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VOL. 50 | ISSUE NO. 7 | JULY 2015 | MUMBAI | ` 150 NEWS ► Industry News/ 6 Technology News / 14
NEWS FEATURES ► Chemtech’s 2015 India Day Seminar - Strengthening Ties Between India and Germany / 18
FEATURES ► Making the Right Maintenance Decisions with Intelligent In-line Sensors / 24 – Stefan van der Wal, Chemical Segment Specialist, Mettler Toledo Process Analytics Challenges in Design and Engineering of Horizontal Buried Vessels / 28 – Ritabrata Pramanik, Mechanical Engineering, Flour Daniel India Pvt Ltd Use of Administrative Control in Process Safety
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– Nikhil Kadam, Assistant Manager, Daelim Industries Co Ltd A Breath of Fresh Air
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– Angela Gong, Marketing Manager, PSG Designing Cooling Water Return Lines Appropriately
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– Vipin Deshpande, Deputy Engineering Manager, Aker Solutions
MARKETING INITIATIVE ► Focus Area for 2015: Lubrication / 58 On Double Digit Growth Track Since 2011 / 60 Design and Development Never Stops at Everest: Malhotra / 62 Reusable Filter Consumables / 64 Reasons For Failures To Occur In Lined Pipe Work / 65 When Others Stop, Saurus939 Carries on / 66
PRODUCTS ► / 72 EVENTS ► / 79 PROJECT UPDATE ► /80 BACK OF BOOK ► Ad Index / 84 Book Shelf / 87 Interview/ 88 Empowering Information Mobility – Atanu Pattanayak and Anne-Marie Walters, Bentley Systems
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Chemical Engineering World
CEW Industry News R o h i t A gg a r w a l i s t h e N ew V P a n d M D o f Huntsman India
Sunil Kumar Sathyanarayanan Appointed Head Industrial Adhesives at Henkel India
Mumbai, India: Huntsman International Pvt Ltd has appointed Rohit Aggarwal as the Vice President and Managing Director of Huntsman India subcontinent with effect from July 1, 2015. Rohit will be succeeding Steve Stilliard who will be retur ning to Singapore. Aggarwal Rohit Aggarwal, Vice President will rejoin Huntsman after 2 years with and Managing Director, Louis Dreyfus Commodities BV where Huntsman India he was Chief Executive Officer for the Asia Region. Aggarwal will continue Steve’s leadership in helping grow the business, drive strategic partnerships and third party investment in India and the subcontinent.
Mumbai, India: Henkel Adhesive Technologies announces the appointment of S Sunil Kumar, as the Head of its Industrial Adhesives business unit in India, in the capacity of Director. In this role, Sunil will be spearheading Henkel India’s Industrial Adhesives business unit, which comprises Flexible Packaging, Packaging and Labelling, S Sunil Kumar, Head – Industrial Adhesives, Henkel Paper, Tissue, Hygienics, Construction India and Shoe steering units. Jeremy Hunter, President, Henkel India, said, “We are delighted to have Sunil on board. He brings with him strong values and leadership culture. Moreover, his experience of leading country teams across functions such as sales, business development and segment marketing to success, will help drive our industrial adhesives business. We wish him success in his role. ”Sunil Kumar holds a B Tech degree in Chemical Engineering from Coimbatore Institute of Technology, Coimbatore. He has also completed an Executive Certificate Program in Business Management from the Indian Institute of Management, Kolkata. In a career spanning well over 25 years, Sunil Kumar has had rich industrial B2B experience in both Sales and Marketing functions in organisations such as BP and Carborundum Universal Ltd.
Speaking on the appointment, Paul Hulme, Huntsman Senior Corporate Officer, India Subcontinent said, “Rohit’s appointment recognises our focus in accelerating our growth in a market that is exciting and filled with opportunities. He brings over 20 years of experience in the chemical industry, having led businesses across multiple chemical specialties, including additives, coatings, advanced materials and textiles. Rohit’s experience in Huntsman from 2003 to 2012 augments a deep understanding of Huntsman’s business and culture and will augur strategic growth in India.” Rohit Aggarwal started as Strategic Marketing Director in the Advanced Materials Division of Huntsman before moving to Textile Effects where he progressed from Vice President and business unit Head to Vice President Strategic Marketing and Planning. Rohit holds a degree in Mechanical Engineering from MS University, and an MBA in International Business from the Indian Institute of Foreign Trade, New Delhi. A native of India, Aggarwal worked out of Germany, Belgium, and Switzerland before moving to Singapore with his family in 2009. His track record includes companies like Monsanto and UCB.
RCF Signs Deal for Importing Urea from Turkmenistan New Delhi, India: Rashtriya Chemicals and Fertilisers (RCF) has signed an agreement with Turkmenhimiya, Turkmenistan for importing urea till 2018. The company would also be open to opportunities of supplying muriate, potash and other chemicals products in the future. A separate agreement will be signed between the two companies on the quantity and rate at which Turkmenhimiya will supply urea. The agreement was inked when Prime Minister recently visited the CIS nations.
Evonik to Initiate Switch to Coal Fired Hot Air Unit India’s Urea Import from Iran Increased 9-Fold New Delhi, India: The import of urea from Iran increased 9-fold to reach 5.72 Lakh Tonnes (LT) in just the first quarter of 2015-16 as a result of the diplomatic deal on the country’s disputed nuclear program. During the same period last year, India imported just about 0.61 LT of urea from Iran. Pricing also played a part here. Urea was imported from Iran through two tenders by India this year. 3.37 LT of urea was imported in May for USD 267 per tonne and about 2.35 LT in June at USD 299 per tonne. Spurred by the landmark nuclear agreement, urea imports from Iran are likely to reach about 10 LT this year. The entire inward shipments into India were 6.52 LT which was less than 10 per cent of the total imports of urea which were 87.49 LT in 2014-15. 6 • July 2015
Mumbai, India: Evonik Industries has started basic engineering for switch from diesel to coal fired hot air unit at Insilco Ltd, Gajraula for precipitated silica. The estimated investment for the project is expected in the low single-digit million Euro range. The completion is scheduled for late 2016. Between 2010 and 2014, Evonik increased its global capacity for precipitated silica by around 30 per cent. Catering to a rising demand, Insilco wants to continue offering its customers high quality silica combined with customised service and high supply reliability. Insilco Ltd. manufactures conventional as well as highly dispersible silica. Lately, the demand for highly dispersible silica is growing in India, specifically influenced by change in demographics and higher sales growth for tires with reducing rolling resistance. By using a silica-silane combination, manufacturers are able to produce tires that allow for fuel savings of up to eight per cent, thanks to a significantly reduced rolling assistance (compared to conventional passenger car tires). Low rolling resistance tires thus make a contribution to climate protection. Chemical Engineering World
CEW Industry News New Possibilities for NZ Urea Production Tauranga, New Zealand: Tenders have been called for a possible redevelopment of Ballance Agri-Nutrients’ ammonia-urea plant at Kapuni in Taranaki. The only plant of its kind in New Zealand, Mark Wynne, CEO, Ballance said the call follows a year-long feasibility study including discussions with international specialists in converting gas to fertiliser. He said, “This has given us confidence to make the next move and ask global experts to scope and cost a re-development. It is an exciting step – but it is the first one on a long journey which includes board and shareholder approvals. We will not be making any decisions before the year is out.” Under the Companies Act, shareholders need to approve any investment requiring more than half the total value of company assets. The Kapuni plant, owned by Ballance for more than 20 years, makes about 260,000 tonnes of agricultural urea each year – around one third of New Zealand’s total needs. It is estimated that local production saves around NZ dollar 150 million in foreign exchange annually in importation costs. “The plant is well maintained, runs efficiently and is achieving higher production following a USD 21 million investment in late 2013. Nitrogen fertiliser plays a key role in New Zealand food production, and we need to take a long-term view on providing a reliable and sustainable supply which is globally competitive. Technology has also advanced and we need to consider the benefits of a new state-of-the art plant versus the cost of maintaining the current one,” said Wynne.
Hanna Instruments Introduces edgeblu pH Metre Rhode Island, USA: Hanna Instruments has released edge blu, the world’s first pH metre that uses pH electrodes with Bluetooth Smar t technology. Free yourself from wires when taking pH measurements. The HI2202 edge blu pH meter uses Hanna’s HALO pH electrodes with Bluetooth Smart technology (Bluetooth 4.0) that connect wirelessly to edge blu or a compatible iPad running the Hanna Lab App. The edge blu is thin and lightweight, measuring just 0.5” thick and weighing less than 9 ounces. edgeblu has a 5.5” LCD with an incredibly wide viewing angle and a sensitive capacitive touch keypad. It is simple to configure, calibrate, measure, log, and transfer data to a computer or a USB drive. The edge blu includes Hanna’s exclusive CAL CheckTM feature to warn if the HALO pH electrode being used is not clean or if the calibration buffers are contaminated. Each edge blu is supplied with the HI11102 HALO Bluetooth pH electrode. The HALO uses Bluetooth Smart Technology (Bluetooth 4.0), which is energy efficient and allows the probe to operate on a single CR2032 battery for approximately 500 hours. The HI11102 HALO pH electrode is a double junction, gel filled, glass body pH electrode with a built-in thermistor temperature sensor, allowing readings to be automatically compensated for temperature variations. The HI11102 HALO pH electrode transmits measurement data up to 10 metres. 8 • July 2015
Albemarle Commissions New Lithium Production Carbonate Plant Louisiana, USA: Albemarle Corporation announced the commencement of commissioning activities associated with its new, state-of-the-art lithium carbonate production plant. The 20,000 MT plant, located at Albemarle’s La Negra site will enable the company to meet the accelerating demand for lithium, especially high purity lithium compounds required for the production of large format lithium ion batteries. The plant is on schedule to produce commercial quantities of lithium carbonate during the third quarter of 2015. Albemarle expects to increase production from the new capacity beginning early in 2016. Initial production will be sold into technical applications while more lengthy battery grade qualifications take place. The commissioning and planned start-up of this new plant further demonstrates Albemarle’s commitment to meeting the demands of its customers, offering a reliable and reputable supply of high quality products and maintaining its position as a global leader in lithium production. Visiting Chile last week, Luke Kissam, President and CEO said, “ The company invested roughly USD 200 million to ensure we have a reliable source of supply for our customers as their demand for lithium, especially high purity lithium compounds, increases.”
BASF Completes Textile Chemicals Business Divestment to Archroma S i n g a p o r e : B A S F h a s c l o s e d t h e p r ev i o u s l y a n n o u n c e d transaction to divest its global textile chemicals business to Archroma, a supplier of specialty chemicals to the textile, paper and emulsions industries. BASF will continue to manufacture and supply textile chemical products to Archroma. Included in the transaction is the legal entity BASF Pakistan (Private) Ltd, Karachi. The closing of this divestiture is expected by August 2015. All remaining businesses of BASF in Pakistan, which are conducted by BASF Chemicals and Polymers Pakistan (Private) Limited, are not in the scope of the transaction.
Amec Foster Wheeler Awarded Feasibility study for Malaysian Refinery London, United Kingdom: Amec Foster Wheeler announces today the award of a contract by SKS Corporation Sdn Bhd, together with Petromin Corporation of Saudi Arabia, and another Asian partner, to supply consultancy services for a proposed new refinery and petrochemical complex in Kedah state, Malaysia. The value of the consultancy contract, which will be delivered during 2015 by an Amec Foster Wheeler team in Reading and Kuala Lumpur, has not been announced. Under the contract, Amec Foster Wheeler will undertake a detailed feasibility study to define the configuration of the complex, develop the infrastructure requirements, establish a project implementation plan and produce a cost estimate to help optimise the project and establish a clear plan to take the project forward. The proposed development supports SKS’s aim to boost investment into the Malaysian economy and develop the region as a world class supplier of refinery and petrochemical products to South East Asia. Chemical Engineering World
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CEW Industry News KBL Launches Revolutionary ROMAK Pump
Orica to Cut Down Ammonium Nitrate Production
Frankfurt, Germany: Kirloskar Brothers Ltd (KBL) announced the launch of technologically advanced ROMAK Pump at ACHEMA, world’s most-followed event for the chemical process industry held in Frankfur t, Germany. The ROMAK (RMK) pumps are process pumps used for handling various types of clear / clean chemical liquids without any suspended particles by various process industries.
Melbourne, Australia: In response to challenging market conditions, Orica is adjusting its operating model at the Yarwun site in Gladstone. Dave Buick, General Manager – Yarwun, said, “While we remain confident in the long term outlook for ammonium nitrate, there is a near term oversupply in the market. As a result, we have made a preliminary decision to adjust the capacity requirements at Yarwun.
RMK pump is magnetic drive pump comprising per manent magnets. With a size ranging between 32mm to 100mm, the pump has a discharge capacity of up to 300 m3/hr. The pump can handle temperatures from -50 0C up to +180 0C. The design aids interchangeability of components among different pump sizes. The sealless pump has liquid protected magnets for longer performance. The design will have a total of 22 models. KBL also launched the technologically advanced GK-P Pump at ACHEMA. GK-P is a process pump used for handling various types of chemical liquids from various process industries. It is an End Suction centrifugal process pump having discharge capacity upto 500 m3/hr at 1450 rpm. With a size ranging between 25mm to 150mm, the pump can handle temperatures in the range of -50 0 C upto +350 0 C. The wide range of smooth hydraulics will meet the customers’ requirements and promote better efficiency of the product. The back pullout design will help in easy and quicker maintenance.
Solvay Opens Asia’s Largest Alkoxylation Plant Singapore: Solvay inaugurated its new large-scale alkoxylation plant in Singapore, the largest plant of its kind in Asia, as part of its global strategy to expand the growth of its specialty surfactants in the region. The nearly USD 50 million ‘on-pipe’ investment will help meet that demand, complementing existing India and China facilities and joining Solvay Novecare’s seven other alkoxylation plants in Europe and North America. Located in the world-class integrated petrochemical hub of Jurong Island, the plant receives a key raw material, ethylene oxide via a dedicated pipeline, and fatty oleochemicals from nearby countries, providing a safe and sustainable source of supply for the near and long term. The unit produces specialty alkoxylate formulations for the agrochemicals, coatings, home and personal care, industrial and oil & gas markets in Asia, especially for those in key South East Asia countries such as Indonesia, Thailand and Malaysia. The plant bolsters Solvay’s competitive position in the region, ensuring the development of alkoxylate solutions for customers who will be supported by strong technical teams from the R&I centre located near the plant. 10 • July 2015
This decision follows extensive analysis of the market and was previously flagged in our interim financial results market briefing in May 2015. Today, we have begun consulting with our employees to understand and address any impacts on the workforce. We expect there will be some impact on staffing levels from this decision. However, the fact remains that Orica is operating in a highly competitive market in which supply of ammonium nitrate is higher than demand levels, and we need to pursue strategies that secure the long-term viability of the business.”
Ferro Completes Acquisition of Nubiola Cleveland, USA: Ferro Corporation has completed the acquisition of Nubiola Pigmentos on a cash-free and debt-free basis for Euro 149 million (approximately USD 165 million), subject to customary working capital and other purchase price adjustments. The acquisition was previously announced on April 29, 2015. Nubiola is a worldwide producer of specialty inorganic pigments and the world’s largest producer of Ultramarine Blue, a pigment for the plastics and construction industries, highly valued for its durability, unique colour attributes and whitening capability. Nubiola has production facilities in Spain, Colombia, Romania, and India and a joint venture in China. “We are excited about the Nubiola acquisition and the opportunities it provides to drive shareholder value, enhance our current position in inorganic pigments, and accelerate our strategy to become a leading global functional coatings and colour solutions company,” said Peter Thomas, Chairman, President and CEO, Ferro.
AkzoNobel to Sell Zeta Fraction Biofunctional Technology to Ashland Amsterdam, Netherlands: AkzoNobel announced the sale of its biomaterials technology to Ashland Inc. The transaction is expected to be completed in the third quarter of 2015. The business is in its early phase of commercialisation and the divestment of this biomaterials technology follows a strategic review of the business’ fit within AkzoNobel’s portfolio. This transaction will enable us to focus on our core technology platforms - specialty surfactants and polymers - and help reinforce our leadership position in both areas. The biomaterials activities are focused on plant-based chemistry, which is used to develop products for various applications, such as high performance beauty technologies. Chemical Engineering World
WHEN CONDITIONS HEAT UP DON’T LET CORROSION SHUT YOU DOWN Whether it’s higher temperatures, rising pressures or more acidic media, conditions in oil refineries have never been more extreme. Tube and pipe corrosion are a constant threat, causing as many as half of all major shutdowns. This is why hundreds of the world’s most demanding petrochemicals refiners are turning to the next generation of corrosion resistant alloys. Like one German oil refinery, which used Sandvik SAF 2707 HD hyper-duplex heat exchanger tubes to reduce the number of shutdowns from 8 to 1 over a period of four years. The result was massive savings on material replacement. So as your tubes’ performance is pushed to new heights, find out how we can help keep corrosion from shutting you down. SMT.SANDVIK.COM
CEW Industry News INEOS Increases the Storage Capacity of Ethane Tank Grangemouth, UK: INEOS Grangemouth today saw the massive roof that covers Europe’s biggest ethane storage tank rise into place using just four low pressure fans, following six months of building work. The huge tank is 56 metres in diameter and 44 metres high – that gives it a displacement volume of 108,372 cubic metres – large enough for 560 double decker buses to fit inside. The investment in the Grangemouth tank and infrastructure is part of the company’s £450 million rescue package to equip the site to import ethane gas from the US. The project will transform Grangemouth overnight and will allow its manufacturing assets to once more compete globally, providing raw materials for thousands of manufacturing businesses across the UK and Europe. John McNally, CEO, INEOS O&P UK, says, “We know that US ethane has transformed US manufacturing and now Scottish industry will benefit as well. This will secure a cost-effective supply of ethane for the next 15 years, and give a sustainable base for Grangemouth for that time.” The building of Europe’s largest ethane storage tank is just part of INEOS’ USD 1 billion global project to get US shale gas to Europe. INEOS has contracts to access a 100 mile pipeline from the Marcellus Shale in western Pennsylvania to the Marcus Hook gas terminal close to Philadelphia. INEOS has commissioned eight huge Dragon class ships to carry the liquefied shale gas ethane from the US to Europe.
Sadara Joint Venture Now 94% Complete Michigan, USA: Sadara Chemical Company (Sadara) is progressing on-budget and on-schedule in alignment with Dow’s strategy to enable cost-advantaged growth in fast-growing regions such as Asia Pacific, the Middle East, Africa, and Eastern and Central Europe. Sadara is a joint venture developed by The Dow Chemical Company and Saudi Arabian Oil Company (Saudi Aramco). Significant progress has been made in starting up key infrastructure and utility systems. Overall construction of the manufacturing facility is now approximately 94 per cent complete with 47,000 personnel on site in Jubail Industrial City II, Saudi Arabia. The commissioning and start-up of key utilities infrastructure is underway and the process for first production units will begin in the second half of the year with initial polyethylene production beginning near the end of 2015. Full site operations remains on track for the end of 2016. Sadara’s 26 manufacturing assets are scheduled for a sequenced start-up process, beginning with the polyolefins envelope to maximise timing in the ethylene cycle, followed by ethylene oxide/propylene oxide and their derivatives, with the polyurethanes portfolio in the final phase. Customer excitement is increasing as Dow businesses actively prepare to market and sell the majority of products produced by Sadara Chemical Company via agreements with the joint venture, to support growth in key markets such as packaging, construction, electronics, furniture and bedding, automotive and transportation. 12 • July 2015
LFM Software Introduces Ground-Breaking New Technology Manchester, UK: LFM Software is launching major enhancements to its laser scan technology portfolio with new releases of LFM NetView and LFM Server. The introduction of new 3D mark-up functionality to both products allows users to add, access and share asset intelligence in the form of tag identifiers, attributes and comments as well as links to associated documents and information. Alongside these new capabilities also comes vastly improved access to massive laser scan projects, supported by cloud and tablet enablement. These deliver the as-operated asset conditions to the desktops and mobile devices of all asset stakeholders allowing for secure global collaboration across multiple project teams and partner companies. LFM NetView 4.0 provides secure, on-demand access to laser scan data via company networks or the internet. The simple, intuitive BubbleView interface has been designed using the latest web technology allowing in browser, ‘plug-in free’ global access to visualise on-site conditions and quickly add or extract reliable intelligence. Tablet enablement and the facility to take data ‘offline’ and synchronise later enables remote use for inspection tasks and on-site reviews. LFM Server 4.3 provides the data backbone for LFM NetView 4.0 by providing a live link to a master dataset ensuring all data is up-to-date and accurate.
Mobile App Brings Industry 4.0 to All Pumps Frankfurt, Germany: To help plant operators increase productivity and transparency as well as improve competitiveness across the entire life cycle, Frankenthal-based pump manufacturer KSB has developed an app for smartphones and tablets that can determine the efficiency of fixed-speed pumps in just 20 seconds. The KSB Sonolyzer app is based on an algorithm that has been integrated in PumpMeter units for five years now, of which well over 30,000 have already been sold. The smartphone-based application does not require knowledge of the individual characteristic curve or any additional technical data of the pump set to be measured, however, and can also be used with pumps from other manufacturers. Users can utilise the app to determine the load at which each centrifugal pump driven by a fixedspeed asynchronous motor is being operated. The following data must be entered for this purpose: the motor rating, the rated motor speed, the head and the flow rate of the pump. This information can be read from the name plate affixed to every pump. The KSB Sonolyzer app is available for the iOS and Android operating systems and can even be used in potentially explosive atmospheres if the smartphone or tablet PC has appropriate protection. The average life cycle of plants used in the chemical industry exceeds 30 years, which is why the pumps installed have only seldomly been connected directly with the Internet of Things. In many cases, users are not even aware of a pump’s current load condition. Chemical Engineering World
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CEW Technology News Genomatica Advances the Commercial Readiness of Biomass Feedstocks San Diego, USA: Genomatica announced significant progress in harnessing cellulosic biomass for commercial production of high-quality chemicals rather than just fuels. Genomatica’s work sets the stage to increase the range of feedstock choices for making chemicals using biotechnology. Through advances in strain engineering and process design, Genomatica has developed clear guidance for biomass pretreatment technology developers to enable their technologies to work better with commercial bioprocesses for chemicals. An extended series of trials by Genomatica confirmed major improvements in process performance and the qualification of multiple types of biomass sugars as suitable feedstock. The results advance the prospects for economical production of polymer-grade chemicals from biomass as pretreatment technologies mature toward reaching their cost targets. As part of the current work, Genomatica developed a ‘sugar specification’ for biomass pretreatment technologies to produce sugars compatible with commercially-proven GENO processes; assessed ten technologies against that standard; and demonstrated that at least four can currently produce sugars suitable for commercial production of chemicals from a quality standpoint. Integrated approach to bioprocess development enabled rapid progress with biomass In late 2012, Genomatica achieved commercial scale with its GENO BDO process, producing thousands of tons of the chemical 1,4-butanediol (BDO) from conventional sugars in just a few weeks. To harness cellulosic biomass effectively required changes to the microorganism and the overall process, including downstream separation and purification unit operations. Changes were guided by Genomatica’s ‘whole-process’ approach to bioprocess development, which is driven by technoeconomic analysis and consideration of downstream unit operations, and leads more rapidly to a commercially viable solution.
An Elusive Molecule, Finally Revealed Arizona, USA: A long-standing chemistry puzzle has been solved, with potential implications ranging from industrial processes to atmospheric chemistry. Scientists at the University of Arizona have discovered a mysterious molecule with a structure simple enough to make it into high school textbooks, yet so elusive that chemists have argued for more than a century over whether it even exists. Andrei Sanov, a professor in the UA’s Department of Chemistry and Biochemistry and two of his students report the first definitive observation and spectroscopic characterisation of ethylenedione, or ‘OCCO,’ representing two carbon monoxide molecules chemically bound together. According to the researchers, the interest in this deceptively ‘simple’ compound is fuelled by many reasons: from its assumed role as a fleeting intermediate in a flurry of chemical reactions to its alleged properties as a wonder drug. The results confirm the existence of the elusive species and reveal its important fundamental properties, with implications not only for the basic understanding of so-called radical molecular species, but also industrial processes and potentially even atmospheric chemistry and climate modelling. Read more about the research at http://uanews.org/story 14 • July 2015
Aluminum Clusters Shut Down Molecular Fuel Factory Washington, USA: Despite decades of industrial use, the exact chemical transformations occurring within zeolites, a common material used in the conversion of oil to gasoline, remain poorly understood. Now scientists have found a way to locate-with atomic precisionspots within the material where chemical reactions take place, and how these spots shut down. Called active sites, the spots help rip apart and rearrange molecules as they pass through nanometresized channels, like an assembly line in a factory. A process called steaming causes these active sites to cluster, effectively shutting down the factory. This knowledge could help devise how to keep the factory running longer, so to speak, and improve catalysts that help produce fuel, biofuel and other chemicals. The team included scientists from the Department of Energy’s Pacific Northwest National Laboratory, UOP LLC and Utrecht University. To make this discovery, they reconstructed the first 3-D atomic map of an industrially relevant zeolite material to track down its key element, aluminium. The images confirmed what scientists have long suspected; Steaming causes aluminium atoms to cluster. Like workers crowded around one spot on the assembly line, this clustering effectively shuts down the catalytic factory. Zeolite crystals often grow in overlapping subunits, forming something like a 3-D Venn diagram. With the guidance of these atomic maps, industry could one day modify how it steams zeolites to produce a more efficient, longer lasting catalyst. The research team will next examine other industrially important zeolites at different stages of steaming to provide a more detailed map of this transformation.
New Design Could Boost Efficiency of Low-cost Solar Panels Menlo Park, USA: A new material design tested in experiments at the Depar tment of Energy’s SLAC National Accelerator Laboratory could make low-cost solar panels far more efficient by greatly enhancing their ability to collect the sun’s energy and release it as electricity. A team of University of California, Los Angeles, scientists found that by assembling the components of the panels to more closely resemble the natural systems plants use to tap the sun’s energy, it may be possible to separate positive and negative charges in a stable way for up to several weeks compared to just millionths of a second – the current standard for many modern solar panels. “In photosynthesis, plants that are exposed to sunlight use carefully organised nanoscale structures within their cells to rapidly separate charges – pulling electrons away from the positively charged molecule that is left behind, and keeping positive and negative charges separated. That separation is the key to making the process so efficient,” said Sarah Tolbert, a UCLA professor of chemistry and one of the senior authors of the research. The team’s X-ray studies at SLAC’s Stanford Synchrotron Radiation Lightsource (SSRL), a DOE Office of Science User Facility, enabled them to see, at a microscopic level, which material design has the most ideal structure at the nanoscale for promoting this charge separation. Read more on https://www6.slac.stanford.edu/ Chemical Engineering World
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CEW Technology News Catalyst Removes Cancer-Causing Benzene In Gasoline
Scientists Study Integrating Biofuels and Food Crops on Farms
Evanston, USA: Nor thwester n University scientists are experimenting with ways to eliminate a cancer-causing agent from gasoline by neutralising the benzene compound found in gasoline. They developed a catalyst that effectively removed benzene from the other aromatic compounds in gasoline, making it cleaner and more efficient.
Illinois, USA: We ask a lot of the land – feed the world with crops, power the world with bioenergy, retain nutrients so they do not pollute our water and air. To help landscapes answer these high demands, scientists from the US Department of Energy’s Argonne National Laboratory are designing ways to improve—and hopefully optimise— land use. In collaboration with the farming community of the Indian Creek Watershed in central Illinois, these researchers are finding ways to simultaneously meet three objectives: maximise a farmer’s production, grow feedstock for bioenergy and protect the environment. These goals, as it turns out, are not necessarily mutually exclusive. All it takes is a multifunctional landscape, where resources are allocated efficiently and crops are situated in their ideal soil and landscape position. Planting bioenergy crops like willows or switchgrass in rows where commodity crops are having difficulty growing could both provide biomass feedstock and also limit the runoff of nitrogen fertiliser into waterways — all without hurting a farmer’s profits. This is what a group of Argonne scientists has discovered through careful data collection and modelling at a cornfield in Fairbury. Negri and her team created a pilot farm site that balances the priorities of economic feasibility, bioenergy and environmental health. Read more about the research on http://www.anl.gov/articles/
An estimated 137 billion gallons of gasoline were consumed in the United States last year, according to the US Energy Information Administration, a daily average of about 375 million gallons. Within each gallon of gas is a chemical compound known as benzene, which has been recognised by the Environmental Protection Agency as a known contributor to cancer. A research team led by Northwestern’s Tobin J Marks has found a way to remove it. “The gasoline we buy is one-third a mixture of aromatics, and benzene is one of them. Only benzene is known to be cancer causing, and it is very difficult to remove. Our catalyst opened a whole new way to do that – and probably a very inexpensive way,” said Marks, explaining that aromatics are necessary to improve gas octane numbers and fuel efficiency. Marks is the Vladimir N Ipatieff Research Professor of Chemistry in the Weinberg College of Arts and Sciences and professor of materials science and engineering in the McCormick School of Engineering and Applied Science. Read more about the research on http://www. northwestern.edu/newscenter/stories
Polymer Mould Makes Perfect Silicon Nanostructures Ithaca, USA: Using moulds to shape things is as old as humanity. In the Bronze Age, the copper-tin alloy was melted and cast into weapons in ceramic moulds. Today, injection and extrusion moulding shape hot liquids into everything from car parts to toys. For this to work, the mould needs to be stable while the hot liquid material hardens into shape. In a breakthrough for nanoscience, Cornell polymer engineers have made such a mould for nanostructures that can shape liquid silicon out of an organic polymer material. This paves the way for perfect, 3-D, single crystal nanostructures. The advance is from the lab of Uli Wiesner, the Spencer T Olin Professor of Engineering in the Department of Materials Science and Engineering, whose lab previously has led the creation of novel materials made of organic polymers. With the right chemistry, organic polymers self-assemble, and the researchers used this special ability of polymers to make a mould dotted with precisely shaped and sized nano-pores. Normally, melting amorphous silicon, which has a melting temperature of about 2,350 degrees, would destroy the delicate polymer mould, which degrades at about 600 degrees. But the scientists, in collaboration with Michael Thompson, associate professor of materials science and engineering, got around this issue by using extremely short melt periods induced by a laser. Read more on http://news.cornell.edu/stories/ 16 • July 2015
Unlocking Lignin for Sustainable Biofuel Tennesse, USA: Turning trees, grass, and other biomass into fuel for automobiles and airplanes is a costly and complex process. Biofuel researchers are working to change that, envisioning a future where cellulosic ethanol, an alcohol derived from plant sugars, is as common and affordable at the gas station as gasoline. The key to making this vision a reality? Unravelling the tightly wound network of molecules—cellulose, hemicellulose, and lignin—that make up the cell wall of plants for easier biofuel processing. Using high-performance computing, a group of researchers at the US Department of Energy’s (DOE’s) Oak Ridge National Laboratory (ORNL) provided insight into how this might be accomplished, simulating a well-established genetic modification to the lignin of an aspen tree in atomiclevel detail. The team’s conclusion—that hydrophobic, or water repelling, lignin binds less with hydrophilic, or water attracting, hemicellulose—points researchers toward a promising way to engineer better plants for biofuel. Jeremy Smith, the director of ORNL’s Centre for Molecular Biophysics and a Governor’s Chair at the University of Tennessee, led the project. His team’s simulation of a genetically modified lignin molecule linked to a hemicellulose molecule adds context to work conducted by researchers at DOE’s BioEnergy Science Centre (BESC), who demonstrated that genetic modification of lignin can boost the amount of biofuel derived from plant material without compromising the structural integrity of the plant. Read more about the research on http://www.newswise.com/articles/ Chemical Engineering World
CEW News Features
Chemtech’s 2015 India Day Seminar – Strengthening Ties between India and Germany
L to R: Yatinder Suri, Dr Andreas Widl, Maulik Jasubhai, B Narayan, Dr Kurt Wagemann, Dr Benno Lueke and Richard Clemens at the India Say Seminar in Frankfurt
T
he 40 years long partnership between Chemtech and DECHEMA was evident during the 2015 India Day Seminar organised by Chemtech Foundation. Elaborating on the association, Maulik Jasubhai, Vice Chairman and Chief Executive, Chemtech Foundation and Jasubhai Group, said that organising such platforms, where people can interact, exchange ideas, develop new technologies helps build greater cooperation between India and Germany and together with DECHEMA, CHEMTECH has been able to successfully organise such a great platform. With regards to the collaboration between DECHEMA and CHEMTECH Foundation, Dr Kurt Wagemann, CEO, DECHEMA stated that it could pave the way for a bright future for both India and Germany. Discussions related to generative technologies, progress and challenges in sectors like biotechnology and chemicals and digitisation will further fortify the partnership of the two nations that has continued since many decades. In the context of the theme of India Day seminar, B Narayan, Group President, Procurement & Projects, Reliance Industries Ltd, spoke about the world economy and the Indian economy; where the chemical industry stands and opportunities available. He stated that India is inching forward and offers hope for favourable results. Regarding the scope for investments, India is a consumption based economy, unlike China. India’s import content is about USD 500 billion, out of which USD 30 billion relates to the import of chemicals, and about USD 9 billion rests with top 14 chemicals.
18 • July 2015
The global chemical industry is about USD 4 trillion and over the past 20 years, this industry has posted the best results. The chemical industry growth in India is about USD 150 billion with a projection of 11 per cent growth which can increase to 15 per cent. This can be possible as the manufacturing bases are being shifted to the East, including India; all products are being accepted outside India; exchange rate is favourable to India which enables being competitive outside India. Besides this, the PM’s campaign of Make in India will surely create a good environment and favourable policies for promoting the Indian industry. Incentivising investments for both Indian investors and investments from outside India will further help the cause. Richard Clemens, Managing Director, VDMA Associations, shared that export of German industrial products to India is on a steady increase and the number of German subsidiaries in India is also growing at a similar pace. India is playing an increasing role with respect to investments in pharmaceutical and other industrial products. ACHEMA serves as the perfect platform since it showcases the latest solutions to achieve operational excellence, energy efficiency, innovative process water management, process automation or digitalisation. Speaking of the association with the growing Indian market, Dr Benno Lueke, CEO - Operating Unit Chemicals, Oil & Gas, ThyssenKrupp Industrial Solutions AG, stated that the work culture, dynamism of Indian companies, vision of captains and approach on the business front makes India a very happening and Chemical Engineering World
CEW News Features
bustling place. Many global players from the chemical industry are seeking the Indian market for investment as there is a growing impetus on knowledge based chemicals – specialty and fine chemicals. Though the current economic conditions and business scenario appear slightly constricting, there is reason for optimism as these are cyclic phenomena. He is confident that a turn of events is around the corner and the Indian growth story will be back on track with the GDP on the better side of 7 per cent in the foreseeable future.
Dr Andreas Widl, Chairman, Samson AG, shared that by expanding the factory, Samson intends to support the India growth story as it views the Indian market as a place to enjoy greater business progress. Government support could further ease out business processes, simplify transaction processes, and reformative measures for issues like labour reforms, uninterrupted electricity supplies, infrastructure development will further facilitate development that would benefit everyone.
Yatinder Suri, Country Head, Outokumpu India, said that from the views expressed by the 4 foreign speakers and fellow Indian B Narayan about the scope for opportunities in India, it is evident that a plethora of substantial prospects await Indian and overseas companies in India. Congratulating Chemtech Foundation on organising such an inspiring platform, he added that it is run by the industry for the industry; where the who’s who of the industry come together to rub shoulders, share their experience and ideas to build a better industry.
B Narayan
Dr Andreas Widl
Dr Benno Lueke
“India is inching forward and offers hope for favourable results. Regarding the scope for investments, India is a consumption based economy, unlike China. India’s import content is about USD 500 billionout of which USD 30 billion relates to the import of chemicals”
“Government support could further ease out business processes, simplify transaction processes, and reformative measures for issues like labour reforms, uninterrupted electricity supplies, infrastructure development will further facilitate development that would benefit everyone.”
“The work culture, dynamism of Indian companies, vision of captains and approach on the business front makes India a very happening and bustling place. Many global players from the chemical industry are seeking the Indian market for investment as there is a growing impetus on knowledge based chemicals”
Dr Kurt Wagemann
Yatinder Suri
Richard Clemens
“Discussions related to generative technologies, progress and challenges in sectors like biotechnology and chemicals and digitisation will further fortify the partnership of the two nations that has continued since many decades”
“...It is evident that a plethora of substantial prospects await Indian and overseas companies in India. Congratulating Chemtech Foundation on organising such an inspiring platform that it is run by the industry for the industry...”
“Export of German industrial products to India is on a steady increase and the number of German subsidiaries in India is also growing at a similar pace. India is playing an increasing role with respect to investments in pharmaceutical and other industrial products.”
22 • July 2015
Chemical Engineering World
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CEW Features Technical Article
Making the Right Maintenance Decisions with Intelligent In-Line Sensors Plant safety and process reliability often rely on analytical field instruments operating correctly, which means sensors must be kept in good condition. This requires regular maintenance and servicing. But knowing exactly when to maintain, service or replace a probe has been very imprecise. Cutting-edge measurement systems that utilise intelligent sensors take all guesswork out of maintenance decisions. This technology also reduces the possibilities of human-error and lowers production costs.
F
ailure of analytical in-line sensors in a process can lead to poor product quality, over- or underuse of reagents, compromise equipment integrity, or cause production downtime. And if a sensor is required for safety purposes, its breakdown can have devastating consequences. Therefore, instrumentation engineers spend a great deal of time ensuring measurement points are operating reliably. However, it has been estimated that as much as 60 per cent of sensor maintenance is conducted needlessly due to it being conducted to a fixed schedule.1 And, despite all this maintenance, half of industrial accidents are maintenance related. 2 Further, 20 per cent are due to human error.3
The goal for chemical production companies therefore, is to be certain that maintenance on individual instruments is actually required and to replace failing sensors before processes and safety are affected, but not so early as to lead to additional sensor replacement costs. Until recently, deciding if and when to perform sensor maintenance or replacement has been based on a combination of past experience and speculation. Now, a new generation of intelligent digital sensors is taking the guesswork out of maintenance. Further, they are simplifying workflows, reducing measurement point downtime and increasing process reliability. The advantage of digital signals There are now many brands of digital sensor available. These output the 24 • July 2015
measurement signal digitally for display and forwarding by a transmitter. This is in total contrast to analog sensors which output a low voltage or ampage signal to an instrument that converts the signal into a parametre value. Such analog systems can be susceptible to delivering unreliable data. This is frequently due to environmental conditions such as electromagnetic fields generated by neighbouring equipment and high humidity. Their presence can severely degrade analog signals and the longer the length of cable from sensor to transmitter, the greater is the potential for signal damage. Digital signals are largely immune to such fields, humidity and cable length. Therefore, the digital signal output by the sensor will be received at the transmitter, unchanged. Intelligent sensors But a more reliable signal is only the start of the advantages offered by intelligent sensors and compatible transmitters. The more sophisticated pH, ORP, DO, etc, sensors carry an in-built microprocessor that enables a range of significant operating advantages including fast, error-free start-up; and more importantly, diagnostics that understand the effects of the process and actually predict when sensor maintenance or replacement should be performed. These advances are nothing short of a revolution in process analytics and are helping to pave the way for the digital chemical facility of tomorrow.
Among the capabilities of the microprocessor in such pH sensors is its ability to retain calibration data. This negates the need to calibrate the sensor at the measurement point, a process that can be inconvenient at best and dangerous at worst if the measurement is located in a toxic process. Further, due to the required position of measurement points, the accompanying transmitter may be located many metres away. Such a setup may require two technicians involved during calibration: one to hold the sensor in buffer solutions and the other to operate the transmitter. Because these sensors store their own calibration data, they can be calibrated away from the measurement point in any convenient location such as a workshop. The sensor can be calibrated using a compatible transmitter or, for the more advanced ones, by connection to a standard PC/laptop using appropriate software. Once calibrated, the sensors can be stored until required. When an installed sensor needs maintenance or replacement, it can be exchanged with
Figure 1 An intelligent digital pH sensor
Chemical Engineering World
CEW Features a sensor that has been pre-calibrated. Upon connection, the calibration data is uploaded to the compatible transmitter which then configures itself without any operator intervention. This hot-swapping of sensors means measurement point downtime during maintenance is almost eliminated. This approach offers additional benefits. If the sensor in the maintenance shop is stored correctly in KCl solution, it will have time to rejuvenate, which can significantly extend its lifetime and improve its speed of response. Rotating two such intelligent digital pH sensors in-and-out of a process means sensor lifetime can be twice as long as for two analog sensors, plus measurement performance will be increased. Predictive maintenance If the data from a measurement point is unreliable, production and safety can be severely compromised. Unreliable data can be seen on transmitters as rapidly fluctuating or totally erroneous readings. As mentioned, false data can be caused by interference to analog signals, but it can also be due to a sensor’s diaphragm becoming blocked or the sensor approaching the end of its reliable operating life. A significant problem for maintenance engineers is not knowing when sensors needs calibrated, replaced or simply cleaned. This burdensome issue has also been solved with intelligent sensors. Sophisticated algorithms constantly run in the background while a sensor measures
Figure 2 The green bar on this transmitter display indicates that the connected sensor will operate reliably for the next 730 days based on current and past conditions.
26 • July 2015
the process parameter. These algorithms monitor conditions in the process and the sensor’s ‘health’ and using current and past conditions are able to determine when calibration or cleaning should be performed and, in the case of a pH probe, when the sensor should be replaced. As process conditions alter, so do the diagnostics to provide continuously reliable data. These diagnostic tools can be displayed as easily interpreted counters, on the transmitter or monitored remotely on asset management software or even on a handheld device. This ability to see when sensor maintenance will be required means needlessly servicing or replacing a sensor becomes a thing of the past. And it increases process reliability and safety as the chance of a sensor failing in the process without providing forewarning, has been removed.
to a fixed schedule, meaning that a probe might be cleaned, calibrated or even replaced when it is not necessary. This costly use of resources is due to lack of information as to what tasks actually need to be performed and when. The highly informative diagnostics available from intelligent sensors combined with the simplified traceability they provide, offers efficiencies in maintenance planning, plant safety and productivity while also reducing production costs. References 1 Shell Global Solutions, Asset Management with Foundation Fieldbus Technology, G. Mooney 2, 3 http://organica1.org/ops_85/ accidentes.pdf
Some sensor diagnostic tools may take days to adjust to process conditions before they provide reliable data. The latest intelligent sensors have resolved this by quickly learning from process conditions and are able to provide dependable diagnostics much earlier. Simplified traceability Recording sensor calibration and maintenance information provides useful data for instrumentation engineers. However, manually recording the information is time consuming and can be subject to human error. Intelligent sensors store this data and it can be easily transferred to software to be retained for future consultation or printed out if required. Conclusion Chemical plants have two main areas of concern: production efficiency and quality; and plant, staff and environmental safety. In-line process analytics often has a significant role to play in both respects.
Author’s Details
Achieving the best performance from inline sensors demands that they be kept in good operating condition. However, sensor maintenance is often conducted
Stefan van der Wal Chemical Segment Specialist, Mettler Toledo Process Analytics Chemical Engineering World
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CEW Features Technical Article
Challenges in Design and Engineering of Horizontal Buried Vessels Horizontal vessel buried inside a pit is one of the very common features of a refinery or petrochemical plant. However the contractors face a challenge while specifying the requirements of the buried vessels due to lack of international standards and specifications specifically catering to buried vessels. This often leads to a lot of variation in design of these vessels resulting in sub optimal engineering. The present article will discuss basic design and selection issues of horizontal buried vessels, which if addressed carefully by the engineering contractors in the early stage of development of specification, can go a long way in minimising the changes during the detailed engineering stage.
A
Review of the Available Design Codes for Design of Horizontal Buried Vessels Let us start with the review of the available design codes and standards with respect to their applicability and limitations vis-avis horizontal buried vessels. 1. EEUMA-190: Guide for the design, construction and use of mounded horizontal cylindrical steel vessels for pressurised storage of LPG at ambient temperatures. a. Applicability: Is applicable for mounded storage steel vessel for pressurised storage of LPG. b. Limitations: The design loads mentioned in cl. no. 4.1.3 of EEUMA-190 neither fully cover all the loads applicable to a buried vessel nor are strictly not applicable for horizontal buried vessels. While EEUMA-190 does not specifically mention about the buoyancy force applicable on a vessel buried inside a pit (it only refers to it in appendix as an example), ‘load due to uneven support by foundation’ (cl. no. 4.1.3.6), ‘load due to temperature and internal pressure’ (cl. no. 4.1.3.7) and ‘loads due to external explosion’ (cl. no. 4.1.3.9) are not applicable for buried vessel. 2. EN 12285-1: Workshop fabricated steel tanks - Horizontal cylindrical single skin and double skin tanks for 28 • July 2015
the underground storage of flammable and non-flammable water polluting liquids. a. Applicability: Shop fabricated cylindrical, horizontal steel tanks, single and double skin for the underground storage of water polluting liquids (both flammable and non-flammable). b. Limitations: i.Nominal diameter: 800 mm to 3 000 mm ii.Maximum length to diameter ratio of 6 iii.Liquids with a maximum density of up to 1,9 kg/l and with an operating pressure of maximum 1,5 bar (abs) 3. IS 10987-1992: Code of practice for design, fabrication, testing and installation of underground/ above ground horizontal cylindrical steel storage tanks for petroleum products a. Applicability: Underground/ above ground horizontal cylindrical steel storage tanks with flat ends for petroleum products b. Limitations: i.Design pressure: Atmospheric ii.Design temperature: Ambient iii.Specific gravity of stored fluid: Less than 1 Why Is Design Basis For Buried Vessel Required? As may be noted from above, the availability of generic standard and
specification related to buried vessel is very limited. Hence a design basis covering the following aspects will help the engineering companies to evaluate various design options related to buried vessels, leaving the actual mechanical design of the vessel to the applicable design code (eg, ASME Sec VIII Div 1, PD-5500 etc.) • Design loads • Combinations of various design loads • Type of saddles • Location and projection of inlet nozzle • Centre to centre distance of nozzles on top of the vessel • Number of manways Design Loads Buried vessel shall be designed according to pressure vessel code applicable for the project, considering the following design loads • Internal pressure with loads due to liquid head during operation and testing • Dead weight (weight of all component parts of the tank and components permanently attached to the tank, such as internal baffles, internal tank, dip pipes, etc) • Partial/ full vacuum due to steam out, if any • External load due to sand • Concentrated live loads (eg, loads due to pump mounted on top of tank) • Buoyancy load • Seismic load Chemical Engineering World
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Final Ad template amol.indd 117
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CEW Features • Loads resulting from connected piping and attachments Combination of Various Design Loads Cl. no. 4.1.4 of EEUMA-190 can be used as guidance in this regard. However, EEUMA-190 does not specifically mention about the buoyancy force and the combination of buoyancy with seismic load needs to be reviewed. Since for sand filled pit the buoyancy load calculation is anyway conservative, the possibility of simultaneous occurrence of seismic with buoyancy may not be a possibility. However, for open pit the simultaneous occurrence cannot be ruled out. Hence, it was suggested to consider the simultaneous occurrence of buoyancy and seismic in case of vessel in open pit and separately in case of vessel in sand filled pit. Type of Saddle Buried vessel can be supported either on steel or on concrete saddle and each one has got its inherent advantages and disadvantages. A careful review of the following parameters may help in selection of correct type of saddle. As rule of thumb, vessels in sand filled pit are supported on concrete saddle while steel saddle is preferred to support vessel in an open pit.
Following three options are available for supporting the vessel on concrete saddle 1. Equipment placed directly on the concrete saddle with steel straps to hold the equipment against buoyancy 2. Equipment placed on concrete saddle with normal bracket support with anchor bolts (as shown in Fig 1 below) to hold the equipment against buoyancy 3. Equipment placed on concrete saddle with inverted bracket support with anchor bolts to hold the equipment against buoyancy. Location and Projection of Inlet Nozzle Since buried vessel is mainly used for blowdown service, the location of centerline of the vessel inlet nozzle is dependent on the final plant layout and piping slope required for effective drainage. The location of inlet nozzle cannot be finalised till the blowdown system layout, in terms of distance of the vessel from the further point of release of the blowdown, is finalised. Till the nozzle location is finalised, the nozzle cannot be ordered (especially when it is of SR type as the length of the nozzle will depend on the location of the nozzle) and till that is not finalised, the vessel fabrication cannot be completed and vessel cannot be dispatched. Hence, the model review for the buried vessel needs to be planned
Table 1: Merits and Demerits of Concrete and Steel Saddles Parameter
Concrete saddle
Steel saddle
Accessibility
Provides better accessibility in sand filled pits since entire pit need not be emptied to access the anchor bolts for vessel removal, only removal of sand from the top half of the pit will suffice. However complete removal of the sand is required for reinstallation of vessel due to the presence of boot(s).
Finds wider in cases in open pits or where sufficient clearance between the vessel periphery and the walls of the pit are maintained.
Handling
It is a challenge to handle vessels, which are on concrete saddle, during transportation since separate transportation saddle to be fabricated and properly bolted to the vessel, as may be noted from Fig 1 below.
Easier to handle during transportation since same saddle can be used during transportation with suitable temporary extension to take care of boots.
Interface with other disciplines
Supporting and anchoring is more difficult than vessels supported on steel saddles, as may be noted from Fig 1 below.
Supporting and anchoring similar to those of conventional horizontal vessels.
30 • July 2015
to meet the vessel RAS (required at site) date of the vessel. The projection of the inlet nozzle is dependent on the project philosophy regarding the connection of the inlet nozzle with the connected piping under the following scenarios • Vessel in sand filled pit: Since no leakage of hydrocarbon vapour inside sand filled pit is acceptable, either of the following two options shall be exercised 1. If ‘golden joint’ inside the sand filled pit is acceptable then the projection can be ‘minimum’ to meet the code requirement and shall be provided with bevel end without and flange, as shown in Fig 1 below. 2. If ‘golden joint’ is not acceptable, then nozzle should be provided with flanged end with sufficient projection to clear the vessel pit into the adjacent valve pit. This should be advised by piping. Since the projection will be substantial (~2 to 2.5m) suitable bracing needs to be provided to avoid damage during transportation and erection. • Vessel in open pit: Since leakage of hydrocarbon in an open pit is not as critical as it is in a sand filled pit, standard nozzle projection with flanged end will be adequate. Centre-To-Centre Distance of Nozzles on Top of Vessel Unlike other horizontal vessels all the nozzles in a buried horizontal vessel are located on the top of the vessel (refer Fig 1 on the next page). This calls for a careful assessment of the vessel tan-totan length due to the following reasons which are typical to buried vessels 1. Code required clearance between nozzle reinforcement pads of adjacent nozzles 2. Minimum clearance required between outside diameters between flanges of adjacent nozzles. 3. Requirement of stiffeners for slender nozzles to protect them against damage during transportation, uplift during flooding, sand filling of the pit Chemical Engineering World
CEW Features Considering the fact that combining pump manway with other manway may severely jeopardise the maintenance of other internals (eg, instrument dip pipes etc) inside the vessel and the requirement of more than one manway is mainly for above ground vessel, where increase in number of manway will not necessarily increase the length of the vessel, the following approach may be used as a guide in deciding the number of manways without increasing the vessel tan-to-tan length • 1 manway for general maintenance, irrespective of the length, and • 1 separate manway for each of the sump pumps
Figure 1. Buried Vessel on Concrete Saddle with Golden Joint
Notwithstanding the above guidelines, a close coordination among various engineering disciplines is a prerequisite for early finalisation of the selection and design and minimising changes during the detailed engineering stage.
Figure 2. Combining of smaller nozzles
Figure 3. Vessel Buried in Sand Filled Pit
etc, as shown in Fig 1 above. 4. The project philosophy for covering the pit.
of 1 to 3 above. This may call for increase in the vessel tan-to-tan length required from process consideration. Hence, other than Process, Civil department also needs to be consulted before finalising the vessel tan-to-tan length.
While requirement of code is complied with by carefully locating the nozzles on the top of the vessel and providing combined reinforcement pads, the challenge of avoiding damage of too many slender nozzles on the top of the vessel is addressed by either providing a temporary horizontal stiffener connecting all the small nozzles (as shown in Fig 1 above) or by locating two or more small nozzles on a single larger nozzle with a blind cover as shown in Fig 2 above. In order to have easier access to the vessel pit, project philosophy may opt for concrete covers supported on removable cross beams, instead of a thin layer of concrete. In case of former, the nozzle center-to-center distance will be governed by the width and number of the cross beams over and above the considerations 34 • July 2015
Number of Manways In the absence of specific project philosophy regarding the number of manways in buried horizontal vessel, we tend to adopt the same philosophy as is being specified for above ground horizontal vessel which is generally governed by the vessel tan-to-tan length, eg, 1 manway for vessel length upto ‘X’ m and 2 manways for length larger than ‘X’ m etc. This approach results is longer than required vessel tan-to-tan length, as discussed in the previous paragraph, and in order to limit the vessel tan-to-tan length sometimes the second manway is combined with the manway for the sump pump, which is an integral part of these types of buried vessels.
References 1. EEUMA-190: Guide for the design, construction and use of mounded horizontal cylindrical steel vessels for pressurised storage of LPG at ambient temperatures. 2. EN 12285-1: Workshop fabricated steel tanks - Horizontal cylindrical single skin and double skin tanks for the underground storage of flammable and non-flammable water polluting liquids. 3. IS 10987-1992: Code of practice for design, fabrication, testing and installation of underground / above ground horizontal cylindrical steel storage tanks for petroleum products.
Author’s Details Ritabrata Pramanik Mechanical Engineering Fluor Daniel India Pvt Ltd E: ritabrata.pramanik@fluor.com Chemical Engineering World
CEW Features Technical Article
Use of Administrative Control in Process Safety Deciding the credibility of the scenario for the PSVs is always found to be a user’s choice. There are many ways by which a user can justify the non-credibility of the scenario. Administrative procedures defined for the plant is one of the ways often used for the justification. However, it is always a question when to apply them in a process safety. This article addresses the question on when to use administrative procedures without hampering the safety of the plant.
S
afety is an utmost concern in any process plant operations. No engineering or design is said to be reliable if it negotiates the safety of the plant. Most of the times, the accidents in the process plants occur due to operator negligence, improper standard operating procedures, instrument malfunction etc. However, in some of the cases, these accidents occur due to improper and inadequate process safety design such as PSV (Pressure Safety Valve), Flare system etc. Sometimes, the minor hazards get overlooked by the designer during process safety design which later results in one of the reasons to the system failure. Thus, it is very important to address every possible hazard while evaluating the safety of the plant. API 521 illustrates various possible scenarios for the PSVs which safety designer can consider in the safety design. Whereas, defining whether any
scenario is credible or not is purely user’s discretion. In some of the cases, the likelihood of the scenario is very low that scenario could be considered noncredible and PSVs designed for these scenarios are very less often going to pop-up. Maintenance of such PSVs is cumbersome and minor leakage from the flanges could result hazards in the plant. Also, in some cases, user does not want not to size the PSV for particular scenario which may affect the disposal system. For example, sometimes user does not want to size PSV for a liquid relief scenario to avoid large quantity of liquid relieving to the flare header and sizing knock out drum to handle this liquid inventory. In such cases, administrative procedures may play vital role justifying a) non-credibility of the scenario b) safety of the system. As per API 521, certain pressure design codes allow the use of administrative controls if the potential overpressure does not exceed the corrected
IA
To Reactor FV-101 IA
Chlorine from B.L
Operating Pressure = 6barg MAWP = 27barg/FV Operating Temperature = 300c Coincident Temperature = 2050C
EBV-101 Air Gap Hot Condensate
Figure:1 Chlorine feed from B.L to Chlorine Knockout drum
36 • July 2015
EBV-102
hydrotest pressure. By defining administrative procedures at the design stage itself, there would be marginal savings on the capital and operating cost for the PSVs. Please be noted that, there is no compromise to the safety since it does not completely eliminate the hazard, whereas it addresses the hazard as a part of an administrative procedures. The example below illustrates the use of an administrative procedure that justifies the non-requirement of the PSV to the vessel without compromising the safety of the system. System Description: Chlorine gas from battery limit is sent to the Chlorine K.O Drum (V-101). The purpose of this drum is to separate any liquid particles from the chlorine gas and send liquid free chlorine gas to the phosgene reactor. The drum is provided with temporary hot condensate tracing which facilitate the boiling off the accumulated liquid chlorine into the boot of the drum whenever required. Scenario Analysis: I. Loss of cooling water or other cooling fluid: There is no cooling water or other cooling fluid used in this system. This is not applicable scenario. II. Loss of power: There are no power operated equipment such as pumps and compressor associated with this system. This scenario is not applicable scenario. Chemical Engineering World
CEW Features Drum V-101 is inherently protected from the overpressure since pressure is selflimiting which fulfills the requirement specified in ASME SEC VIII Division 1, UG-140(a), which concludes that there is no settlement on the safety of the system.
SYSTEM INFORMATION Tag No.
V-101
Operating Pressure
6 barg
Operating Temperature
300C
Maximum Allowable Working Pressure (MAWP) of the drum
27 barg / FV
Coincident Temperature
2050C
Vessel design code
ASME SEC VIII, Div 1
III. Steam failure: There is no steam used in this system. This scenario is not applicable. IV. Instrument air / electrical supply failure: EBV-101 on chlorine gas supply line to V-101, FV-101 and EBV-102 on chlorine gas outlet line from V-101 are having fail closed position. Instrument air failure will cutoff inlet and outlet flow of chlorine gas. Thus, this will not lead to overpressure. V. Individual control valve failure: FV-101 closing inadvertently will lead to blocked outlet from V-101. However, this will not lead to overpressure since maximum pressure (design pressure) of the incoming chlorine gas is 24 barg which is lower than MAWP of the drum, which is 27 barg. VI. Inadvertent valve operation: EBV-102 stuck close will not lead to overpressure. Refer scenario “Control Valve Failure”. VII. Individual equipment failure: See scenario II. VIII. Blocked outlet: See scenario V. IX. Gas blow through: N/A X. External fire: Location of the drum V-101 is on the grade. Also, as per MSDS, chlorine non-flammable gas and vessel V-101 is not coming under any fire circle radius. Hence, external fire is not credible overpressure scenario. XI. Exchanger tube rupture: There are no exchangers in this system. This scenario is not applicable. XII. Liquid overfill: Liquid overfill is credible in abnormal circumstances but overpressure is not credible since maximum supply pressure is lower than MAWP of the drum. 40 • July 2015
XIII. Thermal expansion: This system is not liquid filled. Thus, thermal expansion in case of blocked in scenario is not credible. XIV. Vacuum: The vessel is designed for full vacuum. Hence, it is not applicable scenario. XV. Any other: V-101 boot is provided with tracing with temporary connection for hot condensate to vaporize liquid chlorine. Hot condensate at 105ºC heating liquid chlorine through tracing with vapor outlet blocked will create an overpressure since vapor pressure of liquid chlorine at 105ºC (Hot condensate temperature) is 40.94 barg, which is exceeding MAWP of the drum. However, this scenario can be considered non-credible since administrative procedure will take care of this overpressure concern by providing the air gap of the condensate line connected to V-101. Administrative Procedure: shall be provided between line and V-101 which shall hot condensate is isolated (V-101) is not in operation.
An air gap condensate ensure that when drum
Referring to the scenario analysis, it is clear that the only credible overpressure scenario is the hot condensate heating liquid chlorine when drum is isolated or vapor outlet is blocked. However, this scenario is considered non-credible (not eliminated) by taking credit of administrative control. Sizing the PSV only for this scenario is not justified as the likelihood of the scenario is low also administrative control shall make sure that this scenario would not occur.
Another example below illustrates that by taking credit of administrative control a specific scenario could be considered non-credible for the PSV design. System description: This system is designed to collect the drains from all the pumps after DCB (dichlorobenzene) flush which is collected to Drain Collection drum (V-201). Drain Collection drum pump (P-201) is then transfers the collected liquid to the DCB recovery system. P-201 operates intermittently which starts on V-201 high high level and stops on V-201 low low level. Hot DCB connection is provided to V-201 for start-up which comes from the Hot DCB pump (P202). Pressure in V-201 is maintained using PV-201 by routing vent gas to vent collection system which consists of 8” Vent header and Vent Header Knockout Drum (V-301). Vent from this drum (V-301) is then routed to further treatment. Scenario Analysis: I. Loss of cooling water or other cooling fluid: There is no cooling water or other cooling fluid used in this system. This is not applicable scenario. II. Loss of power: Liquid from all pumps casing and piping to V-201 is normally drained when these pumps are not in operation. Even if the pumps are not in service or during loss of power, liquid draining to V-201 will not lead to overpressure due to liquid overfill since an extra room available at the drum overhead line (an open path assuming PV-201 not stuck) to the vent header system (8” Vent Collection Header and V-301) to accommodate the liquid inventory. III. Steam failure: There is no steam used in this system. This scenario is not applicable. Chemical Engineering World
CEW Features Vent From Other Source
Vent to Treatment Unit
8”Vent Collection Header
To Flare Drain Collection header
Liquid Outlet
to liquid overfill. However, an administrative procedure will take care of this scenario. PSV is not sized for this scenario. XIII. Thermal expansion: This system is not liquid filled. Thus, thermal expansion in case of blocked in scenario is not credible. XIV. Vacuum: The vessel is designed for full vacuum. Hence, it is not applicable scenario.
EBV-201
LV-201 Hot DCB
DCB Recovery system EBV-202 P-202
P-201
Figure:2 Drain Collection Header System
SYSTEM INFORMATION Tag No.
V-201
Operating Pressure
0.5 barg
Operating Temperature
75ºC
Design Pressure of Drum
3.5 barg / FV
PSV set pressure
3.5 barg
Vessel design code
ASME SEC VIII, Div 1
IV. Instrument air / electrical supply failure: EBV-201 on drain collection header to V-201, LV-101 on P-201 discharge line, PV-201 on V-201 vent header line and EBV-202 on P-201 suction line are having fail closed position. Instrument air failure will cut-off inlet and outlet flow. Thus, this will not lead to overpressure. V. Individual control valve failure: PV-201 closing inadvertently will lead to blocked outlet from V-201. This will lead to blocked vapor outlet. PSV is designed to address this scenario. This is not governing scenario. VI. Inadvertent valve operation: LV-201 opening inadvertently may lead to overpressure as discharge pressure for P-202 is 9 barg, which is higher than PSV set pressure. However, taking credit of availability of the vent header at V-201 vapor outlet the liquid overfill does not appear to happen. This is not credible scenario. VII. Individual equipment failure: See scenario II. VIII. Blocked outlet: See scenario V. IX. Gas blow through: N/A X. External fire: Location of the drum V-201 is on the grade. Also, V-201 handles DCB above its flash point. The external fire is credible overpressure governing scenario. XI. Exchanger tube rupture: There are no exchangers in this system. This scenario is not applicable. XII. Liquid overfill: PV-201 stuck close when P-201 is not in operations and P-202 is feeding continuously to V-201 may lead to liquid overfill. Also, discharge pressure of P-202 is 9 barg, which is higher than PSV set pressure of 3.5 barg. This will lead to overpressure due 42 • July 2015
Administrative Procedure: An administrative procedure shall ensure that whenever Hot DCB pump P-202 is online to the Drain Collection Drum, pump P-201 shall always in operation to take care liquid overfill scenario. In this example, Flare knockout drum in flare system which was already sized considering liquid flowrate from other PSVs could not handle the liquid relieving from the PSV located on V-201 since this PSV was added later in the design. However, by taking credit of an administrative control, liquid relief scenario for the PSV was considered non-credible. Bottom line: There would be many views on whether to use administrative control in safety design or not. But, looking to the examples above, it assures that these procedures can be used if they prove to be beneficial and cost effective without diluting the purpose of the safety. References 1.Pressure-relieving and Depressuring Systems, API Standard 521, Sixth Edition, January 2014. 2.ASME Boiler and Pressure Vessel Code VIII, Division 1, Rules for Construction of Pressure Vessels, Edition 2010
Author’s Details Nikhil Kadam Assistant Manager Daelim Industries Co Ltd E: Nikhil@daelim.co.kr Chemical Engineering World
CEW Features Case Study
A Breath Of Fresh Air IndoChem discovers the best way to optimise production rates and air consumption in solvent manufacturing is by using the innovative new Pro-Flo SHIFT AODD pump from Wilden.
F
ounded in 1997, the Asia Pacific Petrochemical Co, Ltd, which is headquartered in Bangkok, Thailand, has rapidly grown into one of the leading importers, exporters and distributors of hydrocarbons, oxygenated solvents and monomers for use in industrial-manufacturing operations in the Asia-Pacific region. Helping Asia Pacific Petrochemical reach its lofty status has been a group of subsidiary companies that are strategically located in an area that includes the Southeast Asian island nations of Indonesia, Singapore, the Philippines and Malaysia. Representing the group in Indonesia is PT. Indochemical Citra Kimia, widely known as ‘IndoChem.’ Based in Jakarta, Indonesia, IndoChem was founded in 1982 and is a recognised leader in solvent production for use in the Indonesian paint and coatings market, and also a significant producer of glues and inks for various industrial applications. IndoChem’s solvent manufacturing business consists of three plants located
in Indonesia. These plants have holding tanks that can accommodate up to 45,000 litres (11,888 gallons), and are constantly being filled and emptied depending on the facility’s manufacturing and delivery needs. In all, IndoChem produces and handles a total of 300 million litres (79.3 million gallons) of solvents per year at its three production facilities. Growing Pains As IndoChem’s customer base has increased, several operational challenges have begun to hamper its ability to reliably and efficiently meet its production quotas: • The time needed to fill one 45,000 litre holding tank has approached seven hours, which is unacceptable for IndoChem’s clients • The capacity of IndoChem’s aircompressor unit has been maxed out and it is not possible to add another compressor from both an economic and available-space standpoint • Perhaps most importantly, the solvents produced by IndoChem are highly flammable, and some of them self-
spark, so it is important from a safety standpoint that they are contained adequately “Our current transfer time is approximately three hours for transferring input and three hours for transferring output, plus halfan-hour for mixing and half-an-hour for preparation,” said Erwin Juardi, General Manager – Operations, IndoChem. “Since we are planning on some improvements, we wanted to add more pumps, but we want to stay with the same air-compressor capacity. I would love to see whether it is possible that I can save air even though I am adding pumps and getting more pumping capacity.” To facilitate the transfer of solvents, Juardi utilises a total of 60 pumps between his three manufacturing facilities. He had been strictly relying on a single brand of AODD pump, but over time he had come to find the pumps unreliable and costly to operate. “They have a high cost of replacement parts, and I have a hard time getting
Over its 30-plus years of operation, PT. Indochemical Citra Kimia, better known has ‘IndoChem,’ has grown into a recognised leader in solvent, glue and ink production for use in a number of industrial markets in Southeast Asia.
46 • July 2015
Chemical Engineering World
CEW Features diaphragms; I am fed up with these pumps,” he said flatly. “The diaphragms do not hold up and it is hard to work on them. It takes two guys to simply change a diaphragm and I do not want manpower wasted on pump maintenance. We needed a simpler, more reliable, higher-performing alternative.” In the search for a better solution, Juardi turned to Winston Engineering Jakarta, Indonesia. Since 2005, Winston Engineering Jakarta, which is an operating company within Singapore-based Winston Engineering Company (PTE) Ltd, has been a pump distributor specialising in pump technology designed for use in general industrial-pumping applications, including the handling of solvents, glues and inks. Seeing Is Believing Juardi worked with Peter Koh, Regional Product Manager for Winston Engineering, who was quick to suggest the new ProFlo SHIFT AODD Pump from Wilden, Grand Terrace, California, USA. Wilden invented AODD pump technology in 1955, and since 2008 has been a member of the Dover Corporation’s Pump Solutions Group (PSG), Oakbrook Terrace, Illinois, USA. The Pro-Flo SHIFT is an AODD pump air distribution system (ADS) that can deliver as much as 60 per cent savings in air consumption when compared to other brands (see Sidebar). “Winston Engineering has a long relationship with Wilden and PSG, and we have been selling their products for more than 20 years,” said Koh. “With the latest Pro-Flo SHIFT technology it is bringing Wilden to the next level. This pump really, really has an edge when it comes to energy savings,” he added. But rather than simply have Juardi take his word for it, Koh arranged to have an on-site test and demonstration of the ProFlo SHIFT technology done at one of IndoChem’s facilities in April. The test involved three separate trials in which both a Wilden Pro-Flo SHIFT pump—specifically, a 51-mm (2-inch) PS800 Advanced Series (bolted) aluminium AODD pump—and a competitive model would pump 200 litres (52.8 gallons) of water, with all pumping done at a pressure of 4 bar (58 psi). Measured would be the time it took to pump the water along with the amount of air that would be required to complete the pumping process. Extrapolating the results for one of IndoChem’s standard 45,000-litre tanks, the test results showed that the Wilden pump would be able to fill the larger tank in 78 minutes less than the competitive model, while needing 2,164.08 fewer standard cubic feet per minute (SCFM) to complete the transfer process. Juardi was easily convinced. Juardi said, “I know that Wilden pumps are very reliable. We have had one here for 20 years and we have not found any problems with it so. So, I am thinking, let us change the old pumps to Wilden. What we are learning from the old Wilden pump is that it has been here forever, but with no problems. I was also 48 • July 2015
Optimising Air Consumption In AODD Pumps Throughout its history, air-operated double-diaphragm (AODD) pump manufacturers have been working to find a reliable solution to the technology’s one blind spot: the ‘overfilling’ of the air chamber during the period from the end of each stroke to the completed shift of the valve without any corresponding displacement of fluid, which is nothing more than wasted air that is vented to the atmosphere. To combat this overfilling, Wilden Pump & Engineering Co, Grand Terrace, USA, has long been an innovator in air distribution system (ADS) development, and while its Turbo-Flo, Pro-Flo and Pro-Flo X ADS models undeniably advanced the capabilities of the technology, the industry was still waiting for that ultimate ‘Eureka!’ moment in ADS development. That moment arrived in 2013 when Wilden completed the development of the Pro-Flo SHIFT ADS. Described as a ‘true game-changer’ and ‘significant breakthrough in energy efficiency’ in AODD-pump operation, the mechanically actuated Pro-Flo SHIFT ADS restricts air flow into the air chamber near the end of each pump stroke through the incorporation of an air control spool that automatically meters the air to prevent overfilling with no corresponding reduction in product yield. This means that an AODD pump outfitted with the ProFlo SHIFT ADS—which is available on Wilden’s Original (clamped) and Advanced (bolted) Series AODD Pumps— can achieve up to 60 per cent savings in air consumption while costing 50 per cent less to operate than pumps that feature an electronically actuated ADS. An additional benefit is that the Pro-Flo SHIFT is mechanically actuated, which is a critical consideration when the pump is handling hazardous or flammable liquids. Electronically actuated ADSs, on the other hand, cannot be used with flammable or explosive liquids since the electric charge can cause sparking which could ignite the liquid and result in a deadly explosion. “Having this Pro-Flo SHIFT pump means I can save air and would not need to add compressors, which means less electricity use, and that I can also increase my productivity,” said Edwin Juardi, General Manager of Operations of solvent manufacturer IndoChem, Jakarta, Indonesia, after watching the Pro-Flo SHIFT pump easily outperform a competitive brand in a side-by-side test that compared transfer times and air consumption. Chemical Engineering World
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CEW Features compatibility concerns, with IndoChem choosing the fullstroke Neoprene diaphragm with Wil-Flex (Santoprene) backup diaphragms for its pumps. Conclusion Too often, the easy suggestion when a manufacturing facility has reached the limits of its operational capacity is this one: Find a bigger facility. In the case of IndoChem, though, that was not a feasible solution. So, that meant the solvent manufacturer needed to find a way to optimise its productivity in terms of time, air consumption and energy usage while operating from the same footprint.
Installing the revolutionary Pro-Flo® SHIFT ADS on a Wilden® Advanced™ Series AODD Pump gave IndoChem the flow rates, air consumption and product-containment capabilities that it requires in its solvent-handling operations.
IndoChem found the answer in the new Advanced Series ProFlo SHIFT AODD Pump from Wilden, which will enable it to simultaneously improve both its fluid-transfer times and energy savings while working out of the same facility with the same air compressor. “The unique features of Wilden pumps are very easy for maintenance, portable and with a very unique high-efficiency ADS, which is the heart of the pump,” said Koh. “Every part is replaceable, even for pumps that have been in the factory for more than 10 years. That is part of why customers stay with the Wilden brand. Wilden is the unique market leader in diaphragm pumps.”
An on-site, head-to-head test at the IndoChem facility unequivocally illustrated that a Wilden® Advanced™ Series AODD Pump outfitted with the new Pro-Flo® SHIFT ADS shortened loading times while cutting air consumption (Competitor Pump shown).
looking for air savings because I cannot afford to buy any more air compressors.” In addition to the air-consumption improvements that the Pro-Flo SHIFT ADS can provide to the Advanced Series AODD Pumps, there are a number of operational benefits that IndoChem will be able to take advantage of. The bolted configuration of the Advanced pumps ensures total product containment, a key consideration with the hazardous materials that IndoChem creates and handles. Additionally, the Advanced pumps have a redesigned friction-reducing liquid path that contributes greatly to their ability to deliver maximised flow rates. In fact, the PS800 (51 mm) pump can achieve flow rates as high as 704 L/min (186 gpm), while the larger PS1500 (76 mm) model has flows to 1,045 L/min (276 gpm). A variety of elastomer options, including PTFE (Teflon), are available to meet abrasion, temperature and chemical50 • July 2015
Author’s Details Angela Gong Marketing Manager PSG Chemical Engineering World
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jacketed. The available materials of construction and design options provided by WITTE offers our customers maximum flexibility. This type of pump is also available as mini gear pump. The CHEM MINI takes fine metering tasks with high precision. Currently the smallest available pump has a specific volume of 0,2 cm3/rev. Smaller pumps are available upon request. CHEM MINI series can be offered in size 9/5,5 (0,2 cm3/rev) to 14/28 (2,95 cm3/rev).
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CEW Features Technical Article
Designing Cooling Water Return Lines Appropriately The following article focuses on the need to analyse the cooling water network as a whole, for a synchronised pressure profile – which is one of the major activity that needs to be distinguished and requires ‘ concentrated efforts.’
C
ooling water line sizing is often considered to be the simplest activity in any project, and hence it is often given less attention. However, inadequate or improper distribution of cooling water directly affects plant performance and consequently the guarantee figures. It is worthwhile to distinguish between two different activities in cooling water network sizing: - Cooling water line sizing of an individual consumer as well as headers based on flow rates - Analysing the cooling water network as a whole, for a synchronised pressure profile The first part may be simpler than the second, which requires more concentrated efforts. It may become an area of concern if due attention is not paid to return line sizing during the design process. This article focuses on the second point, ie, the analysis of a cooling water network based on return line hydraulics. The article discusses the general approach
Consumer Cooling Tower
Figure:1 Typical cooling water system - Simplified scheme
52 • July 2015
of cooling water line sizing in the first section, and identifies loopholes with the help of a case study in the second. The conclusion indicates areas, where process engineers need to pay attention while sizing the return header. A simplified scheme of a cooling tower is as shown in Figure 1. The estimation of the pump head establishes the pressure profile of the network. This is to make sure that there will be appropriate flow distribution to the respective consumers. For this activity, there are two ways in which one may proceed. Option 1: Estimation of the pump head, considering the entire cooling water circuit (up to cooling tower) via different loops and then identifying the loop that requires the highest head. Option 2: Estimation of the pump head, considering the atmospheric pressure at the consumer outlet that is located at the highest elevation. The atmospheric pressure at the consumer outlet that is located at highest elevation in the network is achieved by having vent on return line. (See Figure1) Thus the head available due to the elevation in the return header is sufficient to cause the flow from consumer to cooling tower. Option 2 is more frequently chosen, in view of the power saving it enables. It also ensures proper distribution without the throttling of valves, and hence is
widely used. However, when using this method, appropriate sizing of the cooling water return line becomes vital. Generally, since cooling water lines are expected to be on the pump discharge line, the velocity criteria with which these lines are sized are often considered with respect to this. However, it shall be noted that for Option 2, the cooling water return line is exposed to atmospheric pressure by means of a vent, and will not see any pump discharge pressure. This line will be under the influence of gravity and should be sized accordingly. In order to get more clarity on the subject, we shall evaluate the case study below. There are two cooling water networks in a plant, one catering to the water requirement of consumers located up to the elevation of 15 metres (LP circuit), and another catering to the water requirement of consumers located between the elevations of 15 metres and 25 metres (HP circuit). This arrangement is made in order to optimise power consumption, as the flows in both circuits are quite high. It is always advisable to have a single header running from the plant building to the cooling tower, since minimum piping around the cooling water deck and the pipe rack will reduce civil loading of the cooling tower structure and the pipe rack. With the above considerations, two different set of pumps of different heads Chemical Engineering World
CEW Features are used to feed two networks, such as LP and HP. The return lines of these headers are then combined into to one header, which is laid on the pipe rack that is running up to the cooling tower. As shown in the Figure 2, both return headers are provided with a vent at their respective highest elevations, so as to see atmospheric pressure as ‘back pressure’. Thus, it will be only the elevation difference that will cause flow from the respective consumers to the cooling tower, overcoming piping frictional pressure drop. Reviewing this scheme drives one to analyse the influence of the HP circuit elevation on the flow of the LP circuit. A significant effect may be foreseen on flow distribution. This is because pressure at the common return point will be the same for both circuits. At first sight, it appears that there should not be any problem with this arrangement, as both circuits are exposed to atmospheric pressure and connected to a common header at a single elevation. However, the effect of the elevation difference was not taken into account while considering the atmospheric pressure at the consumer outlet. This is the point at which an issue with back pressure can arise. As discussed in the beginning, the entire line sizing of the cooling water system, including headers, is calculated based on the pump discharge pressure. This calls for the velocity in the pipeline to be in the range of 1.5 – 2 m/s, as per the recommended criteria.
HP user at Highest Ele. Ele: 27 m
LP user at Highest Ele. Ele: 15 m
Cooling Tower
LP CWS Pump Disch. Press: 4.5 kg/cm2a
HP CWS Pump Disch. Press: 5.5 kg/cm2a
Figure2: Case study
the respective elevation matters, in terms of the liquid rise in the respective headers, and thereby the back pressure on the LP circuit. In order to avoid this effect, it is required to size these headers for gravity flow, considering a lower velocity. Furthermore, it is required to size these headers as self-venting lines that are running vertically, so as to release any vapors present therein.
Conclusion Although a cooling tower network works under pump pressure, a return node shall be identified from where gravity flow takes place. Accordingly, the return header shall be sized considering the guiding parameter of the Froude number, which shall be maintained below 0.3. Secondly, it is equally important to analyse whether the elevation difference between the highest consumers of cooling water and the cooling tower deck is sufficient to drive the water under influence of gravity. If the elevation difference is not sufficient, the pump head calculation shall be done up to the cooling tower deck, and the entire circuit will operate under pump pressure. However, in that case, due care shall be taken during start-up to ensure that no air pocket exists in the loop. References Perry’s Chemical Engineer’s Handbook
This can be ensured by getting a dimensionless Froude number less than 0.3. This can be estimated as below. Froude Number = V 2 / Dg <0.3 Where V = Velocity in pipe line, m/s D = Diameter of pipe, m g = Gravitational Constant, 9.81 m/s 2 Ref: Perry’s Chemical Engineer’s Handbook
However, in reality, the return headers are expected to run under the influence of gravity.
With the above consideration, the return header size will be sufficient enough to remove the effect of elevation difference. Thus the vertical portion of the header will have a liquid leg filled to the height of the cooling tower, plus height equivalent to the frictional pressure drop of the return header.
Secondly, it shall be further noted that the atmospheric pressure that is considered as ‘back pressure’ is at two different elevations. Hence, although both headers are at atmospheric pressure,
Hence, each circuit will see the same pressure profile across the entire length of the return header. Accordingly, the HP circuit will not influence the LP circuit or the return header. The cooling
54 • July 2015
water network can run then smoothly without any need for throttling valves for flow adjustment.
Author’s Details
Vipin Deshpande Deputy Engineering Manager Aker Solutions E: Vipin.Deshpande@akersolutions.com
Chemical Engineering World
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Focus Area for 2015: Lubrication Lubes and Greases related New Technologies, Maintenance and Best Practices
A
fter the mega success of earlier 5 editions of MainTech Conferences, Confederation of Indian Industry - CII, Gujarat organised the 6th edition of MainTech 2015 with specific focus on ‘Lubrication’ r e l a t e d M a i n t e n a n c e , Te c h n o l o g i e s , Developments and Best Practices on 17 July 2015 at Vadodara. The conference identified Challenges and Best Practices pertaining to Proactive and Reactive Maintenance related to lubrications and covered wide range of topics of interest to the stakeholders in the various areas Technical Plenaries & Topics covered during the Conference: Basics of Lubrication: Understanding Lubr ication and Selection of Correct Lubricants & Alternative, New Developments in Lubricant Technology, Contamination Control & Best Practices. Maintenance and Lubrication: Bearing Life Enhancement by Proper Lubrication, Gear Box Reliability – Lubrication Centered, Basics of Oil Analysis & Wear Monitoring Techniques through Oil Condition Monitoring – Key to Equipment Reliability, Hydraulics’ Lubrications and Best Practices. Lubrication Management: Lubricant’s Life Cycle Management (Planning, Monitoring, Control, Recycle, Disposal Case Studies: Case Studies on Proactive & Reactive Management Key Speakers addressed during the Conference were: Mr Ashwin Gandhi, Chairman – CII Central Gujarat Zonal Council & Director, Express Hotels Pvt. Ltd., Mr Nishith Dand, Vice Chairman – CII Central Gujarat Zonal Council & Managing Director, Sure Safety (India) Pvt. Ltd., Mr Samir Sabnis, Chairman – 6th 58 • July 2015
edition of CII’s MainTech 2015 & Director, PruftechnikAimil(India) Pvt. Ltd., Mr Vilas Kalyankar, Chief Executive Officer – Gear Division, Elecon Engineering Company Ltd., Mr Sanjeev Kr Jain, General Manager – Gujarat State Office, Indian Oil Corporation Ltd., Mr Sunil Desai, Convener – CII’s MSME & Manufacturing Excellence Panel & Managing Director, Richfield Engineering India Pvt. Ltd., Mr Gourav Kotwani, Dy Manager – Technical Services (P&AD), Bharat Petroleum Corp. Ltd., Mumbai, Mr Nitish Mittal, Sr Manager – Technical Service, Head Office, Indian Oil Corporation Ltd., Mumbai, Mr Nirav Shah, Lubricant Technical Advisor, Shell India Markets Pvt. Ltd., Mr Nitin Mankad, Past Chairman – CII Central Gujarat Zonal Council & Managing Director, Innovative Tyres & Tubes Ltd., Mr Sreepal Rajan Singh Negi, General Manager – Marketing, Technical Services, FAG Bearings India Ltd., Mr Samir A Jethva, Group Head Design – Helical & Planetary Gearboxes, Elecon Engineering Co. Ltd., Mr KNV Subrahmanyam, Head – Oil Analysis Division, Aimil Ltd., Mr Seshan Iyer, Head – Maintenance, Repaiers & Operations (MRO), FAG Bearings India Ltd., Mr Sitanshu Bhatt, Head of Depar tment - Rotating Equipment (ENCR), Linde Engineering India Pvt. Ltd.
M a i n Te c h C o n f e r e n c e C h a i r m a n ’s Message:"The MainTech platform by CII in its 6 th edition, continued in its endeavor to bring the latest trends and technologies in the maintenance arena to the industry. We have seen the industry participation grow over the years and today this is one of the premier maintenance technology forum in India. CII, through maintech 2015 has bought the impor tance of proper 'Lubrication Management' to the Indian industry. The industry today world be losing billions of dollars due to improper lubrication practices and CII has got the manufacturers, users & OEMs on a single platform to impact the awareness. As I Say, CII’s MainTech is in line with the concept of Mr Narendra Modi, Hon’ble PM regarding 'Make in India' initiative. We just add to it and would like to spread the idea of 'Make in India Efficiently!' The Conference was highly successful and was well attended by more than 200 participants from the across the industry, Sectors and States. The 7 th Edition of MainTech is scheduled on Friday, 15 th July 2016 at Vadodara Chemical Engineering World
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On Double Digit Growth Track Since 2011
T
he Asian market for pumps and valves constitutes for 42 per cent of the world market. How much of market share does India have of it? A: India contributes 10-15 per cent, in the global pumps and valves market which stood at around USD 53 billion last year. Many international valve companies view the lack of Asian penetration as a viable growth opportunity. Over the last few years, many international pumps and valve manufacturers have opened manufacturing in India envisaging stronger regional presence in the Indian and Asian market, which is currently witnessing a healthy growth. This is creating strong competition in the Indian as well as regional Asian market. What are the key growth drivers for the pumps and valves industry in India? Well, pumps and valves, as we all know have applications across almost all the industry verticals that one can think of!! Indian economy is booming right now and witnessing growth across all the verticals from oil and gas to chemicals and petrochemicals, power, infrastructure and water, etc. Currently, Indian Pump and Valves industry stands at ` 9000 crores with 500 - 700 suppliers already in the market supplying wide range of products for industrial applications. However technology will be a major differentiator for the players as the users are now more open to opting for energy efficient products. This is where Samson Controls Pvt, Ltd, (SCPL) India can play a major role. Which industries does Samson Controls majorly cater to? Samson products have been witnessing a strong demand from various industries viz, Oil and Gas, Fertilisers, Food and Beverages, Power, Chemicals, Steel and other Metals, Paper and Plastics, etc, where the manufacturers need to comply with stringent regulatory norms. All these industries are witnessing a strong growth presently and we see major scope for 60 • July 2015
our growth in the years to come. Samson India is one of the leading manufacturers of Globe Control Valves, ON/OFF valves, Conventional and Smart Positioners, Self-operated Pressure and Temperature Regulators and supplies various products like Lined Valves, Rotary Plug Valves, High pressure and temperature Gate, Globe, Check, Butterfly valves, Pneumatic actuators etc, from specialist Samson Group Companies. Please talk about the growth of Samson Control Pvt Ltd, India since you took the charge of organisation in 2011? Since 2011, we have successfully brought several changes in our internal processes in Samson India and trying to emulate the international best practices that are followed at our headquarters with the aim to ensure our Indian production is compliant to Samson AG in quality standards. We have scaled up our operations and doubled the machinery and manpower, since I have taken charge of the Indian operations. I must say that our team effort has paid off well and we have been witnessing double digit growth year-on-year over the last four years. Presently, SCPL has a marginal share in Samson AG, but India will continue to be an important market for the group’s global growth strategy. In the years to come, we intend to leverage upon this base and achieving faster growth. Please share your thoughts about the Hon. Prime Minister Narendra Modi’s ‘Make in India’ campaign and your expectations from the present government. The ‘Make in India’ campaign initiated by the Prime Minister holds a lot of promise and the current government has already started taking measures to encourage industrial development and Samson AG is actively investing in Indian market to leverage on this opportunity. However, in my opinion, there are still some challenges like non-uniform tax structures,
Atul Raje changes in input costs, fluctuating power cost and labour reforms, etc, which continue to be hurdles for the Indian manufacturing sector which need immediate attention from the government. I feel that with some more restructuring of policies and government intervention, the ‘Make in India’ campaign can be a game changer especially for small and medium scale companies from the manufacturing sector and help companies like ours to grow faster. What are the biggest strengths of Samson Control Pvt Ltd? At SCPL, we strongly believe in keeping our customers happy, which tops our list of priorities across our entire teams. We strictly adhere to the mandates followed by Samson AG in terms of highest quality, timely product deliveries, provide efficient solutions, imparting proper operational training, excellent service, which has helped us excel during the last three years. We intend to continue doing our best to serve our customers across various industries in and around India.
SAMSON CONTROLS PVT LTD 604, P-3, Pentagon Building, Magarpatta City, Hadapsar, Pune, 411028 Maharashtra, India T:+91 20 67246600 | F: +91 20 67246666 E: infor@samsoncontrols.net W: www.samsoncontrols.net Chemical Engineering World
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Design and Development Never Stops at Everest: Malhotra Everest is the first and the only Indian blower manufacturer to have successfully shifted entire production load of its blowers, boosters and pumps on CNC machines. The company has imported a number of sophisticated Haas make CNC machines from USA. This has resulted in higher production capacities and better quality, claims Daksh Malhotra, Director Marketing, EVEREST Group.
W
hat are the specific advantages of using your products? We are concentrating more on application engineering and in helping our customers save on their processes. This innovation has not only compensated on our general sales but even helped us to outperform on our targets. Our application oriented R&D has made it possible to cover wider areas of application, offering cost effective and energy efficient solutions thus creating larger market demand for our product. Probably the most impor tant issue for any industr y today is better resource utilisation, reduction in process time, higher yields and better product quality. The major issue of concern today is low energy consumption per unit of product produced and this objective is a major decision factor which favours the chance of Everest’s product offerings over any other possible alternative. Innovation is the essence of the world today. Resources and market advantages do not matter much. Intellect and innovation do. There is nothing more powerful than the idea whose time has come. We know that performance of the OEM’s design ultimately depends on the quality and dependability of its components. That is why so many manufacturers of Water Treatment Plants, Effluent Treatment Plants, Cement Plants, Aquaculture Farms, Chemical Plants, Paper Plants, Vacuum P l a n t s a n d S y s t e m s, a n d P n e u m a t i c Conveying Systems have entrusted their reputation to Everest. Our broad product line of Roots Blowers (Bi-lobe and Trilobe) (Air/ Gas Duty), Mechanical Vacuum 62 • July 2015
Boosters, Dr y Vane Pumps, Acoustic Hoods and Industrial Vacuum Systems consists of standard and custom models that fall into major product group. E l a b o r a t e o n yo u r m a n u f a c t u r i n g locations, location of plants, investments, technology and human resources. Everest Group currently operates through t h r e e s t a t e - o f - t h e - a r t m a n u fa c t u r i n g fa c i l i t i e s . T h e s e i n c l u d e t h e p a r e n t company Everest Transmission at New Delhi and other two group companies, Everest Blowers Pvt Ltd and Everest Blower Systems Pvt Ltd at Bahadurgarh, Haryana. Facilities include in house R&D, design and development, production, manufacturing, quality control, inspection and after sales service. A l l t h e m a n u fa c t u r i n g fa c i l i t i e s a r e equipped with latest CNC machines from USA resulting in production of world class, reliable and dependable Everest Blowers, Boosters and Vacuum Systems. The top management at Everest is totally committed to quality and is very open t o i n d u c t i o n o f n ew t e c h n o l o g i e s o r business methodologies. In order to keep ourselves updated on the latest trends. Various in-house seminars are organised and the same are conducted by certified quality professionals and management consultants. Apar t from this we also send our personnel to various external training programmes or seminars being organised by organisations like IIT, FICCI, ASSOCHAM, QCI etc. In fact regular training of every employee is also one of our quality objectives and we ensure that every individual in the organisation
undergoes a cer tain number of hours of inter nal or exter nal training ever y quarter. We make sure that there is a skill enhancement in every employee once they undergo any training. Please outline your company’s focus on R &D for engineering innovations. Everest is the first and only Blower and Vacuum Systems manufacturer in the country to have an in-house R&D Centre which is approved by Depar tment of Scientific and Industrial Research, Ministry of Science and Technology, Government of India. Everest Group recently won a National Award for Excellence in Research and Development which was given by our respectable Prime Minister. Approximately 3 per cent of group turnover is earmarked for R&D every year. Design and Development is one thing which never stops at Everest. It is a continual process. Everest has been in an industrial segment with wide application areas. Our marketing team constantly works on identifying areas where our products can revolutionise process. Having identified a niche, our technical team designs and develops products to suit the requirements. For example, our vacuum boosters have found a niche in vacuum distillation processes in menthol industry Chemical Engineering World
Marketing Initiative had relations with such industrial giants. They taught us the missing quality consciousness. Due to its quality consciousness the company could handle prestigious projects for clients like NTPC, BHEL, Ion Exchange, and Thermax. By working with them, we started understanding their terminologies, their minimum requirements, importance of material selection and calibration of equipment. We learnt these over a period of time.
where it has provided huge improvements in processing efficiency. At Everest we believe in diversifying our application engineering and earning out of satisfied customers rather than diversifying the product mix itself. Excellence in application engineering has been a key component in the company’s growth and profitability. Being an indigenous company we at Everest totally understand the cost effectiveness and price implications faced by customers of a developing nation. Also as compared to our international counter parts, Everest has a high quality manufacturing unit in India and hence enjoys the benefit of having lower cost of production. Our management believes in forwarding these benefits/ privileges to our customers, not compromising on quality, performance and services at any time. What are your thoughts on the Quality Assurance Measures? Everest is ISO 9001:2008 certified organisation and the ISO support mechanism itself takes care that our customers receive quality products. The success story of Everest germinates from its commitment to quality. Circa 1980, Everest started manufacturing ‘Twin Lobe Rotary Air Blowers’ when India was importing them from USA. During that period the industrial giant BHEL started a program of Vendor Development, which was intended for stage inspection of various vendors. BHEL invested a lot of money on that program. Then they thought of their engineers training some qualified vendors and improving their level of reliability and quality so that there would be no need for individual component inspection. That was an opportunity for Everest and it was selected as the company was manufacturing quality products and the people were technically sound. In 1985, it developed a Quality Assurance Plan. Based on that plan, it maintained good quality and high standard of products. Moreover, its drawings and designs were standardised and approved. Even before we went in for ISO certification we were maintaining the required records. We were lucky that we Chemical Engineering World
What are the key drivers of your industry? The major driving factor for the industry today is the 'need to change' and bring in cleaner and better ways of production. Rapid industrialisation and ever increasing population is putting a lot of negative impact on our environment. Our future generations shall have to suffer if it continues in the same pace. Strict environmental norms, pollution control, increase in scarcity of water and need for decreasing energy consumption are major challenges of the day and this is what has forced the big industries to re-think on conventional methods of production and introduce newer and environment friendly technologies with lower cost of manufacturing (A typical example of same being the replacement of Steam Jet Ejector by dry type vacuum systems giving heavy saving in cost, quality and performance). Please comment on the marketing strategies that have led to the success of your products in India Everest Group is a Radical Innovator. We expand the market. Most of other players in the industry work as incremental innovators. Incremental innovators focus on trying to grab market share from the competition and fight within the existing market space. Radical innovators go a step further. They create a brand new space for themselves and bring in buyers from two streams: existing and brand new. Our USP, “We don’t just offer blowers, boosters & systems, we offer SOLUTIONS!!!!!” helps us in becoming a radical innovator.
Everest Blower Systems Private Limited Plot No. 6, Sector 16, HSIIDC Industrial Area, Bahadurgarh-124507, Haryana, India T: +91-11-4545 7777 F: +91-11-4545 7718 E: daksh@everestblowers.com W: www.everestblowers.com July 2015 • 63
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Reusable Filter Consumables
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ith a traditional Filter System, the cost of consumables was a major concern. After product’s usage to dispose the consumables in environment was a major concern. Filter Concept accepted the challenges to overcome pollution related problem faced by various industries. As a part of it, Filter Concept has introduced Stainless Steel Filter Cartridges to reduce emission of hazardous contaminants generated by various industries as well as to reduce the
cost of consumables. Stainless Steel Filter Cartridges, which has many advantages, compare to conventional Filter Cartridges like reusable, washable; which helps the industr ies to fulfill environmental pollution control norms across the globe. SS Cartridges are designed to overcome the temperature and chemical compatibility limitations of fabric or synthetic fiber media.
-SS Random Fiber / Sintered Metal Fiber Type -SS Multi Layered Wiremesh Filter Concept is an ISO, OHSAS & CE Certified Company involved in business of Manufacturing & Export of Industrial Filter Systems and Consumables for Air, Gas & Liquid Applications. It’s core business is micron & macron filtration. Filter Concept is one of the largest and fast growing entities dealing in most diverse filtration systems in the world. Filter Concept offer complete filtration solutions to almost all Industries. Their products adhere to highest international quality standards of manufacturing and meet ISO, OHSAS standards and the international design s t a n d a r d s l i ke A S M E , C E , D I N , a n d BS Standards.
This will offer ver y high temperature resistance and can withstand high differential pressure. Stainless Steel Car tridges are offered in various SS grades materials. These elements can be plain cylindrical or in pleated configuration to increase filtration area. Normally all stainless steel pleated and cylindrical filters are supported with coarser filter media to ensure no direct damages to main filtering media under process upsets. A bubble point test can be done to certify that no opening larger than the specified pore size exist in product joints or seams. No media migration occurs due to stainless steel material. These elements can be back washed and reused.
Filter Concept 302, Aalin, Opp. Gujarat Vidhyapith Ashram Road, Ahmedabad, Gujarat T: +91-79-27541602 ; 27540069 F: +91-79-27540801 E: info@filter-concept.com W: www.filter-concept.com
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Reasons For Failures To Occur In Lined Pipe Work
T
he core element of a fluoropolymer lined process, one needs to ensure that the lined piping and fittings have the highest performance level. This also enables the plant to be retained as a multi-purpose unit so that the same equipment can be reused with confidence to make multiple products.
Any discussion on performance needs to cover 3 elements of Lined piping system. 1.The external metals selected for pipes and fittings. 2.The grade and make of fluoropolymer selected. 3.Most important – the processing methods applied for producing the tubes and the type of fit ensured between the metal and lining. Though Lined piping systems particularly PTFE/PFA lining was perceived and promoted as a total solution to handle highly corrosive chemicals at elevated temperatures, it unfortunately does have limitations leading to premature failures which are identified below. There are primary two reasons why field failures can occur in Lined Pipe work. A. When adverse process conditions exist i. Erosion of lining – This is prone to occur when transfer of abrasive media is done at high flow velocity as the plastic liner is soft and therefore easily abraded. ii. Permeation – This problem is a known phenomenon and will exist if the media both gas & liquids are prone to permeate. The piping if not effectively vented externally, it allows corrosion to build up between the metal pipe inner wall and the liner causing deformation of liner and further degrading the liner’s vacuum resistance. Over a period of time this will impinge the flow of fluid through the pipe. iii. Blisters get formed in the top layer of liner due to rapid changes in temperature cycles involving process. Over a period of time the lining fails. iv. Build-up of static charges within the pipe line. The principal source of charging to occur is through tribo charging which when occurs can puncture the liners. Transferring poorly conducting chemicals or solvents there is a high potential to develop electrostatic charges which need to be dealth with. v. Product or media solidification caused by crystallisation inside the pipe line. Chemical Engineering World
July 2015 • 65
Marketing Initiative vi. Swelling in lining due to absorption of media vii. Pressure/ Temperature upsurge which cannot be monitored/ controlled due to process limitations or constraints. viii. Vent holes are blocked by paint or other media ix. Regular maintenance and re-torquing of bolts if not done periodically. B. When poor quality products with improper lining techniques are sourced to save costs failures are imminent. i. Pipes are not able to withstand full vacuum at max specified temp due to loose/ slip fit lining techniques or inadequate liner thickness used resulting in collapse/ bulging of liner. ii. PTFE flares getting cut off at flange ends and or liner shrinks into the pipe.
iii. Liners elongating within the metal pipes resulting in bulging/ blocking the flow iv. Cold spots forming in liner/ mouldings during processing stage. v. Vent holes are not provided by the equipment supplier. vi. Achieving an uneven lining thickness especially in moulded fittings/ valve bodies - a design flaw to maintain min bore dia. A compromising technique adopted to be competitive.
vii. Poor fabrication-weld on flange face not ground off to form a radius from wall to flange/ lap face.
viii. Operating a sinter profile cycle with no adequate and reliable controls to ensure uniform heating and cooling in all the zones of the oven resulting in producing PTFE tubes being either 'under' sintered or 'over' sintered.
ix. Not using correct bolts for installation or awarding the erection contract to
66 • July 2015
a contarctor who has limited or no knowledge in installting lined pipework.
x. Products made from processed/ re-ground, mixed and unproven grades of polymer.
Lined products should be procured in full compliance to material and testing standards as specified in ASTM F 1545. Pipe material, plate flange thickness and liner thickness if not maintained as specified in ASTM/ANSI stds should be rejected and returned to the supplier. Polymer/ Resin processed must be virgin and only proven grades of polymer should be selected/ specified with request for test reports to be provided to support for each batch of sintered tubes. Lining techniques adopted and resulting in loose fit of liner in metal pipe should be rejected and not used. W h e n s e l e c t i n g l i n e d p i p ew o r k d u e consideration needs to be paid to following facts. 1. Pressure – generally more to decide the steelwork – 150/ 300 class. 2. Temperature – The maximum and minimum temperatures and potential for thermal shock and upset conditions to be ascer tained. Lined equipment manufacturer should be able to provide data on pressure v/s temperature for guidelines. 3. Vacuum – A most often ignored aspect but a major source of failure. A good lined piping system should be able to withstand full vacuum at maximum operating temperature for each type of liner listed in the ASTM. In the case of PTFE (200 deg. C) for line sizes upto and including 150 NB should be absolutely possible. The equipment supplier cannot act ignorant or argue that this information was not shared. The liner thickness and lining technique should guarantee and ensure capability to withstand the desired vacuum conditions. For higher sizes the manufacturer should provide the vacuum rating at different temperatures determined
and concluded when carrying out the qualification test as per ASTM F 1545.
4. Media or flow of chemicals being carried can influence the design of piping.
- For permeant services – consideration for selecting type of liner, thickness and venting systems is absolutely essential. - For non-conducting flammable mainly solvents static–dissipating materials are recommended. - Always consider for any upsurge/ nasty conditions which can upset the process parameters. - It is always wor th consider ing the combination of PTFE and PFA lining rather than opt for PTFE/ FEP especially when it is planned to use the same plant and equipment in the future for more severe applications. Horizon stays ahead of competition – the only processor capable of producing an optimised lined piping system wherein the materials, process and techniques applied ensures full strength of metallic pipe and corrosion resistance of the liner.
HORIZON POLYMER ENGG. PVT LTD C-1/B, 1605/1618- GIDC Chhatral- 382729. Dist. Gandhinagar, Gujarat, India. Chemical Engineering World
Safety valves for Oil & Gas industry LESER India launches Type 526 IC and 459 IC UV Stamp
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When others stop, Saurus939 carries on The vacuum pump unique in reliability, performance and consumption.
S
aurus939 has all the Italvacuum experience, a vacuum pump that guarantees unrivalled performance in all the main chemical and pharmaceutical processes, ensuring total recovery of extracted solvents, even in severe operating conditions. A simply designed machine, that combines traditional robustness and reliability with the most evolved technology. Saurus939 has always been the core business of Italvacuum, one of the leading manufacturers of vacuum pumps as well as a worldwide reference point in the design and manufacture of vacuum dryers. Resistance, strength and consumption of oil virtually eliminated thanks to the innovative LubriZero system, that guarantees perfect operation and optimum results with total respect for the environment. Saurus939 has no fear of aggressive and corrosive solvents, powders and condensates, nor distillation by-products. But above all it does not fear confrontation because it is designed and manufactured to work 24 hours a day with a constant excellent performance and minimum operating costs, thanks to a low-energy motor, negligible oil consumption and easy, immediate maintenance. Powerful, efficient, but absolutely safe: Saurus939 guarantees optimum safety through the whole process and complete purity of the final product. In other words, ensures an uncontaminated vacuum. Applications The Saurus939 vacuum pump has a vast range of uses, as it can be used in various sectors ie, Chemicals, Pharmaceuticals, Cosmetics, Oil and Gas, Plastic and Rubber, Bio-science and Waste Management. 68 • July 2015
Processes: Vacuum Drying, Reaction, Distillation, Crystallization, Filtration, Evaporation and Polymerization. Features The design is simple and traditional. The great added value is Italvacuum’s consolidated experience that year after year has perfected, innovated and improved the Saurus939 vacuum pump, guaranteeing optimum operation in all chemical and pharmaceutical processes, such as drying, distillation, reaction and crystallization. Saurus939 can intake both the vapours of common solvents (methyl alcohol, ethylic alcohol, chloroform, acetone, ethyl acetate, methyl chloride, benzene, toluene, isopropyl alcohol , ethyl ether, heptane) as well as those of more aggressive solvents (hydrochloric acid, acetic acid, chlorobenzene, dimethylformamide, acrylonitrile, dichloroethane, cyclohexane, pyridine, dimethyl sulfoxide, dichloromethane). Construction Details Cylinder, pistons, piston rings and head are made of special anti-acid cast iron. The other components are made of cast iron, special steel and PTFE with special charges. The pump is completely sealed: a characteristic that makes it extremely reliable and efficient for a long time, even in damp and dusty environments. The discharge valves have automatic openings and are available in different materials, including Hastelloy. Cooling is by air. Saurus939 has two completely separate, independent lubrication circuits: • one circuit for the process part, with metered injection of fresh oil, thanks to the LubriZero system
• one circuit for the mechanical part with recirculated oil. LubriZero System Saurus939 is equipped with the exclusive LubriZero system that ensures best possible performance with truly negligible oil consumption, completely compatible with the environment. The LubriZero system combines the metered injection of oil with a kit of new materials in PTFE with special charges that are not only resistant to corrosion, but require virtually no lubrication. This also allows for the use of synthetic FDA approved oils. The metered flow of a few drops of fresh oil (about 10 g/h) guarantees an effective barrier from even the most aggressive solvents, considerably increasing the duration of the perfect cylinder-piston coupling and hence the working life of the vacuum pump. Uncontaminated Vacuum Powerful, resistant, efficient, but also completely safe: Saurus939 guarantees maximum safety throughout the whole process and complete purity of the final product. In other words, guarantees uncontaminated vacuum.
Figure 1: Saurus939_double stage with all accessories
Chemical Engineering World
Brilliant technology Italian quality SE Brilliant technology Italian quality Saurus939: Versatile and long life vacuum pump for continuous recovery of the solvents extracted Saurus939:
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EMJAY Unit – I : J – 415, MIDC, Bhosari, Pune – 411026, Tel. No. : (020)ENGINEERS, 66300305. Mr. Jayant Joshi B/102, Shubh Sarita CHS, Shrikirshna Nagar, Unit – II : Plot No. 4/18, Sector No. 10, PCNTDA, Bhosari, Pune – 411026, No.Near : (020) 66146033. EMJAY ENGINEERS, Mr.Tel. Jayant Joshi Appasaheb Sidhaye Marg, Borivali (East), Your vacuum drying Unit–specialist III : J-414, MIDC, Bhosari, Pune - 411026 B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Mumbai 400066 Mobile : 98600 98706, 97663 26240, 7776025551 Appasaheb Sidhaye Marg, Borivali (East), Your vacuum drying specialist marketing@italvacuum.com Tel.400066 02228975275 Mobile 9820047858 E-mail : sanjayraut21@hotmail.com | sanjayraut22@gmail.com Mumbai marketing@italvacuum.com italvacuum.com Website : www.samarthengineers.com, www.samarthengg.in E-mail:electromech.engg.entp@gmail.com Tel. 02228975275 Mobile 9820047858 italvacuum.com E-mail:electromech.engg.entp@gmail.com
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In fact, during the entire work cycle, not even one molecule of oil reaches the processed product. This is certified by the Department of Material Science and Chemical Engineering at the Politecnico of Torino, as part of specific research carried out on a complete process of vacuum drying. The results leave no space for doubt: the final product is absolutely pure with no risk of oil contamination in the process. Best Results Better quality is never an expense: it’s an investment. And investment is always rewarded with good results. Over time the Saurus939 vacuum pump, achieves more, lasts longer and has lower running costs with respect to other main technologies for vacuum systems. The use of oil not only avoids any contamination in the process, but also improves performance and increases pump life, reducing maintenance costs, even in the presence of very aggressive solvents. The choice of materials, technology employed and the appropriate solutions taken by Italvacuum in every design detail make Saurus939 the best in the sector, with reliability and results beyond comparison. Range Saurus939 range includes single stage and double stage models. 70 • July 2015
Accessories The high quality of Saurus939, not only in the unquestionable reliability of the vacuum pump, but also the wide range of accessories, allows for turn-key installation of the entire vacuum group: Atmospheric post-condenser for 1) the recovery of solvents from the pump outlet 2) Condensate recovery tank from the post-condenser outlet 3) Pump suction filter with particle centrifuge separation and metal filtering cartridge 4) Control panel board, also available in compliance with ATEX DIRECTIVE 94/9/ EC 5) Support base for easy, fast installation. Certifications Saurus939 complies with the requirements of the most demanding European Directives : • MACHINERY DIRECTIVE 2006/42/EC • ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2004/108/EC • ATEX DIRECTIVE 94/9/EC. The standard version, CE x II 2G T4/ T3, is suitable for installation in an area classified as ZONE 1-GAS and temperature Class T4 (135°C). The Saurus939 special version can be supplied with ATEX certification up to ZONE 0-GAS (internal pump), ZONE 1-GAS (external pump) with three different classes of temperature T4 / T150°C / T3. Strengths • Complete robustness in any work environment • High resistance against corrosion • High resistance against powder, condensates and distillation by-products recovery • Continuous of the extracted solvents
• Unlimited use over the entire vacuum range • Uncontaminated vacuum and complete purity of final product • Lower operating costs than any other vacuum technology -LubriZero system with negligible oil consumption -Extremely limited environmental costs -Low-energy motors -Easy and economical maintenance • Absence of warm-up cycles and waiting times • Physical separation between process and mechanical parts • Unrivalled performance in the constant recovery of extracted solvents • Low noise (<70 db) and low operating speed (250 rpm) • Low average working temperatures. • ATEX certification up to zone 0. Innovative by Tradition Pushing forward the frontier of innovation every day. This, from the very beginning, has been Italvacuum’s mission, among the world’s leading manufacturers of vacuum pumps and vacuum dryers for the chemical, fine chemical, pharmaceutical and cosmetics industry. Italvacuum is able to realize cuttingedge equipment, particularly suitable for production processes under controlled atmosphere. Top quality, safety and productivity in any application, with a special care for sustainability and total respect for the environment. A reliability guaranteed by an established presence all over the world, with a constantly growing number of installations in both consolidated markets and emerging areas, and by a prestigious collection of national and international patents. In India for vacuum pumps Italvacuum cooperates with EMJAY Engineers, consolidated company based in Mumbai and well rooted in the whole country. Chemical Engineering World
EMJAY ENGINEERS, Mr. Jayant Joshi B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Appasaheb Sidhaye Marg, Borivali (East), Mumbai 400066 Tel. 02228975275 Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com
Your vacuum drying specialist marketing@italvacuum.com italvacuum.com
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CEW Products Humidity and Temperature Calibrator
Advanced Liquid Advanced Liquid Ring Technology
HygroGen has become the benchmark for transportable RH and temperature calibrators. The second generation HygroGen builds on the excellence of the first series with higher specifications, additional features and improved design. Using a state-of-the-art embedded controller with touch screen user-interface has been developed to provide the user with simplified setup and configuration tools. This includes a programmer function so that multiple set-point changes can be user-defined. The embedded platform also provides additional features such as an integrated nine port USB hub, external DVI monitor connection, integrated data acquisition and calibration adjustment software.
Pompetravini’s experience in manufacturing of liquid ring vacuum pumps acquired over the years has led to the creation of new improved liquid ring pumps that offer optimum performance and reliability They offer minimal water consumption and an innovative impeller design that assure extremely Pompetravini’s experience in manufacturing of liquid ring quite operation and extending its life even under vacuum pumps acquired over 70 years has led to the creation of new improved liquid ring pumps that offer harsh condition.
For details contact: Jupiter Electronics A-401 & G 414-416 Kailash Indl Complex B/h Godrej Colony, Parksite Vikhroli (W), Mumbai 400 079 Tel: 022-67551606, 25185474 Fax: 91-022-25170867 E-mail: sales@jupiterelectornics.co.in or Circle Readers’ Service Card 1
Ring Pumps
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Pompetravaini has the most advanced manufacturing process with the objective to reduce manufacturing and delivery time. Toshniwal leader in vacuum engineering now provide further solution to your vacuum Toshniwal leader in Vacuum Engineering over 40 years, now provide further solution to your vacuum needs. needs. For Details contact:
Toshniwal Instruments (Madras) Pvt. Ltd.
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
267 Kilpauk Garden Road, Chennai - 600 010. India / Tel: +91(0)44 26448983 / 8558 Fax: +91(0)44 - 26441820 / Email: sales@toshniwal.net Web : www.toshniwal.net
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pH Meter The HI2202 edgeblu pH meter uses Hanna’s HALO pH electrodes with Bluetooth Smart technology (Bluetooth 4.0) that connect wirelessly to edgeblu or a compatible iPad running the Hanna Lab App. The edgeblu has a 5.5” LCD and a sensitive capacitive touch keypad. edgeblu is simple to configure, calibrate, measure, log, and transfer data to a computer or a USB drive. The edgeblu includes Hanna’s exclusive CAL Check feature to warn if the HALO pH electrode being used is not clean or if the calibration buffers are contaminated. A probe condition indicator is displayed after calibration showing the overall state of the pH electrode. Each edgeblu is supplied with the HI11102 HALO Bluetooth pH electrode. The HALO allows the probe to operate on a single CR2032 battery for approx 500 hours. The HI11102 HALO pH electrode is a double junction, gel filled, glass body pH electrode with a built-in thermistor temperature sensor, allowing readings to be automatically compensated for temp variations. The HALO pH electrode transmits measurement data up to 10 meters. Each HALO pH electrode is automatically detected, the edgeblu or an iPad running the Hanna Lab App, transferring pH sensor type, serial number, and calibration data. The Hanna Lab App is a free application that turns the iPad into a full-featured pH meter when used with a Hanna HALO pH electrode. Functions include calibration, measurement, continuous data logging, graphing, and data sharing. Measurement and logging of pH and temperature at one-second intervals start as soon as the probe is connected. Measurements can be displayed with tabulated data or as a graph. The graph can be panned and zoomed with the iPad’s pinch-to-zoom technology for enhanced viewing. For details contact: Hanna Equipments (India) Pvt Ltd 3/4/5/6, Aum Sai Bldg, Plot No: 23 C Sector 7, Kharghar, Navi Mumbai 410 210 Tel: 022-27746554, 27746555 | Fax. 91-022-27746557 E-mail: sales@hanna-india.com or Circle Readers’ Service Card 3
72 • July 2015
Chemical Engineering World
Cooling - Scrubbing - Conveying Venturi and jet scrubbers provide for clean air • separation of dust • direct gas cooling • removal of pollutants (SO2, Cl2, HCl, NH3, HF, etc.)
• gas conveying without fan Körting Hannover AG 30453 Hannover/Germany Tel.: +49 511 2129-258 st@koerting.de
www.koerting.de Wäscher-175x120-Proposal for India-150717.indd 1
17.07.2015 10:31:18
CEW Products SS Seamless Pipes, Tubes & “U” Tubes Suraj Ltd, an ISO-9001, 14000, BS OHS 18001 certified company offers stainlesss steel seamless pipes (up to 12 metre long, all austenitic, ferritic, duplex and super duplex stainless steel), tubes up to 30 metre long and “U” tubes in various sizes (6.0 mm OD to 323.9 mm OD), specifications (as per ASTM, ASME, EN, NFA, JIS Standards), thickness (0.8 mm to 25 mm), grades and also as per customer’s requirements. Suraj has strong presence in the global market. It finds a application in refinery, petrochemical, food, pharma, fertilizer, oil and gas, breweries,sugar, ship building, etc. The company specialises in heat exchangers, heating elements, surface condensers, evaporators digestors, instrumentation tubing and fluid piping. Suraj also holds various certificates for quality in accordance with AD2000 MERKBLATT W0 and Pressure Equipment Directives [PED] 97/23/EC from TUV, NORD and supply our above products under all National and International Third party Inspecation authorities. SURAJ also have their own Testing Labortories. To undertake various tests such as Hydro, Eddy Current, PMI, IGC, UT, RT, Spectro analysis, Mechanical properties and many others as per customers and specification requirements. For details contact: Suraj Ltd Suraj House, Opp: Usmanpura Garden Ashram Road, Ahmedabad Gujarat 380 014 Tel: 079-27540720, 27540721 | Fax: 91-079-27540722 E-mail: suraj@surajgroup.com or Circle Readers’ Service Card 4
Uniformance Technology Boosts Asset Uptime Honeywell Process Solutions (HPS) offers Uniformance Asset Sentinel, which continuously monitors equipment and process health, assisting industrial facilities to predict and prevent asset failures and poor operational performance. The new offering expands HPS’ Uniformance software suite and supports the emergence of the Industrial Internet of Things (IIoT) in the process industry, enabling companies to collect, organize and analyze data for a specific asset or “thing.” These analytics can transform work processes from reactive to proactive, helping industrial plant operators avoid unplanned downtime and improve plant performance and safety. The technology works by continuously accessing data from a variety of sources, including process parameters, vibration data and alarms. Using a real-time complex event processing engine, Uniformance Asset Sentinel continuously performs performance, health, efficiency and safety-related calculations and compares those results of the current actual performance to an expected performance model. Predicted or detected deviations from these models are used to generate notifications to facilitate investigation and intervention to minimize the cost and frequency of an event. Uniformance Asset Sentinel’s pre-defined best practice templates for more than 100 equipment types, such as pumps, compressors, exchangers, valves and turbines combined with its seamless interface to its process design simulation software (UniSim Design) helps customers rapidly deploy equipment or process monitoring on any plant asset, eliminating the need for complex model development. Several major refining and chemical facilities are now implementing Uniformance Asset Sentinel to help them overcome the challenge of accessing data from multiple sources and turning it into actionable information. In addition to the positive impact on safety, this capability can translate into higher operational efficiency, agility and, ultimately, higher margins. For details contact: Honeywell Automation India Ltd 56 & 57 Hadapsar Indl Estate Hadapsar, Pune, Maharashtra 411 013 Tel: 020-66039400 | Fax: 91-020-66039800 or Circle Readers’ Service Card 5
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Chemical Engineering World
Mumbai 400066 Tel. 02228975275 Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com
marketing@italvacuum.com italvacuum.com
Plot No.1, Door No. 3/7, Krishnaveni Ammal Street, Thirumalai Nagar, Ramapuram, Chennai - 600 089. Telephone : 044-24863811, Web: www.dynamiccontrols.in, E-mail: sales@dynamiccontrols.in, admin@dynamiccontrols.in, dynamic.dcs@gmail.com
AUTHORISED STOCKIST
D.K. Instruments Pvt. Ltd.
CEW Products Gasket Tape De Dietrich Process Systems has endorsed and will provide support for GORE Gasket Tape Series 1000, a new sealant product from W L Gore & Associates. GORE Gasket Tape Series 1000 was developed to meet the sealing challenges of glass-lined steel equipment utilizing aggressive media under demanding process conditions such as high temperatures, alternating system pressures, limited gasket loads and deviation of sealing surfaces. The new Gore product incorporates a unique barrier core, which enables it to maintain an extratight seal across the full width of the flange even at low loads, and even in the presence of highlypermeating media. Manufactured in the form of a highly-conformable spooled tape, Series 1000 is optimized for use in large (≥DN 600/ASME 24”) or non-standard flanges typically found in columns, mixer vessels, reactors, storage and receiver tanks. With Series 1000, gaskets can be customized on-site, as needed. This eliminates the need for offsite fabrication of large gaskets, and the associated long lead times and complicated logistics for shipping, handling and installation. With Series 1000, gasket inventories can be streamlined, and inventory costs reduced. For details contact: De Dietrich Process Systems Pvt Ltd B-Wing, 807 Sagartech Plaza, Andheri Kurla Road, Nr Saki Naka Junction, Andheri (E), Mumbai 400 072 Tel: 022-67424272 E-mail: sales@dedietrich.co.in or Circle Readers’ Service Card 6
Diaphragm Valve GF Piping Systems adds the new diaphragm valve Type 604/605 with integrated pneumatic actuator to its product range. The valve´s compact design fits standard installation lengths. The valve is flexible in its operating modes and offers fail safe to close (FC), fail safe to open (FO) and double acting (DA) options. The connection with the valve body is full plastic without any metal parts. Therefore all materials have the same temperature expansion coefficients which prevents leakages and avoids re-torqueing of screws. Thanks to the optimized linear flow characteristics the kv value is up to 30 per cent higher than with comparable valves. The valve is available in DN15 with the pressure rating of PN6. The valves are available in PVC-U, CPVC, PP-H and PVDF. Diaphragms in EPDM, FPM, PTFE/EPDM and PTFE/FPM enable the handling of aggressive media as well as neutral fluids. Valve Type 604 can be mounted into your system with true union connection matching all standard GF unions and inserts and solvent cementing. Type 605 has a spigot for welding resp cementing. The valves meet the standards ISO, BS, ASTM and JIS. The new diaphragm valve will communicate with you as well. A unique QR code on the product leads to installation manuals, online training videos and certifications. For details contact: Georg Fischer Piping Systems Pvt Ltd Plot No 9-B 1 st Floor, Kopri Village Powai, Mumbai 400 076 Tel: 022-40072000 | Fax: 91-022-40072020 E-mail: branchoffice@georgfischer.com or Circle Readers’ Service Card 7
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Products CEW Improved Sealing Capability with ePTFE Gaskets In the chemical industry, polytetrafluoroethylene (PTFE) has several advantages. Nonetheless, PTFE has one disadvantage: it is mechanically week. To address this disadvantage, a unique process was developed with a combination of heat and rapid expansion, PTFE could be stretched to form a strong, porous material: expanded PTFE (ePTFE). In addition to the almost universal chemical resistance properties of PTFE, ePTFE has indeed enhanced strength and creep (cold flow) resistance under high loads and temperature, making it an ideal material for industrial flanges. GORE® Gasket Tape Series 500 is available on a spool and the user may customize a gasket on the flange in minutes. The tape form can eliminate unnecessary downtime while waiting for custom-produced gaskets to be applied offsite. The adhesive backing holds the gasket in place securely resulting in a quicker and safer installation. The microstructure of gasket tapes such as GORE Gasket Tape Series 500 results in greater reliability. For details contact: W L Gore & Associates (Pacific) Pte Ltd 802, A-Wing, 215 ATRIUM, Andheri-Kurla Road Chakala, Andheri (E), Mumbai 400 059 Tel: +91 22 67687000 or Circle Readers’ Service Card 8
Multistage Vertical In-Line High Pressure Pumps KSB has further enhanced range of materials for its existing range of pump Series – Movitec B. Multistage, vertical in-line high pressure pumps, Movitec B; are now available in complete SS materials in addition to the existing version of Cast Iron (VCF). These versions will be known as VF and VSF having SS-304 and SS-316 grades respectively. Movitec pumps are capable of handling variety of applications like RO plants, irrigation systems, pressure boosting, washing plants, chemical applications, HVAC system, etc. Pumps are available in 2, 4, 6, 10, 15 sizes. Higher sizes can also be made available on request. These pumps can generate a flow up to 22 cu metres per hr with the head up to 250 metres. And can handle liquid having temperature between -20 and +140 degree Celsius with a pressure of 25 bar. For details contact: KSB Pumps Ltd Mumbai-Pune Road Pune Maharashtra 411 018 Tel: 020-27101000, 2710 1233 Fax: 91-020-27426000 E-mail: bipin.kode@ksb.com or Circle Readers’ Service Card 9
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CEW Products Remote Collaboration Software GE Oil & Gas offers InspectionWorks Connect, a remote collaboration software platform for the nondestructive testing (NDT) and inspection industry. InspectionWorks Connect provides real-time access to live inspection video and data from anywhere in the world, which enables smarter, faster decision-making, improves inspector productivity and reduces training costs. Technological advancements, such as InspectionWorks Connect, allow organizations to operate with greater inspection productivity, conduct more accurate, consistent inspections and shorten the learning curve for new inspectors. Real-time collaboration during asset inspections can deliver many asset reliability, process safety management (PSM) and productivity benefits for asset owners. Inspection Works Connect is a secure, encrypted solution that is embedded on NDT devices without the use of any additional equipment. It is also zero-install, which means that users only need a web browser to log in remotely. Inspection Works Connect provides: live video streaming of inspections; collaboration tools, including 2-way chat communication and telestration; cloudbased infrastructure; wireless connectivity; and over-the-air software updates. InspectionWorks Connect is currently available for use with visual inspections on the GE XLG3 and GE Mentor Visual iQ Videoprobes, as well as the Mentor EM eddy current portable. For details contact: GE Sensing & Inspection Technologies Gmb Robert-Bosch-Str 3, Hürth, 50354 Germany E-mail: chris.janssens@ge.com / nate.pepper@ge.com or Circle Readers’ Service Card 10
Moisture Analysis Servomex has updated its DF-700 ultra-trace moisture analyzer range with new firmware and an improved user interface. Optimized for semiconductor, LED and specialty gas applications that depend on exceptional ultra high purity (UHP) gas quality, Servomex DF-700 moisture analyzers offer exceptional accurate and repeatable performance. The DF-700 Series utilizes Servomex’s Hummingbird Tunable Laser Diode (TDL) sensing technology, which delivers robust reliability and industry-leading sensitivity when analyzing moisture at ultra-trace levels. The ultra-sensitive measurement is enabled by the direct measurement of moisture in the infrared spectrum. This exceptional measurement is further improved by brand new firmware that ensures exceptional low-end stability. Specially designed to eliminate the spurious effects of background noise at very low ppb levels, the resultant performance produces a stable measurement that meets the most demanding requirements of semiconductor manufacturers. In addition, a new graphical menu interface has been designed. Seven different models are available: the DF-730 (measuring moisture in HCl), DF-740 (moisture in ammonia) DF-745 (high sensitivity electronic gases) and DF-745 SGMax (specialty gas trace moisture), DF-749 (ultra-high purity electronic gases) and DF-750 (ultra-trace quality control for semiconductor fabs). The DF-760E combines the DF-750 and the recently upgraded DF-560E analyzer into the same 19” package for the unique combination of oxygen and moisture measurement from a single product; the new firmware not only improve trace moisture analysis performance but delivers an unprecedented trace oxygen measurement of 45ppt LDL. For details contact: Spectris Technologies Pvt Ltd Servomex - India Business, Systems Engg and Service Centre Plot No: A-168 MIDC TTC Indl Area, Thane-Belapur Road Khairane, Navi Mumbai 400 709 Tel: 022-39342700 | Fax: 91-022-39342701 E-mail: MEI_sales@servomex.com or Circle Readers’ Service Card 11
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ChemTECH Chennai 2015 Dates: 10-12 December, 2015 Venue: TNTPO, Exhibition Ground, Chennai Details: World meet of chemicals, petrochemicals, pharma and process industry in India encompassing exhibition and conferences. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com ChemTECH Gujarat 2016 Dates: 10-12 February, 2016 Venue: Ahmedabad, India Details: World meet of chemicals, petrochemicals, pharma and process industry in India encompassing exhibition and conferences. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
2015 SNO Conference Dates: 8 - 10 November, 2015 Venue: Portland, USA Details: This year’s SNO conference sessions will be organized around selected ‘systems’, eg, air-water systems Organiser: Sustainable Nanotechnology Organization Email: info@susnano.org Website: http://susnano.org/ POWTEX OSAKA 2015 Dates: 14-16 October, 2015 Venue: International Exhibition Centre, Osaka (INTEX) Details: The 11th Powder Technology Exhibition Osaka Organiser: The Association of Powder Process Industry & Engineering Contact: +86 10 6422 2898 Email: info2015@powtex.com Website: www.intex-osaka.com
AUTOMATION 2015, 10th Edition Dates: 24-27 August, 2015 Venue: Bombay Exhibition Centre, Mumbai Details: Showcasing technologically empowered machineries catering to Industrial Automation, Factory Automation, Robotics, Logistics, Hydraulics and Pneumatics and more Organiser: IED Communications Ltd Contact: +91-22-22079567 / 22073370 Email: jyothi@iedcommunications.com Website: www.iedcommunications.com Aquatech India 2015 Dates: 11-13 August, 2015 Venue: Pragati Maidan, New Delhi Details: Showcase the latest products and innovations in process, drinking water and waste water Organiser: Amsterdam RAI Contact: +31 20 549 1212 Email: aquatech@rai.nl Website: www.aquatechtrade.com Chemical Engineering World
Biorefinery I Dates: 27 Sept - 2 Oct, 2015 Venue: Chania (Crete), Greece Details: An event on chemicals production from renewable resources Organiser: Engineering Conferences International Contact: 1 212 514 6760 Email: info@engconfintl.org Website: www.engconf.org Plastics Recycling Show 2015 Dates: 25-26 November, 2015 Venue: Belgium Details: European exhibition & conference for plastics recycling Organiser: Engineering Conferences International Contact: +32 2 742 96 82 Email: info@plasticsrecyclers.eu Website: www.plasticsrecyclers.eu July 2015 • 79
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 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 400-TPD 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 H2SO4 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 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, 0.30TPM 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-m3/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. Astrica Laboratories is implementing a 240-TPA synthetic organic chemicals manufacturing project at a cost of ` 78.8-million in village: Ananthsagar, district: Medak, Telangana. Team Labs & Consultants are the environmental consultants. The project will come up on 6.97-acre of land. According to MoEF sources, it is proposed to treat all HTDS effluent in stripper followed by MEE and ATFD. All LTDS effluent including domestic effluent shall be treated in biological treatment followed by RO system. RO rejects sent to MEE and permeate is used for cooling towers as make up. Solid wastes are generated from the process, solvent distillation, collection/neutralization tank, waste oil from DG sets, used batteries from DG sets. The ash from boiler is sold to brick manufacturers. The solid wastes; evaporation salts, wastes from the process in inorganic form, ie, process salts and filtration aids shall be disposed to the TSDF, while the hazardous wastes of organic nature, i.e, distillation residues shall be disposed to authorized cement units and other wastes like used oil and 80 • July 2015
used batteries shall be sent to authorized recyclers. The sludge from treatment plant shall be sent to TSDF. The basic technology involved in the manufacturing of bulk drugs is the process kettles, heat exchangers, centrifuges and storage tanks. To support the process, equipment boilers, chilling plants, cooling towers, etc, are required. All the above equipment can be sourced indigenously. 80 per cent of civil work has been completed and remaining 20 per cent is in progress. The project is scheduled for completion in December 2015. 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. Lakhani Dyestuffs is implementing a 100-TPM reactive dyes manufacturing project in MIDC, Ambernath (W), district: Thane, Maharashtra. Environmental clearance has been received for the project. Land has been acquired and civil work is in progress. The project is scheduled for completion in H2 2015. 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. Superhouse is planning an expansion of its chemical mixmanufacturing project from 200-kg/day to 500-kg/day in UPSIDC Industrial Area, district: Unnao, Uttar Pradesh. The product will be used in leather tanneries. The project will involve installation of containers. The project is in planning stage. Stellar Chemical Laboratories is planning an expansion of its organic chemical manufacturing project from 7.1-TPM to 84.1-TPM in village: Derol, district: Panchmahals, Gujarat. Machinery is yet to be ordered. Work on the project is expected to commence after receipt of environmental clearances and the completion date is yet to be finalized. • MINING DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance. Mining work is expected to commence in December 2015. According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls in agricultural land (outside river bed). Method of mining will be opencast semi-mechanized without drilling and blasting. The mine will Chemical Engineering World
Project Update CEW be excavated out in layers up to a depth of 3-m in riverbed and 9-m in agricultural field. Letter of Intent (LOI) for mining contract has been granted for a period of 9 years. Barmer Lignite Mining Company, a JV between Rajasthan State Mines & Minerals & Raj West Power, a subsidiary of JSW Energy is planning an expansion of the Kapurdi Open Cast Lignite Mining project from 3.75-MTPA to 7-MTPA in Kapurdi, district: Barmer, Rajasthan at an estimated cost of ` 18,000-million inclusive of a new lignite mining project at Jalipa mines. The project is waiting for environmental clearance. • NON-CONVENTIONAL ENERGY Kranthi Edifice is implementing a 20-MW solar photovoltaic power project in village: Tadoor, district: Mahabubnagar, Telangana. The estimated cost of the project is ` 1.2-billion. The project is being set up on 100-acre of land. Equipment supplier is under negotiation. Civil work is done in-house. Power generated will be sold to Telangana State Transmission Corporation (TSTRANSCO). The project is scheduled for completion in September 2015. Karnataka Renewable Energy Development is planning a 10-MW solar power project at an estimated cost of ` 600-million (approximately) in village: Tingloor, taluka: Madhugiri, district: Tumkur, Karnataka. Surana Telecom And Power has received Letter of Award (LoA) for development of the project. Maharashtra State Power Generation Company is planning a 50-MWp solar photo voltaic power project in Gangakhed, district: Parbhani, Maharashtra. The company is scouting for land. Other details are yet to be finalized. Azure Power India is implementing a 10-MW solar photovoltaic power project in taluka: Hiriyur, district: Chitradurga, Karnataka. PPA has been signed with Bangalore Electricity Supply Company (BESCOM). Civil work and panel installation work is in progress. Government of Odisha is planning a 20-MW solar power plant in Manmunda, district: Boudh, Odisha. Green Energy Development Corporation of Odisha is the nodal agency. According to reports, the nodal agency has identified about 120-acre of land at Manmunda for establishment of the project. Land has been allotted to the agency from the industrial park area earmarked by Odisha Industrial Infrastructure Development Corporation (IDCO).The EPC tender is for development of the power plant and maintenance for a period of 10 years. Apart from the Boudh project, the agency is in the lookout for additional land in Koraput, Kantamal and Bolangir areas for installing about 200-MW solar energy capacity. ACME Solar Energy is planning a 30-MW solar photovoltaic independent power project at a cost of ` 2.4-billion in Chhattisgarh. The company is a JV between ACME Cleantech Solutions, EDF Energies Nouvelles (EDF EN) and EREN, Luxembourg. PPA is yet to be signed with Chhattisgarh State Power Distribution Company (CSPDCL). The project is in planning stage. The project is planned for completion in 1-year from zero date. • THERMAL POWER Rain Cements is planning a 7-MW waste heat recovery-based power plant in village: Boincheruvupalli, Peapully Mandal, district: Kurnool, Andhra Pradesh. The estimated cost of the project is ` 700-million. The project will come up in the existing cement plant premises. The project will generate up to 7-MW of gross electrical energy from the waste heat and the flue gases evolved during the cement manufacturing process. The project that will be financed by a combination of internal accruals and bank loans is expected to be completed in about 14 months. The Board of Directors of the company had approved of the project at its meeting held on 27th February, 2015. Chemical Engineering World
July 2015 • 81
Project Update CEW Seven Star Steels is planning an expansion of its thermal (coal-based) captive power project from initial 8-MW to 12-MW at a cost of ` 600-million in village: Kalendamal, district: Jharsuguda, Odisha. The project will come up along with an expansion of its sponge iron plant from 60,000-TPA to 180,000-TPA and ingot plant from 39,200-TPA to 80,000-TPA. Machinery will be partially procured locally and partially imported; orders are yet to be placed. The project is waiting for industrial clearance. Work on the project will commence soon. Raichur Power Corporation, a JV between Karnataka Power Corporation and Bharat Heavy Electricals plans a 800-MW coal-based super-critical power project at an estimated cost of ` 88,062.3-million in village: Edlapur, district: Raichur, Karnataka. This is an expansion of the Raichur TPP by addition of 800-MW and would generate 5,957-MU of energy annually. According to MoEF sources, 382-million tonnes of coal to KPCL has been allocated in DeochaPachami Coal Block in West Bengal, which has a total reserve of 2,012-million tonnes. The blended coal 2.92-MTPA (indigenous coal of 2.044-MTPA (70 per cent) and imported coal is 0.876-MTPA (30 per cent)) will be used for the proposed TPP. Edlapur TPS is proposed to be commissioned in 51 months from zero date. Imported coal would be utilized. Coal would be transported by rail for the entire route from mines to power plant site. Clearances for the project are received from Airports Authority of India and Archaeological Survey of India, Health & Family Welfare Department and Fisheries Department, GoK. The project is waiting for environmental clearance. Work will commence after receipt of clearances from MoEF. Birla Corporation is planning a 50-MW captive power project in district: Nagaur, Rajasthan. The project will come up as a part of its integrated cement project. Land acquisition is in progress. Further details of the project are yet to be finalized. ARS Metals is planning an 8-MW waste heat recovery-based captive power project in Naidupet, district: Sri Potti Sriramulu Nellore, Andhra Pradesh. The project will come up as a part of its 4-phase greenfield integrated steel project in the same location, which is also in planning stage. The power generated will be used for the upcoming greenfield integrated steel plant. The project is waiting for environmental clearance. 58-acre of land has been allotted by APIIC for the project. The entire project is planned for completion in 30 months from zero date. Adani Power Rajasthan is planning an expansion of Kawai Thermal Power Plant in Kawai, district: Baran, Rajasthan. The capacity will be augmented from 1,320-MW by addition of 2x800-MW. The project is waiting for environmental clearance. Anantha Power Projects is planning a 3x2.6 MW hydro-electric power project at village: Mohanpur, district: Rajnandgaon, Chhattisgarh. The company is in final stages of placing orders for machinery. Clearances have been received. Work on the project commenced in September 2014 and is planned for completion in September 2015. Astrix Laboratories is planning a 5-MW coal-based captive power project in village: Gaddapotharam, district: Medak, Telangana.The project will come up along with a modernizationcum-expansion of its API manufacturing project. The estimated cost of the total project is ` 600-million. The project is waiting for environmental clearance and planned for completion in 2 years from zero date. Neyveli Lignite Corporation is planning the 4,000-MW Sirkali Thermal Power Project in Sirkali, district: Nagapattinam, Tamil Nadu. The project will spread over an area of 1,221.82-hectare of land. Phase-1 will consist of 1,980-MW at an estimated cost of ` 144.82-billion. Phase-2 will consist of 2,020-MW. Action has been initiated for preparation of Feasibility Report (FR) for coal jetty and marine EIA study. The company is to expedite the issue of administrative sanction for acquiring land. Letter of Award (LoA) for consultancy services for the preparation of FR has been issued to Tractebel, which is in progress. Chemical Engineering World
July 2015 â&#x20AC;˘ 83
CEW Ad Index Sr. No.
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Chemtech Events
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Book Shelf CEW A Working Guide to Process Equipment, Fourth Edition Author : Norman Lieberman, Elizabeth Lieberman Price : USD 60.95 Pages : 624 (Hardcover) Publisher : McGraw-Hill Professional About the Book: The latest methods for troubleshooting and maintaining process equipment; applicable to a broad range of technicians and industries and fully updated throughout, A Working Guide to Process Equipment, Fourth Edition, explains how to diagnose, troubleshoot, and correct problems with chemical and petroleum refining process equipment.
Process Technology Equipment and Systems Author : Charles E. Thomas Price : USD 105.65 Pages : 544 (Paperback) Publisher : Delmar Cengage Learning About the Book: Developed by the recognised authority in the field, PROCESS TECHNOLOGY EQUIPMENT AND SYSTEMS, 4e introduces you to the concepts and techniques used in today’s most sophisticated manufacturing facilities. This book delivers technical accuracy along with an engaging writing style, and supports readings with full-colour graphics and photos that show how systems and equipment operate in the real world. Chapters explore the workings of valves, vessels, and piping; pumps and compressors; motors and turbines; heat exchangers, cooling towers, boilers, and furnaces; reactors and distillation; extraction and separation systems; process instrumentation; and much more. Upholding the tradition of excellence established by the first two editions, PROCESS TECHNOLOGY EQUIPMENT AND SYSTEMS, 4e can help launch your career as a process technology technician! Industrial Megaprojects explains the underlying causes of over-budgeted, delayed, and unsafe megaprojects: poor project management, destructive team behaviours, weak accountability systems, an almost pathological focus on the short-term, and the unwillingness to invest in deep technical expertise. Modern life as we know it relies on the success of these projects. Leaders and stakeholders of future megaprojects would be wise to heed the warnings and take note of the best practices outlined in this book.
Chemical Process Equipment, Third Edition: Selection and Design Author :james R Couper, W Roy Penney, James R Fair Price : USD 121.43 Pages : 864 (Hardcover) Publisher :Butterworth-Heinemann About the Book: Chemical Process Equipment is a results-oriented reference for engineers who specify, design, maintain or run chemical and process plants. This book delivers information on the selection, sizing and operation of process equipment in a format that enables quick and accurate decision making on standard process and equipment choices, saving time, improving productivity, and building understanding. Coverage emphasises common real-world equipment design rather than experimental or esoteric and focuses on maximising performance.
Process Plant Equipment: Operation, Control, and Reliability
• Legacy reference for chemical and related engineers who work with vendors to design, specify and make final equipment selection decisions.
Authors :Michael D Holloway, Chikezie Nwaoha, Oliver A Onyewuenyi Price : USD 125.67 Pages : 728 (Hardcover) Publisher : Wiley
• Copious examples of successful applications, with supporting schematics and data to illustrate the functioning and performance of equipment.
About the Book: Discover how to optimise process plant equipment, from selection to operation to troubleshooting. From energy to pharmaceuticals to food, the world depends on processing plants to manufacture the products that enable people to survive and flourish. With this book as their guide, readers have the information and practical guidelines needed to select, operate, maintain, control, and troubleshoot process plant equipment so that it is efficient, cost-effective, and reliable throughout its lifetime. Following the authors’ careful explanations and instructions, readers will find that they are better able to reduce downtime and unscheduled shutdowns, streamline operations, and maximise the service life of processing equipment. Chemical Engineering World
• Provides equipment rating forms and manufacturers’ data, worked examples, valuable shortcut methods, and rules of thumb to demonstrate and support the design process. • Heavily illustrated with line drawings and schematics to aid understanding, as well as graphs and tables to illustrate performance data. July 2015 • 87
CEW Interview
Interview CEW
Empowering Information Mobility
Anne-Marie Walters
Atanu Pattanayak
88 • July 2015 Chemical Engineering World
With its comprehensive range of software and services for the design, construction, and operations of infrastructure across multiple industries, including process manufacturing, water and wastewater, power generation, and oil and gas, Bentley Systems has been able to meet varied requirements of its clients in India, says Atanu Pattanayak, Vice President & Managing Director, Bentley Systems India Private Limited. According to Pattanayak, Bentley has devoted ‘considerable time to educating these organisations on the benefits of moving beyond software for design.’ Harshal Y Desai also seeks views of Anne-Marie Walters, Industry Marketing Director – Process, Bentley Systems, Incorporated, on how Bentley’s ‘commitment and approach’ differ from its competitors.
July 2015 • 88
Interview CEW How well established is Bentley in India in the sphere of Process Manufacturing, Water and Waste Water, Power Generation and Oil & Gas? Will you please briefly update our readers on the number of jobs you are/will be undertaking in near future in India? Atanu Pattanayak: Our users in India have been successfully employing our software and delivering desired results not only for projects in India, but also for a number of international projects. Bentley users in India submitted 74 project nominations for the 2015 Be Inspired Awards programme, 50 project nominations for the 2014 Be Inspired Awards programme, and close to 90 project nominations for the 2013 Be Inspired Awards. Pall India, based out of Pune, won the Be Inspired award in 2013 in the Innovation in Process & Manufacturing category. Bentley globally is a leader in software for sustaining water and wastewater infrastructure around the world, including in India. A number of the major AEC firms, like CDM, MWH, Black & Veatch, CH2M HILL, use our software tools, with some of our most notable users in the oil and gas industry being Reliance, Essar, BPCL, and IOCL. How is the demand for advanced software reflected in the Indian market? Will you please cast some light on the latest trends that are driving the market for companies like Bentley in India? Pattanayak: Indian infrastructure organisations have been adopting advanced design and analysis tools for quite some time. In the last four to five years, Bentley has devoted considerable time to educating these organisations on the benefits of moving beyond software for design and analysis to also include solutions for construction, operations, and maintenance. For this to happen, information has flow from the design stage through construction and, ultimately,
into operations. This requires software that empowers information mobility (among disciplines as well as across the infrastructure lifecycle), which is a hallmark of Bentley offerings. Other trends that have a lot of potential in India and elsewhere include asset performance management and risk-based inspection for enhanced asset performance. Bentley is a leader in these areas. Integrated refinery and petrochemical operation is one of the prevailing trends in the country. Can OpenPlant and AssetWise suites be of great use for the same? Please elaborate. Anne-Marie Walters: Both OpenPlant and AssetWise products are able to provide significant benefits to integrated refineries and petrochemical operations. OpenPlant is used by engineers for the engineering design and construction phases of plant projects of all types, including large and complex integrated refineries and petrochemical projects – which generally involve multiple EPC firms. Leveraging ISO 15926 as its native data model, OpenPlant is uniquely able to bring together data from multiple engineering systems to normalise the information as it moves across them and resolve any engineering differences. The software is able to produce the required deliverables for procurement, fabrication, and construction from a single managed source, reducing risks and streamlining information sharing and workflows across multiple project participants. OpenPlant is also able to provide high-quality, open information for handover to operations. Our AssetWise platform is focused on improving asset performance during operations. Its applications help operations and maintenance personnel reduce costs, improve safety, and increase efficiency. AssetWise APM (asset performance management) supports a
reliability and risk-based approach to maintenance, while AssetWise Amulet enables operational decision support input from performance and maintenance history and conditions sensors, applying predictive and prescriptive analytics to improve safety and throughput. Our AssetWise ECM (engineering content management) offering manages asset data across the lifecycle, from projects through operations to decommissioning. AssetWise ECM ensures engineering information is always accurate, up to date, and reliable for improved decision making and regulatory purposes. At ARC Advisory Conference, Mr Greg Bentley had spoken about ‘extending its offerings beyond design modelling and project collaboration services to address the challenge of sustaining infrastructure across its entire lifecycle.’ Will you please throw some light on this statement? Walters: Bentley’s 30 years of cumulative BIM advancements began with its growing portfolio of information modelling applications spanning all infrastructure disciplines in design modelling. In response to demand for virtualisation of talent, streamlined and secure collaboration, and comprehensive engineering content management to accommodate the needs of distributed project teams, Bentley introduced ProjectWise in 1998. Advancing from visualisation into visibility, Bentley began to add analytical modelling for simulation of behaviours, to ‘optioneer’ infrastructure improvements. Next it made it possible for design work to be sustained and referenced within overlaid construction modelling workflows, including workface planning and advanced work packaging. Our reality modelling breakthrough (led by our new Acute3D acquisition) can now perfect the alignment of the ‘virtual’ with the physical
In the last four to fi ve years, Bentley has devoted considerable time to educating these organisations on the benefits of moving beyond software for design and analysis to also include solutions for construction, operations, and maintenance. Chemical Engineering World
July 2015 • 89
CEW Interview Leveraging the reach and computing power of the Microsoft Azure cloud, and supporting a hybrid environment that includes on-premise servers, desktop applications, and mobile apps, the CONNECT Edition completes the reach of information mobility for advancing infrastructure. context, continuously throughout the project and asset lifecycle. Bentley launched its AssetWise initiative focused on improving asset performance during operations with its acquisition of Exor and Enterprise Informatics (eB) in 2010. The acquisition of Ivara (now AssetWise APM) integrated OPEX and CAPEX. Our very recent addition of Amulet software for operational analytics (through our acquisition of C3global) extended asset performance management to asset performance modelling, enabling operational decision support with input from performance and maintenance history and condition sensors, applying predictive and prescriptive analytics to improve safety and throughput. How do you evaluate the rate of subscription of Bentley’s software in India? Which are the industries using your application the most in the country? Pattanayak: On a global basis, Bentley’s subscription revenue (as a per cent of total) grew to 76 per cent in 2014. And subscription revenue retention exceeded 97 per cent. Regarding the AECO market segments that are using our software the most in India, plant, road, rail, water networks and structural consultants would be the predominant ones, though we serve most of India’s infrastructure community. There are several companies offering plant information management solutions to streamline collaboration between design firms and systems, enhance the front-end loading, and connect data to help empower project teams and other activities while executing EPCM. How is Bentley’s approach different in assisting its 90 • July 2015
clients? What distinguishes Bentley from others? Walters: One of the primary areas in which Bentley differs is its commitment and approach to information mobility across disciplines and the infrastructure lifecycle. It’s an approach that enables solutions that bring together and manage information from across plant information management applications, even those of other software vendors. The CONNECT Edition, our next generation of infrastructure engineering software, further enhances information mobility through its provision of a purposefully connected environment to improve the performance of infrastructure projects and assets from design through construction and operations. The CONNECT Edition provides the first common environment for comprehensive project delivery – comprising a common modelling environment, common performance environment, and common data environment. Leveraging the reach and computing power of the Microsoft Azure cloud, and supporting a hybrid environment that includes on-premise servers, desktop applications, and mobile apps, the CONNECT Edition completes the reach of information mobility for advancing infrastructure. Could you mention top five things from plant owners’ point of view that should be considered while choosing right solutions for the plant? Walters: Of utmost importance to plant owners is the ability to generate trusted and reliable information that their operations and maintenance personnel can use with confidence. Even one small error could cause them to doubt the data and this would lead to inefficiency at best and unsafe situations in a worst-case scenario. So an application with strong change management capabilities is vital.
Bentley’s AssetWise ECM has been tried and tested in the nuclear power industry, which is rigorously regulated and therefore requires highly accurate data and maximum data integrity. Second, plant owners need a reliable and trusted supplier that can provide both applications and support for those applications on a mission critical basis. Bentley offers global coverage through a team of professional engineers in support that is second to none. We are especially strong in India, with a large development office as well as a significant operations presence. Third, plant owners must consider a supplier’s track record and ability to provide user references. The top oil and gas companies rely on Bentley software for asset information management, as do numerous utility and government organisations. Fourth is the longevity and the future stability, both in terms of the information generated and managed and the supplier. As I mentioned earlier, Bentley has a unique, open approach to data and believes in using open, industrybased standards. This protects users’ data into the future. Bentley has just celebrated its 30th year in business and has experienced steady growth over the years. Finally, plant owners should look at a supplier’s list of partners, as well as the strategic relationships it initiates and maintains. Bentley has a partnership with Microsoft that now includes the provision of secure, managed cloud services via Microsoft Azure. Bentley also has a partnership with Siemens that is enabling the process industry to truly collaborate across all engineering and construction disciplines. Such strong partnerships demonstrate credibility in being able to deliver tried and tested solutions that will last the life of the asset – which, for a refinery and petrochemical plant, is going to be in excess of 50 years. Chemical Engineering World
R.N.I. No. 11403/1966 Date of Publication: 29 th of every month. Postal Registration No: MCS/095/2015-17 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 29th & 30th of every month. Total Pages No.:92