to the developed international markets. The primary reason being huge domestic consumption coupled with availability of the raw material and processing units. Most of the material required for chemical process equipment manufacturing is available in the country, giving price competitiveness. Some developing markets have shown similar trend in recent years. However, the expertise and the skill developed at HRS help us compete well in the international market.
developing products and solutions which cater to these industries. Give us a brief overview on HRS’ offering to the chemical industry. HRS offers a range of heat exchangers and heat exchanger based systems for the chemical industries like condensers, coolers, heaters, reboilers, evaporators, heat recovery units, kettle vaporizer and heater, etc. Our range of product consist of ECOFLUX* corrugated tube heat exchanger, HRS Funke plate type heat exchanger, UNICUS® scraped surface heat exchanger, Heat exchanger based systems, Customized heat exchanger fabrication. We offer heat exchangers in various grades of stainless steel, duplex, alloy 20, 904L, duplex/super duplex, hastelloy C227, C22, high nickel alloys, titanium and tantalum. We cater to chemical, specialty chemicals, organic and inorganic fertilisers, paint, and dyes etc sectors of the chemical industry. How is the company positioned in global and Indian markets? HRS is an ISO 9001 company with ASME ‘U’ certification. With our technology expertise and suitably accredited manufacturing facility we are able to offer all types of heat exchangers to Indian and Global markets. We are operating from Pune with set of region offices in the country to have closed connect with our customers. For South East Asian market we have a group company in Malaysia. We directly market in the neighboring Asian countries. In India Chemical Engineering World
alone we have an installed base of over 20,000 heat exchangers/heat exchanger based systems for various products, processes and industry segment. We have a heat transfer solution for all applications. With our strong financials and product references we are able to give confidence to customers and win orders. What do you think sets HRS Asia apart from companies with similar offerings? HRS is a technology driven company and that differentiates us from most of the other companies who are predominantly fabricators. We have the key heat transfer products – ECOFLUX* corrugated tube heat exchanger, plate type heat exchanger, smooth tube heat exchanger and scraped surface heat exchanger – which enable us to offer right solution to customer for their application, rather than a fabricated equipment. Thus, we are able to give customers value for money solution and in many cases resolve their process problems being faced due to current equipments in use. This win-win association is amply demonstrated by the fact that over 60% of our business is from customers who have our heat exchangers in their plant, “Once a Customer, Customer for life”. Please elucidate over the chemical process equipment market in India? How do you compare this with other international markets? Chemical process equipments market in India has been growing steadily as compared
Over the past several years, what are some of the trends that you’ve noticed in chemical process equipment market, and how has HRS responded to these trends? The Chemical Process Equipment market has grown in size and also in adopting latest technology and material for various process / equipments. This has necessitated enhancement in material processing and fabrication technology. Many companies have upgraded their facilities to have latest machinery. Also, there is a growing need for special metals. HRS had already anticipated the growth in chemical process industry and we upgraded our manufacturing facility in 2007 to incorporate ASME ‘U’ certification and further expansion in 2013. We have installed some of the latest machinery for fabrication of heat exchangers. Our facility is equipped to manufacture heat exchanger in all kinds of stainless steel, high alloy steels, special metals like duplex, hastelloy, alloy 20 and exotic material like titanium and tantalum. HRS today is capable of supplying heat exchangers to key sectors like steel, power, cement, fertilizer, etc. We also have expertise in manufacturing of copper alloy based heat exchanger which is used for marine and similar applications. What, in your opinion, are the challenges that need to be addressed? Chemical process equipment manufacturing has many challenges; one of the primary challenges to be addressed is regarding the cost economics of technology product vs fabricated equipment. Price competitiveness has always been a challenge. There need June 2017 • 77
CEW Interview condensers, coolers, heaters, reboilers, evaporators, heat recovery units, kettle vaporizer and heater, etc. What are your thoughts on impact of Make in India campaign? Make in India campaign has been a very thoughtful concept which has give opportunity for the global market to manufacture / source from India quality products and equipments. This will help the chemical process equipment manufacturers too. In the coming years this initiative will attract more investments and provide job opportunities in the country. How is the company planning to carry forward company’s legacy in future?
to be a better understanding of cost of ownership of equipment viz-a-viz one time buying cost. Even today many customers decide based on one time cost rather than looking at cost of ownership over the period of time. Other areas are infrastructure, availability of finance, labour reforms, employment opportunity, etc. There are times when Customer is unable to decide on a technology product in absence of references. In such instances the company and product track record is important. What are some of the opportunities that are still under-utilized in this field? Chemical Process Equipment market has potential to offer better and cost effective solutions to the industry with outsourcing of processing components. Outsourcing by each company of non-proprietary / noncritical items to a sub-vendor will develop the network of good part suppliers which can benefit the equipment manufacturer.  Of late, how difficult has it been for process equipment manufactures to maintain profitability? Profitability is under pressure for process equipment manufactures due to increasing overhead costs, lack of skilled labour, 78 • June 2017
policies and lack of infrastructure. Low project investment in the process industry results in less business, so many companies vying for the same job. Competitive pressure can lead to price war and reduced profitability. There has to be a right evaluation else the companies which take order at lower margin may not deliver and this affects the entire sector. Please elaborate on thermal processing technology and its application in chemical industry? Thermal processing technology has been the back bone of chemical industry and used for all types of heating and cooling applications. Shell and tube heat exchangers have been used for decades and the plate type heat exchangers about 50 years ago. HRS introduced its innovative ECOFLUX* corrugated tube shell and tube heat exchanger technology in 2003 which has made a mark in the industry by giving better performance at competitive price. All industries used heat energy in different form to produce finished goods. Thus there is a need to have effective and efficient use of energy. There are various heat transfer equipments used in the industry some of which are for very special application. Common application areas include
HRS is committed to being a partner in progress for our customers. We have expanded our product range to include products and manufacturing capability to be able to cater to the growing demands of thermal processing equipments of the industry. We have application engineering which looks into various process applications and developed suitable costs competitive heat transfer solution. We have research center in Murcia, Spain, where we carryout product trials before introducing new product in the market. With a healthy growth and robust financials, we are geared up to carry forward our company to the future. We planned to become a Rupee 1 billion company soon. What would be your message to the aspiring entrepreneurs in this field? One of the most important aspects in any business is commitment and delivering on commitment. Anyone who wants to enter in this field must have long term commitment and able to provide products that performance and be in pace with the growing need of the industry. We must always have a long term vision, which will help growth.
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