Fluid Handling International March/April 2016

HELPING TO KEEP YOUR BUSINESS FLOWING

MARCH/APRIL 2016

Extra safety in one neat package The challenges and benefits of single-unit DBB valve systems

Moving liquid with sound

New sound-based technology transfers fluid accurately

Issue 1 Volume 4

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Part of

COMMENT & CONTENTS CONTENTS 30

Picking the perfect magmeter What to consider when choosing a magnetic flowmeter and why

Sense and actuate Use of valve actuators and sensors in pharmaceutical production will enhance safety and maximise production

32

Accuracy defined Considering how flowmeters define their accuracy will help in selecting the right meter for the job

Woodcote Media Ltd Marshall House 124 Middleton Road, Morden, Surrey SM4 6RW, UK www.fluidhandlingmag.com

16 Solving the homogenisation dilemma

Pharmaceutical operators experiencing issues with homogenisation processes will benefit from calling professionals

34

Choosing the right flow measurement technology

37

Event preview: Tank World Expo 2016

18

Extra safety in one neat package The challenges and benefits of single-unit DBB valve systems

40

Listen to your heart Sensor technology takes infusion pumps to the next level

MANAGING DIRECTOR Peter Patterson Tel: +44(0)20 8648 7082 peter@woodcotemedia.com

20

Easy selection, powerful performance Pneumatic pilot-operated valves offer multiple advantages over traditional solutions

42

Tanker loading challenges in the pharmaceutical industry

22

Drop the shovel, use a pump Installing a peristaltic pump has saved a food company time, energy, and back muscles

24

Nao is the time Solving the pumping challenges in pharmaceutical applications requires innovative solutions

26

A bit of bitumen

28

Don’t throw the baby out with the bath water!

Even a grizzled veteran of a flow element can get a new lease on life with a fresh flowmeter installation

March/April 2016

2

Latest news

13

Product showcase

14

ISSUE 1 • VOLUME 4

EDITOR Ilari Kauppila Tel: +44 (0)20 8687 4146 ilari@woodcotemedia.com DEPUTY EDITOR Liz Gyekye Tel: +44 (0)20 8687 4183 liz@woodcotemedia.com ADVERTISING SALES MANAGER Georgina Barry Tel: +44 (0)208 6487 092 georgina@fluidhandlingmag.com PRODUCTION Alison Balmer Tel: +44 (0)1673 876143 alisonbalmer@btconnect.com SUBSCRIPTION RATES A one-year, 6-issue subscription costs £150 (approximately $240/€185 depending on daily exchange rates). Individual back issues can be purchased at a cost of £30 each Contact: Lisa Lee Tel: +44 (0)20 8687 4160 Fax: +44 (0)20 8687 4130 marketing@woodcotemedia.com

Join Fluid Handling International on Linkedin to discuss important issues Follow us on Twitter: @FluidHandIntl

44 Moving liquid with sound

New sound-based technology enables pharmaceutical producers to transfer tiny amounts of fluid accurately 46

Coupling into the future

47

Proactive: not just a buzzword Knowing the signs of hydraulic hose degradation will save operators time and money

49

Upcoming events

Comment Dear reader, The price of one of the most precious fluids on the planet – oil, that is – doesn’t seem willing to settle. At the time of writing this comment, the price of an oil barrel is at $32. It’s more than it was back around when Fluid Handling International’s previous issue went to print, but the oil industry is still feeling the shakes.

Or is it? The fluid handling equipment markets at least – valves especially – seem to be very much up and kicking, testified by the recent slew of acquisitions in the valve field. Market experts seem to agree, as the industrial valve market is expected to grow by a comfortable annual 4% during the next few years. New fields in the developing areas of Africa and Asia should drive the growth, overtaking Western Europe and the US. The demand for stainless steel control valves in the Asia Pacific region, just to give one example, is expected to grow by more than $100 million to $371.6 million by 2023.

Pumps aren’t doing badly either, but the industry might be gearing up for some internal struggle. According to the Transparency Market Research consultancy, positive displacement (PD) pumps can expect to face stiff competition from centrifugal pumps in the next two years, which might throw a spanner or two into the works for PD pump manufacturers. The increased competition might be offset by new opportunities for PD pumps in the poultry and pharmaceutical sectors.

Talking about pharmaceuticals, in this issue of Fluid Handling International we have a special focus on the pharmaceutical/medical industry. Several fascinating articles will highlight recent innovations and applications in the sector. Just to mention a couple, on page 44 you can read about Labcyte’s futuristic Extra safety in one neat package sound-based liquid transfer technology, while Swissinnov talks about a new Moving liquid with sound type of pump for pharmaceutical applications on page 24.

This year has just started, but looking at the world – and the fluid handling industry – we are already sure to be in for quite a ride before 2016 comes to an end. But for now, we hope you enjoy this latest issue!

HELPING TO KEEP YOUR BUSINESS FLOWING

MARCH/APRIL 2016

No part of this publication may be reproduced or stored in any form by any mechanical, electronic, photocopying, recording or other means without the prior written consent of the publisher. Whilst the information and articles in Fluid Handling are published in good faith and every effort is made to check accuracy, readers should verify facts and statements direct with official sources before acting on them as the publisher can accept no responsibility in this respect. Any opinions expressed in this magazine should not be construed as those of the publisher.

Issue 1 Volume 4

The challenges and benefits of single-unit DBB valve systems

New sound-based technology transfers fluid accurately

Best wishes, Ilari

Machine cleaning pharmaceutical products. © kadmy. Picture from bigstockphoto.com

ISSN 2057-2808 1

VALVE NEWS

Hantemp Controls expands refrigeration ball valve line Hantemp Controls, a US-based manufacturer of stainless steel valves and controls for the food and beverage industries, has expanded its line of ball valves for corrosive and harsh environments.

Featuring all stainless steel construction ensuring high resistance to corrosion, the Cobra-Neck ball valves are now available in a wider range of sizes (3/4” to 4” connections) to meet a greater number of systemspecific needs and applications.

The Cobra-Neck ball valves are versatile and can be equipped with an actuator for motorised control.

The valves can be used to control pressure, temperature, flow, and refrigerant liquid levels.

They have been approved for a safe operating fluid temperature of -57 to 115°C and a safe working pressure of 55 bar.

The Cobra-Neck ball valves are compatible with common refrigerants including ammonia, CO2, and many secondary refrigerants. z

3” stainless steel ball valve with electric actuation

2

Hillenbrand acquires Red Valve Hillenbrand, a US-based manufacturing company, has completed the acquisition of Red Valve Co. for a purchase price of $131.9 million (€120.7m) in cash, including $3.3 million for related real estate.

Based in Carnegie, Pennsylvania, Red Valve is a global valve manufacturer for harsh municipal and industrial

wastewater environments.

Its products support mission critical applications in water, power and mining, and other general industrial markets.

Red Valve joins Hillenbrand’s Process Equipment Group, which includes Abel, a global positive displacement pumps designer. z

World industrial valve demand to rise 4.3% annually through 2019 World demand for industrial valves is projected to climb 4.3% annually through 2019 to $98.5 billion (€87.7bn), a new market study says.

According to market research company Freedonia, market advances will be stimulated by growth in chemicals

below average increases in process manufacturing output and associated fixed investment expenditures.

and other process manufacturing output, electric power generation, and construction activity in a generally healthy economic environment.

Ongoing efforts to expand water infrastructures in developing countries and maintain or upgrade water and wastewater treatment and distribution systems in developed nations will also contribute to sales increases through 2019.

Dollar gains will be boosted as well by greater use of “smart” valves and actuators and other better performing, higher priced items.

Industrial valve market growth in developing parts of Asia, the Africa/ Mideast region, Central and South America, and Eastern Europe will outpace product demand in Western Europe, Japan, South Korea, and the US. China will post the strongest advances of any national market in value terms, accounting for 23% of all additional valve sales on a global basis.

India, a considerably smaller but still sizable valve market, will register larger gains in percentage terms.

A number of smaller national markets are also expected to record healthy sales increases.

Gains in US valve demand will be bolstered by growth in business investment spending as economic conditions continue to improve, while product sales in Western Europe and Japan will also expand.

However, market advances in these areas will lag behind those in most other parts of the world, limited by

Automatic valves are forecast to continue growing at a faster pace than sales of standard hand-operated valves.

This shift in market share away from standard valves is driven by the advantages that automatic valves offer, which include improved safety and reduced operating costs.

Automatic valves are also used in inaccessible and remote locations where manual operation is impractical.

The fastest sales gains of any major product type will be posted by automatic actuators, fueled by valve users’ ongoing efforts to automate standard valve operation by installing automatic actuators as a less costly alternative to replacing units with automatic valves.

Process manufacturing is the largest market for industrial valves internationally, reflecting the wide range of applications and significant fluid handling requirements in many industries.

Process manufacturing valve demand will also expand faster than product sales in other major valve markets, which include oil and gas, water infrastructure, and other miscellaneous applications such as construction, electric utilities, and mining.

Advances will be stimulated by both increases in process manufacturing output and the introduction of new specialty valves, which will help boost replacement demand.

The oil and gas market will register the slowest increases due to low oil and gas prices, although new drilling activity and the construction of related oil and gas infrastructure will continue in many areas. z

Automatic valves to outpace standard types

FLUIDHANDLING MAGAZINE l MARCH/APRIL 2016

VALVE NEWS

AS-Schneider’s E Series valves and manifolds certified fireproof AS-Schneider, a German industrial valves specialist, has received the Fire Safe Approval for its E Series valves and manifolds.

The approval, granted by the international testing and certification body TÜV SÜD, certifies that the E Series valves perform safely and reliably in shut-off duties also in case of fire.

The tested valves were deemed leak-free under extreme test conditions and were still fully operational after the testing.

The Fire Safe Type Test ensures that the valves demonstrate minimal leakage and can still be operated in case of fire.

During the testing, they are first placed under pressure with water and must withstand a fire for 30 minutes, after which the examiners cool the fittings down for 10 minutes to below 100°C. Throughout the test, leakage within the valve seat as well as without is measured according to strict limits.

Finally, the valve must be able to be fully opened at least once after the previous tests.

The examiners could not identify any leakage during testing and there were no limitations in the operability of the E Series valves after the testing.

Parker Bestobell to supply cryogenic valves to Korean LNG units UK-based Parker Bestobell Marine, a manufacturer of liquefied natural gas (LNG) cryogenic valves, will supply cryogenic globe and check valves for five floating storage regasification units (FSRUs).

Hoegh LNG, operator of the FSRUs, owns and operates floating LNG import terminals worldwide, but these FSRUs are being built at the Hyundai shipyard in South Korea.

The valves, which were manufactured in Sheffield, are a combination of manual, pneumatic, actuated, and check valves and come in sizes ranging from diameter nominal (DN) 15 to DN100.

“Supplying cryogenic valves for FSRUs is a growing part of our business, as international markets recognise the greater speed of construction of an FSRU and cost savings from storing and distributing LNG in this way,” said Duncan Gaskin, sales director at Parker Bestobell Marine.

Bestobell previously supplied the Excelerate FSRU famously used to supply gas during the FIFA World Cup in Brazil. z

A typical Bestobell valve delivered to the Korean installations

The E Series valves are manufactured exclusively from high quality stainless steel with pure graphite gaskets being used for the outside sealing.

This design ensures that the valves function reliably even under extreme conditions.

The approval applies to both the standard valve head units of the instrumentation range as well as for the OS&Y design.

In this version belleville washers are used, which compensate for the linear expansion of the individual components and thus provide more reliability at the primary shut off. z

May River Capital buys Hunt Valve

Private US equity firm May River Capital has acquired Hunt Valve, a fluid power engineering company specialising in severe duty valves and components.

May River plans to invest in the company to build a platform that will accelerate the company’s profitable growth.

Brad Sterner, Hunt Valve’s new president and CEO, said the company’s history of supplying severe-duty valves to the metals industry and US Navy provides a solid foundation to expand in Hunt’s core markets, as well as new sectors that include energy, transportation, process, and oil and gas.

Hunt is currently working with industrial blue chip customers, along with naval boat contractors Electric Boat and Huntington Ingalls Industries, and the US Navy. z

A&B Valve and Piping Systems sold to Houston entrepreneurs The US-based A&B Valve and Piping Systems has been acquired by a pair of Houston entrepreneurs.

Don Poarch and Joe Swinbank, co-founders of the Sprint Companies,

bought Louisiana-headquartered A&B at an undisclosed price.

A&B supplies pipe, valves, and fittings to the energy, petrochemical, power and industrial sector.

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

Plans are to continue operations as normal and A&B will not change its name.

A&B was founded in 1972 in Broussard, Louisiana, and has one location in Houma and four others in Texas. z 3

PUMP NEWS

Peristaltic pumps with gentle roller mechanism Wanner Engineering, headquartered in Minnesota, US, has introduced the Vector model 2006 peristaltic pump to handle difficult or challenging fluids without altering their composition.

The pump can move high-viscosity fluids (up to 15,000cPs) and pasty, pulpy, thick, abrasive, and corrosive solutions as well as fluids containing compressible solids up to 27mm in size.

It can be used to pump process fluids such as acids, slurries, sewage, chemicals, cosmetics, pigments,

dyes, paints and inks, plus a variety of foodstuffs in commercial, institutional, industrial, and municipal facilities.

The Vector 2006 has a maximum flow rate of 53.4l/min, a maximum discharge pressure of 4.1 bar, and its suction lift capability is 7.3m.

The self-priming Vector 2006 compresses and relaxes a hose to pump fluid, and unlike many other peristaltic pumps, it features a roller mechanism instead of a rigid shoe to push the fluid through the hose.

This system isolates the fluid being

pumped within the hose so it can handle difficult fluids without contamination and to help ensure longer service life with less downtime and maintenance.

Vector pumps can run dry without damage and have no seals or packing that can leak, clog, wear out, or require replacement.

They can also be used as a vacuum pump to clean up spills or to evacuate gases, or as a metering pump due to them being positive displacement pumps, in which output flow is directly proportional to pump speed. z

Double-acting valve configuration for Enerpac cordless pumps Enerpac’s XC-Series cordless pumps are now available in both single-acting and double-acting valve configurations.

Offering the power of an electricitypowered pump with the convenient portability of a hand pump, XCSeries cordless pumps provide a cost-effective solution for remote locations or hard-to-access areas.

This combination of features also makes the XC-Series one of the safest, most ergonomic hydraulic pumps for everyday use.

Featuring a lightweight design with integrated handle and carrying strap,

XC-Series cordless pumps can be easily transported from job to job.

The pump features a unique bladder reservoir that eliminates venting, prevents contamination, and provides leak-free operation in any position.

XC-Series pumps are also equipped with an efficient electric motor powered by an industrial grade 28V Lithium-Ion battery, delivering high speed and run time.

The pumps will actuate a hydraulic tool as fast as a basic electricity-powered pump and create up to 10,000 psi of pressure, making them up to five times faster than manual hydraulic

pumps and up to two times faster than popular pneumatic pumps.

Designed to provide optimal safety to operators, the XC-Series offers several safety features, including zero trip hazards through cordless design, overload protection circuitry from excessive amp draw or temperatures, and a trigger lock-off mechanism to protect against unintended operation during transport.

XC-Series Gen II cordless pumps are well-suited for a wide range of industries such as mining, construction, industrial, and power generation, solving diverse and demanding applications. z

Lyma Kemiteknik to supply Liquivac pumps in Scandinavia UK-based pump manufacturer Tomlinson Hall’s liquid ring vacuum pump, Liquivac, is to be distributed in Scandinavia by Swedish company Lyma Kemiteknik.

Part of the Indutrade group, Lyma Kemiteknik is a specialist in corrosive and abrasive flow technology.

It offers a range of products from leading pump brands, as well as valves and pipes, and has a long-standing relationship with Tomlinson Hall.

Liquivac, which can handle combinations of liquids, gases, and fine solids, and can perform in a wide range of applications, will be 4

distributed in Sweden, Norway, and Denmark by the firm.

Liquivac pumps are widely used by utilities companies, chemical processors, food and drink producers, environmental engineers, desalination plants, and sea life centres, and have a proven track record across a wide range of industry sectors.

Recognised for its durability and reliability, Liquivac’s ring vacuum design can accommodate solids of up to 2mm in diameter during the transfer of liquids, air, foam, emulsions, and vapours.

The pump’s cast iron or 316 stainless steel pump body, combined with a stainless

A wide range of industries use the Liquivac pump

steel rotating element, makes Liquivac robust in operation, and it is able to transfer volatile liquids or collect waste.

Liquivac can also be used in pump priming systems to increase process efficiency and to protect larger vacuum pumps from damage and it can also provide vacuum cooling during chemical processing.

The pump can operate from long suction lines – 500m or more – enabling the pump to

be positioned a considerable distance away from a hazardous site, or source of effluent, and can be easily transported due to its small size.

In seawater extraction operations, Liquivac can work with sub-sand intakes, which draw seawater through the beach and make use of sand’s natural filtering properties.

Liquivac is manufactured at Tomlinson Hall’s facility in Billingham, Northeast England. z

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

PUMP NEWS

Oerlikon Leybold Vacuum to supply vacuum pump systems to Korea A well-known Korean group producing lithium-ion batteries has awarded a contract for the supply of vacuum systems to Oerlikon Leybold Vacuum.

The company will equip several production lines with vacuum pump systems for electrode drying by summer 2016.

With a system combination of the dry compressing screw vacuum pump Dryvac DV 450C and the Roots Ruvac WH2500, the customer will optimise its production lines.

Decisive factors for awarding the contract were in particular process capability at low operating costs and the services offered.

In the manufacture of battery cells, vacuum technology is used for several production steps and has a high importance for the efficiency of production.

During their entire life cycle, batteries need to maintain a high quality, therefore high-performance vacuum systems are necessary in order to provide the conditions for high-quality batteries, e.g. in specified drying processes.

Especially with Li cells for electric vehicles, these quality requirements are increasingly important, as the demands for volumetric storage capacity, lightweight, and safety are growing.

Apart from electrode drying, the vacuumassisted manufacturing steps comprise cell assembly and leak detection testing. z

Quiet pump operation for oil and gas applications Graco, a US-based manufacturer of fluid handling equipment, has updated its hydraulic Dyna-Star product line with the release of the high-pressure hydraulic Dyna-Star grease injection pump.

The new pump is field-proven to be capable of operating at pressures of up to 10,000 psi, even with low flow rates in wireline, slickline, and wire rope applications.

It also reduces freezing, stopping, and stalling, and the pump’s quiet and smooth operation provides less downtime and a lower cost of ownership.

The high-pressure Dyna-Star pump requires about one-third of the energy of pneumatic pumps, and operates more quietly.

Additionally, the pump is self-lubricating, reducing the need for maintenance.

It is well-suited for oil and gas well services, as well as for preventing internal corrosion in wire rope applications. z

Pump maker Varisco acquired by Atlas Copco

Sustainable productivity solutions provider Atlas Copco has completed the acquisition of Varisco, an Italian pump manufacturer with a global sales network.

Varisco, employing 135 people, is based in Padua near Venice, Italy, and had revenues of €30 million in 2014.

Founded in 1932, Varisco is known for the design and manufacture of high-quality pumps used by a wide range of customers.

The company’s pumps are typically used to remove unwanted water or other liquids in the construction, mining, and oil and gas industries, but they also find use in industrial process plants and for emergency services in case of floods.

The parties have agreed not to disclose the purchase price. z

Sulzer to ship energy efficient process pumps to Finland Swiss pump maker Sulzer has received an order for the delivery of an extensive process pump package to Metsä Group’s next generation bio-product mill in Finland.

Construction work at the Metsä Fibre mill, located in the town of Äänekoski in Central Finland, is scheduled to be completed during the third quarter of 2017.

The investment of €1.2 billion put into the plant is the largest ever in the wood-processing industry in Finland.

The mill’s annual pulp production will be 1.3 million tonnes, of which 800,000 tonnes will be softwood pulp and 500,000 tonnes hardwood pulp.

Besides pulp, the mill will produce a broad range of bio-products, such as tall oil, turpentine, lignin products, bioelectricity, and wood fuel.

Sulzer will deliver Ahlstar process pumps, the latest generation of Sulzer MCE medium consistency pumps, as well as agitators and vacuum pumps to the Äänekoski mill.

The equipment is designed for high reliability and energy efficiency as well as for low operating costs.

The contract includes the manufacturing, testing, packaging, and installation inspection of the equipment.

Energy efficiency and low emissions were the central design criteria for the green field bio-product mill. z FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

Sulzer Ahlstar process pumps will be put to action at the Äänekoski bio mill

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PUMP NEWS

Amarinth designs custom pump solution for produced water challenge Centrifugal pump manufacturer Amarinth has designed a bespoke vertically mounted API 610 OH 1 pump with Plan 13 seal support system.

The pump was created for AI Energy Solutions (AIES), the specialist process engineering division of the Arabian Industries Group, to use with its nutshell filters for cleaning produced water.

AIES approached Amarinth, which has delivered pumping solutions for several produced water treatment systems, to design a pump for the final cleaning phase of produced water using its nutshell filters on an offshore platform.

The location of the platform, however, posed project specific challenges of high daytime and low night time temperatures, high salinity, and a high 30% rated solids concentration.

The pump had to exhibit low shear properties in order for the AIES nutshell filters to work optimally by ensuring that the oil and water mixture was not emulsified.

This requirement could be achieved using an API 610 OH1 pump, but in order to fit with the nutshell filter package, Amarinth had to design a bespoke solution.

The design process involved taking the OH 1 hydraulic design and engineering

a vertically mounted close coupled arrangement so that the suction was at the bottom and the discharge at the top.

Manufactured in stainless steel, the pump incorporates an open impeller design to handle the high solids concentration and a vacuum operated backwash facility to allow for easy cleaning and maintenance.

A single seal Plan 13 seal support system, normally used on vertical pumps, was integrated with the vertically mounted OH1 pump.

In line with project schedule, Amarinth supplied the bespoke pump on a fast track basis, with delivery, in 23 weeks. z

Two new Franklin pump series for water applications Franklin Electric Co., a manufacturer of complete pumping systems, has introduced two new pumping innovations for water and wastewater operations.

The new FPS IGPH Series of high head grinder pumps are engineered for the tough demands of higher head conditions found in many low pressure sewage transfer applications.

Available in an automatic or manual version, the FPS IGPH Series utilises a proven and patented cutter system with tight clearances for high-efficiency grinding at 414,000 cuts per minute.

These new units incorporate two non-clogging impeller stages for efficient pumping of sewage slurries with a shut-off head of 200ft.

With only 16 full-load amps at minimum head requirements of 100ft, the units can replace other grinders that fail to meet current application needs.

The submersible centrifugal FPS NC Series non-clog pumps meet challenging water transfer needs in commercial, residential, and industrial applications.

Manufactured in 3” and 4” 125# ANSI flange discharge connections, they are available in 3, 5, 7.5, and 10hp models with heads up to 66ft and flows up to 610gpm.

Non-clog pumps can pass up to 3” solids, retrofit easily to any standard rail system, and contain replaceable internal components for optimal maintenance.

Ductile iron casted impellers provide added corrosion resistance and handle rigid debris versus cast iron versions better.

A fluoroelastomer motor enclosure sealing system has improved chemical and temperature resistance, the doublerow ball lower bearing offers better loading and wear characteristics, and a unique field adjustable wear plate offers optimum performance. z

Franklin 4” FPS NC Series non-clog pump

New submersible Flowserve motor uses permanent magnet technology Flowserve Corp., a Texas, US-based provider of flow control products and services, has introduced a new submersible electric motor that utilises permanent magnet technology.

Based on the Pleuger three-phase, AC, squirrel-cage induction motor, the new Pleuger PMM8 features advantages over asynchronous designs, including higher efficiency at full and partial loads, lower thermal losses and a large air gap configuration.

6

The motor can reduce energy costs by up to 10% and boost power output by more than 100% while extending the overall life of the motor, Flowserve reports.

The PMM8 motor technology has demonstrated over 93% efficiency, making it one of the most efficient 8” submersible motors.

Operated in conjunction with variable frequency drives, the PMM8 runs at synchronous speeds with no

rotor losses, which allows the pump to run at a high efficiency point under variable flow conditions.

Due to the high power output, in many cases the 8” PMM8 design can be substituted for conventional 10” asynchronous motors.

The PMM8 is currently available in a 190mm (8”) motor size with power output of 50kW (67hp) to 200kW (268hp), and Flowserve intends to release additional sizes in the future. z

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

PUMP NEWS

Sundyne pump protection system receives safety certification

Graco launches redesigned sealed four-ball lower for circulation pumps

Colorado, US-based centrifugal sealless magnetic drive pump designer Sundyne’s VapourView pump protection system has been cUL, ATEX, and IECEx approved.

VapourView monitors gas inside the process fluid as it passes through a Sundyne sealless magnetic drive pump.

When the probe detects the presence of gas levels – even as low as 1% per volume – a warning signal is sent to the process operator.

This instant feedback helps prevent harm to the pump from occurring by providing early warning of incorrect priming, venting, cavitation, or entrained process gas, which can result in pump damage or even failure.

Power and vibration monitors only alert the operator to the symptoms of gas in the process liquid and in many instances the pump may already be damaged when these monitors are triggered.

By measuring the process fluid condition in real-time with an ultrasonic probe, the VapourView provides feedback instantaneously, ensuring that the pump is working reliably and without risk of damage.

Field installation experience shows that a Sundyne sealless magnetic drive pump fitted with the VapourView system is 50% more reliable compared to other pumps utilised in the same processes, the company reports.

Key features of the VapourView include a noninvasive detection sensor, flameproof electronics, onboard data recording, and a local visual display, as well as a wide temperature operating range of -40-180°C. The VapourView’s 4-20mA output signal is compatible with standard digital control systems and complies with cUL, ATEX, and IECEx standards.

The VapourView system is available as an optional accessory for Sundyne API 685 sealless magnetic drive pumps, including the LMV801S and HMD/Kontro GSP models, or as a retrofit kit for pumps already in operation. z

US-based liquid handling equipment manufacturer Graco has released a new sealed four-ball lower, compatible with all Graco circulation pumps.

The model has longer maintenance cycles and does not require throat seal liquid (TSL), which reduces maintenance costs and unplanned downtime.

Common components also make the lower simpler to maintain and reduce inventory levels on repair parts.

“In industries where unplanned downtime can be extremely costly, our new sealed four-ball lower reduces the need for routine maintenance,” said Bill Heuer, Graco’s industrial products division’s worldwide product marketing manager.

“This combination of longer maintenance cycles, no TSL, and common components takes away the threat of downtime and keeps the system operating longer.”

The lower is completely sealed, so it can be used for every pumping application in a mix room, including catalysed coatings.

It also contains the additional security of a backup seal in case of bellow leakage.

“The completely sealed fluid section with bellows provides leak resistance for even the harshest materials,” said Heuer.

In addition, the lower features Ultralife series ceramic coating on its rods and cylinders.

According to Heuer, the Ultralife Series ceramic coating is an industry standard for handling harsh materials, including waterborne paints.

The sealed four-ball lower is available on all of Graco’s circulation pump assemblies and is compatible with the Bulldog, NXT, President, Viscount, E-Flo, and E-Flo DC circulation pumps.

An open wet cup version is also available, which has many of the same Graco sealless four-ball lower features as the sealed version. z

Wilden launches natural gas-run diaphragm pumps for oil and gas Wilden, an air-operated doublediaphragm (AODD) pump technology developer, has released a new line of natural gas-operated double-diaphragm pumps.

Specifically designed for the oil and gas industry, the pumps have been certified CSA International to be used in applications where natural gas is the energy source to drive the pump.

Well-suited for upstream and midstream oil and gas applications,

the new pumps are available in Wilden Original (clamped), Advanced (bolted), and Advanced FIT models.

They come equipped with either the patent-pending Wilden Pro-Flo Shift air distribution system (ADS), which is CSAcertified ANSI LC 6-2008, or the Wilden Pro-Flo X ADS, which is CSA-certified for the ANSI LC 6-2008 and TIL R-14.

The pumps are offered in 13 mm (1/2”) clamped and 25 mm (1”), 38 mm (1-1/2”), 51 mm (2”), and 76

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

mm (3”) bolted configurations.

Wilden CSA-certified pumps also comply with all CE and ATEX requirements, and feature extreme shear sensitivity, highviscosity handling, dry-run capability, anti-freezing, and no deadhead damage.

The maximum flow rate is 993lpm for the 76mm model, and the maximum discharge pressure is 6.9 bar for all models.

Wetted paths are aluminium or stainless steel and available diaphragm materials are Buna-N, PTFE, or Wil-Flex. z 7

FLOWMETER NEWS

Avanti Co. acquires flowmeter maker Avery-Hardoll The Avanti Co., representatives of flowmeter and accessories company Liquid Controls, has recently acquired AveryHardoll and its metering product line.

Avery-Hardoll has a worldwide reputation as the standard in bulk fluid metering and fluid measurement accuracy.

It has been around since the 1930s and besides its bulk meters, it also designs and produces valves, couplings, and other fluid management products.

Avery-Hardoll’s BM Series is among the most widely used flowmeters, combining high accuracy with a simple design and construction. z

Litre Meter appoints new flowmeter distributors for Southeast Asia UK flowmeter specialist Litre Meter has appointed two new distributors in Southeast Asia to distribute its flow measurement solutions and chemical injection packages.

The new distributors – Wehaya in Selangor, Malaysia, and Lasindo in Jakarta, Indonesia – will deliver Litre Meter devices for the offshore oil and gas industry in Asia and Australasia.

Litre Meter has appointed the two new distributors following the creation of an office in Singapore in 2015.

Litre Meter has received orders for its VFF positive displacement flowmeters for oil and gas production projects in the region, including the Kinabalu NAG project in Malaysia and Bien Dong 1 in the Nam Con Son basin off Vietnam.

Wehaya distributes flowmeters, sensors, and other instrumentation for a number of industry sectors including oil and gas, petrochemicals, and processing industries in Southeast Asia and China.

Lasindo is a supplier specifically to the oil and gas industry in the region, providing product solutions and engineering services. z 8

New Festo flow and pressure sensors feature status-check IO-links German flow solutions provider Festo has launched two new easy-to-use flow sensors with an IO-Link output to provide fast process status checks and increase production efficiencies.

Developed in response to the trend for increased monitoring and diagnostics, the new SFAW sensor is the first flow sensor from Festo for sensing liquid media, while the SPAU is a new modular system designed for the monitoring of pressure and vacuum in process and factory automation applications.

The sensors are available with IO-Link output options and the modular electrical output concept makes the sensors flexible and open, allowing simple integration into numerous control systems.

They are also available with switchable PNP/NPN output, which means users can simplify their stock management and make cost savings associated with reduced warehousing, says the company.

“IO-Link is increasingly being used in the UK for point-to-point serial communication protocol to communicate with sensors and/ or actuators in new automation systems,” said Steve Sands, product manager at Festo.

“Remote maintenance and parameterisation as well as simpler sensor change are made possible

via IO-Link, which means set-up and changes can be made faster and with less opportunity for errors.”

The new pressure and flow sensors are easy to set up and use, combining functionality with simplicity.

They have an intuitive menu guidance with a large high-contrast back-lit blue/white/red LCD so users can clearly check the flow and pressure of their systems.

The SFAW sensors are wellsuited for monitoring the flow rate, consumption and, optionally, temperature of liquid in cooling circuits, for example in welding guns in the automotive industry or in front-end applications in the semiconductor and other electronics industries.

The sensors offer two flow measurement ranges of 1.8 to 32l/ min and 5 to 100l/min and are suitable for use with liquids that have a viscosity up to 2mPa/s.

Temperature of liquid media can be measured from 0 to +90°C. The new SPAU sensor for pressure measurement, monitoring, and sensing is designed to keep pressure levels under control, ensuring greater productivity and process reliability as well as faster system commissioning.

Pressure indication, pressure switch outputs, and analogue value output are all possible in one device and the sensor can reliably measure from 0-16 bar.

It has a range of functions for non-corrosive gases including network, regulator and vacuum monitoring, leak Festo SFAW flow sensor tests and object detection. with IO-Link output The sensors are quick and easy to mount in all installation scenarios.

The modular concept enables the sensor and connections to be purchased separately, ensuring maximum flexibility during assembly, with screw, flange, and tubing connection options available.

In addition, the sensor can be changed quickly and easily without the need for specialist tools, minimising downtime.

Both the SFAW and SPAU sensors are sealed to IP65 making them suitable for use in harsh process environments. z FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

OTHER NEWS

Motion Industries to acquire Missouri Power Transmission

Scottish RCP to deliver well control systems to Singaporean oil client

Motion Industries, a wholly owned subsidiary of Genuine Parts Co., has entered into a definitive agreement to acquire Missouri Power Transmission, a power transmission equipment distributor.

Execution of the transaction is expected to take place on 1 March, 2016.

Missouri Power Transmission specialises in chains, sprockets, bearings, seals, electric motors and controls, belting, and related industrial parts.

Headquartered in St. Louis, Missouri Power Transmission services customers from 15 branch and affiliate offices.

Its machine shop performs services including gearbox repair, shafting (keyed and plain), welding, and customised machining and millwork.

With annual sales of $4.6 billion (€4.1bn), Motion Industries is one of the leading industrial parts distributors for bearings, mechanical power transmission, electrical and industrial automation, hydraulic and industrial hose, and hydraulic and pneumatic components. z

Control and instrumentation company RCP, based in Aberdeen, Scotland, has been awarded a contract to supply and install integrated well control equipment for a Singaporean client.

The £300,000 (€386,600) contract will see RCP install and commission the systems on high-specification Chinese new build oil rigs, where they will streamline the well control process by combining multiple systems into one.

The integrated system consists of a main hydraulic console with all-electric remotely operated panels, which are used to operate and control dual choke valves, dual gate valves (utilising different working pressures), accurately monitor the liquid seal integrity of the mud gas separator, and also display three pump stroke counts.

The system’s design was based on RCP’s CE and ATEX certified choke control console design.

Under the contract, RCP will build and deliver the well control equipment in four stages over the next six months, the first of which was scheduled for delivery by mid-February 2016. z

New carbon floating ring seals from EagleBurgmann Germany-based EagleBurgmann Espey has introduced the WD200/500 series of carbon floating ring seals for nearly all machine types with a rotating shaft.

The seal type is used in industries such as chemical, metal, cement, and food industries (with FDA certificate), power station technology, and mechanical and plant engineering.

It typically seals all kinds of gases, flammable (Atex), acidic, toxic, vaporous, liquid mist, oil mist, creeping oil, or water.

The WD200/500 is user-friendly due to its divided housing and segmented seal rings.

Seal assembly or seal ring replacement occurs without having to first dismantle machine parts, such as the motor or gears.

The Espey WD200 is fitted on the process or product side, and the seal ring features a gap to the shaft that enables

a defined buffer gas flow into the process compartment, which prevents process gas from escaping into the atmosphere.

The Espey WD500 seal ring type is fitted to the atmosphere side.

The seal rings with overlapping mortised joints slide on the shaft and are self-adjusting, which reduces the radial gap to the shaft.

The volume of leakage as well as the consumed buffer gas to the outside is extremely low.

The seal components are not mounted on the shaft ,which helps prevent additional shaft vibrations.

A short axial installation length provides potential savings in machinery design while also preventing vibrations.

The seal housing can be executed with diverse connection bores for, among others,

EagleBurgmann Espey WD200/500 seal

the feeding of buffer gas, the injection of a flushing medium as well as for the selective removal of residual gas and condensate to prevent leakages to the environment. z

Emerson to help Cameron LNG in gas liquefaction project Emerson Process Management has been tapped by Cameron LNG to help automate its new liquefaction project, adding three liquefied natural gas (LNG) trains to export US natural gas to international markets.

Cameron has chosen Emerson to provide automation expertise and technologies that will help the company manage the LNG facility’s operations safely and efficiently.

The estimated value of the project

to Emerson is $20 million (€18.1m).

Three new liquefaction trains will give the Louisiana, US-based facility the flexibility to export up to 12 million tpy of US-produced natural gas.

The plant can also continue to import LNG for domestic use, or reexport LNG from other countries.

Emerson will provide its DeltaV distributed control and DeltaV SIS integrated safety system for both new and existing

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

portions of the facility, together with its AMS Suite predictive maintenance software to optimise the availability and performance of key production assets.

Project specialists in Houston, US, and in Pune, India, will provide related design and configuration services to help accelerate the project schedule.

Emerson has been awarded automation contracts for more than half of all North American LNG export capacity. z 9

OTHER NEWS

Nidec launches market’s only IE4 certified EC motor Nidec Motor Corp. has launched a new motor for variable torque pumps, fans, blowers, farm vents, and hydronic pumps.

The US Motors brand 3-10hp electronically commutated (EC) motor, with an IE4 (Super Premium efficiency) rating, comes integrated with a tuned variable frequency drive (VFD) and is part of the Accu-Series line of variable speed products.

The new motor is the only integrated EC motor in the marketplace that is rated IE4.

Commercial and industrial users

choosing to move to the expanding IE4 motor category are doing so in large part because of the high efficiencies and the quicker return on investment in the form of electricity savings that these motors can provide.

The new integrated motor and drive was designed with ferrite magnets rather than rare earths for more consistent pricing and cost structure.

The brushless permanent magnet motor (BPM) and drive have an integrated user interface that allows for easy setup.

The product is simpler than a modular approach, and it reduces costs and lead-time by eliminating cabling between motor and separate control.

It also reduces electromagnetic interference (EMI) and corona, which can result in power loss and interfere with performance.

The motor is designed to mount in all standard NEMA or IEC mechanicals/ constructions, has an IP54 rating, and can replace an induction motor and off the shelf drive. z

Retractable sensor assemblies for hygienic applications Endress+Hauser has introduced Cleanfit CPA875 and CPA871 sensor assemblies that allow pH, ORP, oxygen, and NIR sensors to be installed or removed during operation.

By moving the sensor from the measuring position to a service position, these retractable assemblies allow the sensor to be cleaned, calibrated, or replaced without interrupting the process.

The retractable assemblies permit removal and installation while protecting both the process and operating personnel.

In hygienic or sterile processes, the CPA875 assemblies are protected against contamination in accordance with international standards including EHEDG, ASME BPE, FDA, ATEX Directive 94/9/EC, CE/PED, EC VO 1935/2004, and Biological Reactivity (USP Class VI).

In pneumatic operating mode, the CPA871 meets ATEX and CE/PED standards.

The CPA875 assemblies, along with their service chambers and process adapters, are certified by EHEDG for cleanability and sterilisability, which guarantees that residual media is not only destroyed, but is also removed completely from the service chamber and the sealing surface.

The service chamber and sealing surface thus remain free from product residue and micro-organisms and the design of the service chamber allows liquid media to drain freely and completely.

The alignment of the inlet and outlet, as well as the flow configuration, ensures that solid built-up deposits are loosened and removed when cleaning.

It is also possible to clean and sterilise the seals’ contact surfaces, which ensures the sensor is free from contamination 10

A variety of connections for Endress+Hauser CPA875 sensor assembly

when it is reinserted into the process.

The CPA875 assemblies are available with single or dual service chambers, with the front chamber in the doublechamber system capable of being used as a protective barrier to the process.

The chamber can be continually rinsed with water for injection, which ensures the cleaning solution cannot enter the process, even if the process seal is damaged.

At the same time, this front chamber can be used to isolate the service chamber temperature from the process.

The sensor can therefore be checked, replaced, calibrated, adjusted, and cleaned with hot water or sterilised, all without influencing the process.

The Cleanfit CPA875 assembly has seals, process connections, and couplings that make it suitable for use in food, pharmaceutical, life sciences, and specialty chemical applications, while the CPA871 has

similar options for the water/wastewater and general chemical industries.

Materials in contact with the process medium are all stainless steel, while seals can be EDPM/FMP or Viton/ FFKM, depending on the application.

The immersion tube, process connection, and service chamber can be stainless steel, titanium, Alloy C22, PEEK, or PVDF, again depending on the application.

Both sensor assemblies are available with a manual or an automatic drive, the manual drive featuring self-retaining thread to hold the sensor in any intermediate position, and can be used for process pressures up to 116psi.

The pneumatic drive can be used for process pressures up to 232psi, and in assemblies with a pneumatic drive, the service and measuring positions of the sensor are detected and reported to connected monitoring and control systems. z

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

OTHER NEWS

Toshiba medium voltage motor targets harsh petrochemical applications Toshiba International Corporation (TIC) has introduced the new Petrochem SD+ medium voltage motor for tough material processing applications.

The totally enclosed and fan cooled motor package features rugged construction and durable design, and it is built with certain IEEE Std. 841™-2009 specifications.

The SD+ motor is aimed at the oil and gas, mining and mineral, and pulp and paper industries.

“The new motor is best suited for applications including compressors, pumps, fans, and conveyors,” said John Rama, business director for the TIC Motors and Drives division.

“The low temperature and low vibration design provides additional durability to withstand these harsh environments, decreasing maintenance requirements and chances of failures while ultimately increasing the motor lifespan.”

Available in 2300, 3300, 4000, or 6600V, the motor features severe duty IP55 protection for the motor and terminal boxes, in addition to an insulation system capable of withstanding an immersion test in accordance with NEMA MG 1.

For further protection from environmental conditions, the motor’s windings, rust-inhibitive paint system on motor and rotor/shaft assembly, and corrosion-resistant hardware have undergone tropicalisation treatment. z

Suprafilt secures £2m deal for London wastewater plant Rochdale, UK-based Suprafilt has landed a £2 million (€2.56m) contract for Deephams Sewage Treatment Works in London to supply an aeration system with airmain, header pipework, and control valves.

The project is currently at the design stage, with phase one expected to be completed by the end of April.

Phase two should be completed

by June with the project due to be finished completely by June 2017.

The Deephams project is the largest Suprafilt has undertaken with Thames Water.

“It’s a big contract which will provide ongoing work for our team for the next two years,” said Suprafilt sales director Graeme Fielden.

“We have previously worked with AECOM on a project at Liverpool’s Wellington Dock, so the fact we’ve been awarded this job is testament to the previous work we have done with them.”

Bearings Plus achieves ISO 9001:2008 quality management system certification Bearings Plus, a Waukesha Bearings business, has received ISO 9001:2008 standard certification for its quality management system at Dover Pearland Operations (DPO).

DPO is a 150,000ft2 facility shared by Bearings Plus and fellow Dover companies Cook Compression and Midland Manufacturing.

The shared services strategy exemplified at DPO provides not only internal efficiencies but also enhanced processes and synergies to improve quality and customer service.

The certified quality management system recognises the joint efforts of Bearings Plus and Cook Compression, covering the design, manufacture, service, and repair of compressor valves, fuel gas injection valves, engineered plastics, fluid film bearings, seals, components for turbo machinery, and sealing systems. z FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

Suprafilt will be installing the aeration system into six aeration lanes at the site in Enfield, London.

Suprafilt works with some of the UK’s major water companies and leading industrial organisations such as Seven Trent Water, Thames Water, and Diageo.

It specialises in the design, installation, and commissioning of both fixed and lift-out fine-bubble diffused aeration systems for municipal and industrial wastewater treatment plants. z

Cashco introduces new back pressure regulator Cashco, a Kansas, US-based industrial product manufacturer, has introduced a new Model BR back pressure regulator for use with a wide range of liquids and gases.

With the appropriate options, applications include upstream overpressure regulation of cryogenic liquids, sour gas, industrial gases and chemicals, as well as common industrial fluids, such as water, oil, steam, and compressed air.

Available in globe or angular porting configuration, the Model BR valve controls inlet pressures up to 13.8 barg in multiple spring ranges and can be used in the majority of industrial pressure relief applications.

“Our engineers saw the opportunity to take some of the features of our popular Model D pressure reducing regulator, such as the body and internal spring components, to make a

Cashco Model BR back pressure regulator

cost-effective in-line back pressure regulator. At the same time, we’re able to convert it and offer it in an angular port configuration as well,” said Clint Rogers, president of Cashco.

According to Rogers, the BR regulator is available in five sizes from 3/8 to 2” and can handle material temperatures from -6 to 200°C with the appropriate body/spring chamber and trim material combinations.

Trim designs include metal-seated or composition-seated with a metal or composition diaphragm.

“Two body materials will also be available, with 27 different trim material combinations from which to select,” Rogers added. z 11

OTHER NEWS

Star Envirotech wins leak detection patent appeal from Redline Detection Star EnviroTech has won the final US “nitrogen smoke” leak detection patent challenge by Redline Detection in the US Federal Circuit Court of Appeals.

In a precedential 33-page opinion, the Court fully upheld Star’s patent, used by every major automaker (OEM).

Previously, STAR prevailed against three other Redline Detection challenges for the ownership of the nitrogen smoke technologies for safer vehicle fuel evaporative emission (EVAP) testing.

The earlier cases include two patent re-examination proceedings and an Inter Partes proceeding before a three-judge panel of the US Patent Trial and Appeal Board (PTAB).

Redline Detection previously also filed two failed challenges

of Star’s dye patents.

Twenty other STAR patents were unchallenged by Redline Detection.

“We’ve worked hard to secure our US and international patents. We invented this technology and we have an ethical obligation to our distribution partners to guard those patents,” said STAR EnviroTech’s CEO Jim Saffie.

“They’ve made an investment in us and our technologies. We will protect those investments.”

Star EnviroTech, the inventor of diagnostic smoke leak detection technologies, worked in collaboration with various partners including Ford, GM, and Chrysler, through the OEMs’ USCAR organisation, to develop a universally-accepted EVAP and vacuum

system leak detection technology.

Star’s nitrogen smoke patent (6,526,808) uses an exclusive method of producing smoke with any inert gas to virtually eliminate the risk of a vehicle fuel tank fire or explosion during an EVAP test.

Papers published by SAE International and other data support this method as safer than testing with shop air in a fuel tank.

Adding air containing oxygen to a volatile environment such as a fuel tank can create a flammable mixture inside the fuel tank, but nitrogen smoke eliminates the risk of fire during the testing process.

Star’s smoke dye patents use a unique, non-contaminating, non-permanent UV dye to mark the spot of the leaks, making even hidden leaks easy to find. z

Boca Bearings expands range of ceramic and ceramic hybrid bearings The Boca Bearing Co., based in Florida, US, has launched a new extended line of full ceramic balls, full ceramic and ceramic hybrid deep groove radial bearings, full ceramic thrust bearings, and full ceramic and ceramic hybrid insert bearings.

Ceramic bearings are suitable for use in many specialty applications, with ceramic being a suitable material for any application seeking to achieve higher RPM’s, reduce overall weight, or for extremely harsh environments with high temperatures and corrosive substances.

Ceramic silicon nitride balls, for example, exhibit much greater hardness than steel balls resulting in at least 10 times greater ball life due to the ability to hold the surface finish longer, according to Boca.

The ball has smoother surface properties than a steel ball, resulting in less friction between the balls 12

and bearing race surfaces.

Thermal properties are also improved over steel balls resulting in less heat build-up at high speeds.

Ceramic has 35% less thermal expansion, 50% less thermal conductivity, are lighter weight, and are non-corrosive.

Similarly, the inner and outer races of antifriction bearings often become frosted, fluted, or can get a corrugated pattern imprinted on them.

These are not mechanical scars but are due to electromagnetic forces and can lead to bearing failure and they are usually found in modern systems that routinely feature pulsemodulated adjustable-speed motors and inverters with high switching frequencies and short rise times.

The best solution substitutes ceramic hybrid bearings for the more traditional, chrome steel counterparts to eliminate scarring and also run cooler due to less

micro-weld adhesion.

Ceramic hybrid ball bearings use ceramic balls and steel races, with ceramic balls weighing up to 40% less than steel balls, depending on size.

This feature reduces centrifugal loading and skidding so hybrid ceramic bearings can operate up to 50% faster than conventional bearings, meaning that the outer race groove exerts less force inward against the ball as the bearing spins.

This reduction in force

reduces the friction and rolling resistance, while the lighter ball allows the bearing to spin faster and use less energy to maintain its speed.

Suitable applications for ceramic hybrid or full ceramic bearings include cryo-pumps, medical devices, turbine flowmeters, food processing equipment, semiconductors, machine tools, robotics, and optics.

The Boca Bearing Co. stocks a full range of ceramic balls, ceramic hybrid bearings, and full ceramic bearings. z

Boca full ceramic bearings

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

PRODUCT SHOWCASE

ENERGY EFFICIENT WASTEWATER DISINFECTION n Xylem’s Wedeco Duron is a vertically-inclined, open-channel ultraviolet (UV) system featuring an integrated automatic lifting device and energy-efficient Ecoray lamps. The system is designed for new plant installations or retrofits into existing chlorine contact channels and provides efficient disinfection for mid-size to large wastewater treatment plants.

The Duron UV system delivers lower capital costs and reduced energy consumption by up to 30%*. The OptiDose feature automatically adjusts energy consumption to the minimum needed by dimming the lamps to match dosage requirements. The Ecoray 600W lamps are more energy efficient than other lamp options, further reducing energy costs. *Based on tests conducted by Carollo Engineers.

SHINING A LIGHT ON LEAKS n The Spectroline Opti-Lux 365 leak detection flashlight provides pure UV light for optimal fluorescent dye response, making it a good fit for all industrial fluid system leak applications. The flashlight works with all Spectroline oil-based fluorescent dyes available in several colours, as well as the company’s water dyes. It produces a brilliant glow that makes leaks easier to find, slashing valuable diagnostic time.

The Opti-Lux 365 is lightweight and more than twice as powerful as most corded, high-intensity UV lamps. “Instant-on” operation enables the flashlight to reach full power immediately, and it provides up to four hours of continuous run-time. Its rugged, anodized aluminum lamp body reduces corrosion and stands up to years of heavy use.

HYGIENIC ROTARY LOBE PUMP FOR FOOD AND PHARMA DUTIES n For pumping applications that involve liquids containing solid particles – such as chocolates and fats – or those that are highly viscous, including syrups, honeys and gels, the Inoxpa SLR Rotary Lobe Pump is a suitable solution.

Available through Michael Smith Engineers, the SLR pump is a positive displacement sanitary construction rotary lobe pump suitable for use in the dairy, food processing, beverage, cosmetic, pharmaceutical, and fine chemical industries.

Designed for maximum efficiency and reliability, the SLR pump incorporates two lobe rotors which rotate synchronously inside a casing without contact. The pump generates a continuous smooth flow thanks to the tolerances between the lobes and the pump casing. This enables efficient, low shear pumping, even for delicate or viscous liquids and those containing solids.

PUMPING WITH TOTAL CORROSION RESISTANCE n The AMX-GG from Crest Pumps is the new and improved model upgrade of the AMX magnetic drive process pumps. The pump is built with full polypropylene parts to offer improved efficiency, greater simplicity, and reduced maintenance for even the harshest of acidic and corrosive chemicals. The AMX-GG operates above 70% efficiency, is completely leak-proof, and comes complete with two years warranty as standard.

Users benefit from increased time between maintenance and servicing, as the pump’s patented buffer system absorbs vibrations and shock caused by adverse operating conditions.

The AMX-GG also offer a reduced running cost due to all external parts being totally corrosion resistant, meaning less maintenance parts are required over the pump’s life.

POWERFUL PERISTALTIC PUMP FOR PHARMACEUTICAL PROJECTS n Thermo Fisher Scientific’s Fisherbrand peristaltic pumps are easy-to-use peristaltic pumps with integrated pump heads. They are well-suited for applications where media transfer and filtration are required. The pumps provide contamination free pumping, as fluid comes into contact only with the tubing or hose material, eliminating the chance of cross contamination.

Their high volumetric efficiency allows operation in metering or dosing applications where high accuracy is required. The flow rate range is between 0.002 and 4,000mL/ min. The available tubing materials are approved to global pharmaceutical standards.

The Fisherbrand pumps are capable of running dry and pumping fluids with high quantities of entrained air. They are programmable, easy-to-use, low maintenance units that do not require check valves, preventing parts replacement and downtime.

Want your product here? Email georgina@fluidhandlingmag.com FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

13

Sense and actuate

VALVES

Use of valve actuators and sensors in pharmaceutical production will enhance safety and maximise production In 2012, it was reported that weaknesses in the manufacture of sterile injectable drugs resulted in almost one third of the biopharmaceutical industry’s manufacturing capacity being taken off-line. A major reason for these shortages has been quality and manufacturing issues1. According to US Government Accountability Office’s 2014 report, the most frequently cited immediate cause of drug shortage was manufacturing disruption due to quality problems – 40% of shortages between 2011 and 2013 resulted from quality issues or plant maintenance issues2.

The widespread shortages caused inferior treatment regimens, interruptions in care, higher health care costs, and even premature death. To reverse these alarming trends, it is essential that drug manufacturers maximise product quality to ensure patient safety.

Advancements in valve and sensor technology have enabled manufacturers in the life science industry to improve their manufacturing capabilities through maximising uptime, reducing overall cost of equipment ownership, and lowering maintenance costs. These benefits extend throughout the value chain in the form of financial returns and increased maintenance resources, all of which result in better patient care.

But how can valve actuation and sensor technology improve operational performance in the pharmaceutical manufacturing industry? Technologies and materials exist which are designed to complement and improve existing manufacturing trends while contributing excellent performance to the entire plant architecture.

Diaphragm valves in pharmaceutical manufacturing Diaphragm valves form an integral part of the pharma manufacturing process, in that they enable drug manufacturers to safely control different types of media.

Diaphragm valve technology has been around the pharmaceutical industry 14

since its invention by PK Saunders in 1928.

In general, the pharmaceutical industry has adopted common practices that incorporate the use of industrial communication networks. Industrial networks not only provide efficient control over one common physical media, but also dedicated diagnostics that contribute to preventive maintenance and reduce costly interruptions. The desire to implement new technologies by pharma manufacturers has pushed the valve industry to create new accessories that, in conjunction with aseptic valves, offer unparalleled control, complete and accurate status of a valve, and in the bigger picture a much more solid and reliable manufacturing process.

As the inventor of the diaphragm valve, Saunders’ vision for the future aligns with the goals of the pharmaceutical manufacturing industry as a whole. Manufacturers seek new processes and technologies that drive the current offering of materials for valve bodies or diaphragms (valve design and polymers). The company likewise drives innovation of electronic devices that offer new possibilities to end users, engineers, integrators, and OEMs. Part of the new generation of products specifically designed to increase accuracy and maximise diaphragm life include actuators and sensors. Together, innovations in these two devices can deliver outstanding performance, ultra-reliable valve position indication, and unique diagnostics that can be extracted

Pair of Saunders S360 actuators

remotely or locally at the sensor.

Solutions that maximise manufacturing cycles, reduce maintenance time, improve the accuracy of valve position readings, and offer efficient control and robust diagnostics are key differentiators that can reduce the overall cost of ownership of an aseptic valve. The use of this technology can eliminate recurrent issues that are common in the industry, such as: • False indication of valve position: An unknown valve position could lead to nuisance trips and other associated events (instrumentation failure, batch contamination, etc.)

• Lack of individual cycle counters that monitor diaphragm status: An unknown number of cycles could lead to diaphragm failure and potential batch contamination.

• Long commission time for limit switches during start-ups and factory acceptance tests (FAT), which can lead to higher operating costs • Overall size and weight of valve assemblies • Thermal degradation of the

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

VALVES diaphragm during steam in place, which can lead to failure.

Considerations for actuator and sensor selection Actuation is often critical to valve operation, not only from a reliability standpoint, but also because the chosen method of actuation can affect the accuracy of the process.

In highly-controlled pharmaceutical applications, this consistency and precision is especially important.

Generally, the more mechanical linkages there are in a process, the greater is the potential for error due to wear at the linkage points.

Variations in linkages can vary the piston stroke, causing accuracy problems. Therefore, valve users should carefully evaluate methods of actuation to mitigate any accuracy concerns and hysteresis effects3.

The following list outlines some important considerations in actuator selection, arranged by importance: • Closure performance: Actuator should be able to provide powerful closure performance under wide range of operating conditions. Improper closure can lead to catastrophic failure including loss of a batch • Compact design: A piston actuator with a compact design (versus diaphragm type actuators) is best-suited for the operating conditions found in most biopharmaceutical manufacturing facilities. A compact dimensional envelope will minimise the deadleg between associated valves and enable a more compact skid design that will optimise system performance • Ability to rotate: An actuator able to fully rotate the actuator head by 360° enables flexible installation and optimises air-port alignment. This in turn reduces installation overall cost for both new and existing projects, and optimises the incorporation of actuators in compact valve arrays or skid arrangements • Maintenance free: Corrosion resistance and easy cleaning ensure conformity with a hygienic environment, thus reducing maintenance costs • Material: Stainless steel housing material delivers a clean OD profile that can withstand the wash-down regimes required in the sterile pharmaceutical manufacturing process While actuators are critical to a

valve’s open and close performance, sensors are essential to the accurate determination of overall system status. While not every valve in a pharmaceutical system may have a sensor, those that do are considerably more effective in process control.

Valve sensors are intended to provide positive confirmation of valve position.

A lack of confirmation or inaccuracies in valve position indication can result in batch contamination, compromising both the manufacturing process and patients’ health. To ensure that cross contamination and harmful chemicals are not inadvertently introduced into drug manufacture, valve users should employ a robust and reliable sensor system.

The following list outlines some important considerations in sensor selection: • Mechanical vs. electromagnetic sensors: Mechanical sensors fail over time and have a tendency to provide erroneous indications, including false open or false close positions. Sensors with ultra-reliable electromagnetic sensing technology provide a high degree of accuracy – potentially less than 0.2mm – reducing the potential for error • Compatibility: Standard switch controls may not be compatible with all process control systems. Sensors

that are compatible with existing systems like Point-to-Point (P2P), AS-i, and DeviceNet can offer substantial benefits to ease of integration • Solid state continuous sensing technology: Continuous sensing technology enables diaphragm valve position to be known throughout the range of travel, allowing unsurpassed and accurate monitoring especially in smaller valves • Valve size: It is important to ensure that a sensor can be effective on a comprehensive range of valve sizes • Automated valve calibration: Installation can be simplified by utilising sensors with automated valve calibration. This capability enables a sensor to be incorporated into the system without opening the sensor enclosure, and can drastically reduce set up times Conclusion Manufacturing practices currently implemented in biopharmaceutical plants have been enhanced through the integration of actuation and sensor technology. Not only does the incorporation of these controls maximise system uptime, but it can reduce overall cost of ownership and enhance safety throughout the production process.

Actuators that deliver superior valve performance and sensors that eliminate false position indication are some of the most important contributions to better performance and maximum safety for the manufacturing industry. Designed to complement existing manufacturing trends while improving entire plant architecture, this equipment will help ensure a more promising future for the pharmaceutical manufacturing industry. z

References:

1. FDA’s Contribution to the Drug Shortage Crisis, STAFF REPORT, U.S. HOUSE OF REPRESENTATIVES, 112TH CONGRESS COMMITTEE ON OVERSIGHT AND GOVERNMENT REFORM, 2012.

2.www.fda.gov/downloads/ AboutFDA/CentersOffices/ OfficeofMedicalProductsandTobacco/ CDER/UCM442666.pdf 2. Avis, Kenneth. Sterile Pharmaceutical Products: Process Engineering Applications, Volume 1 of Drug manufacturing technology series. CRC PRESS. 1995. Page 104.

For more information: Saunders I-VUE smart valve sensor

This article was written by Edgar Marino, applications specialist for Crane ChemPharma & Energy, Saunders. Visit: www.cranecpe.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 15

VALVES

Solving the homogenisation dilemma Pharmaceutical operators experiencing issues with homogenisation processes will benefit from calling professionals

A standard homogenisation valve

Many will have surely heard the word homogenisation before, but might not necessarily know what it is. Basically, homogenisation is a process used to make a mixture of two mutually non-soluble liquids the same throughout. This is achieved by turning one of the liquids into a state consisting of extremely small particles distributed uniformly throughout the other liquid.

Sometimes two types of homogenisation are distinguished. In primary homogenisation the emulsion is created directly from separate liquids, while with secondary homogenisation the emulsion is created by the reduction in size of droplets in an existing emulsion.

Homogenisation is achieved by a mechanical device called a homogeniser, where the process is carried out in a special valve under high pressure (up to 2000 bars).

Controlled flow action subjects the fluids to conditions of high turbulence and shear that creates the most efficient mechanism for reducing the size of particles and droplets.

Originally homogenisers were designed for the dairy industry in search of a way for raw milk “standardisation�, where milk fat globules need to be reduced in size and dispersed uniformly through the rest of the milk. Today, homogenisers are an integrated part of most fine liquid product manufacturing lines, bringing higher process efficiency, better quality, and longer shelf time of the end product, all across the industrial market.

The pharma application In the pharmaceutical field, homogenisers are used for dispersions such as benzoyl peroxide in cream or lotion bases, for antacid dispersions, and for vitamin suspensions. Homogenisation at high pressures is required for perfluorocarbon emulsions (also known as a blood substitute), intravenous emulsions, and liposomes.

To understand how the homogeniser works and what it does, it is first necessary to trace the path of the liquid mixture through the homogenising valve. The accompanying picture shows a plug-type homogenising valve and standard valve seat. The unhomogenised product enters the valve seat from the pump cylinder at a relatively low velocity but at a high pressure.

16

For example, the velocity may be about 3-6m/s, while the pressure will be at 200 bar.

The pressure is generated by a positive displacement (PD) pump and by the restriction to flow caused by the valve being forced against the seat by an actuating force. The PD pump provides a relatively constant rate of flow and will therefore generate the required pressures as the flow area between the valve and seat is increased or decreased.

The liquid flows between the valve and seat at high velocity. In the case of the previous example, at 200 bar the corresponding velocity would be about 150m/s. As the velocity increases, the pressure decreases producing an instantaneous pressure drop. The liquid then hits on the wear ring (impact ring) and is finally discharged as homogenised product.

The time it takes for the liquid to travel across the face of the valve seat and to undergo homogenisation is less than 50Âľs. Therefore, it can be seen that a large amount of energy is dissipated in a very short time, producing a large energy density in the liquid. This results in a dissipated energy density of about 1000kW/cm3.

This explanation demonstrates how the homogeniser concentrates high energy into a small fluid volume. The homogenising valves are unique in carrying out the required degree of micronisation and dispersion at lowest possible pressure. A range of valves with respect to their design and material are available to meet the varying properties of handled fluids. Handling fluids under such high pressure is a technology in its own right, combining the specialist disciplines of machine design, strength of materials, and the behaviour of fluids under extreme flow conditions.

Case study In 2015, Tapflo Poland, part of International Swedish Tapflo Group, was required to solve a problem at one of the leading Polish pharmaceutical companies. The production of a specific medicine was suspended for several weeks, due to mistakes in installation adjustment for proper operation with a homogeniser.

The problem came from the system failing to deliver air-free product to the homogeniser.

Small air bubbles were responsible for pressure shocks in the homogenising valve, which FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

VALVES eventually resulted in damaging its parts.

It took several visits and tests to help the customer diagnose the installation, find the source of the problem, and the places where air was seeping in to the product.

For the benefit of all current and potential homogeniser users, some core rules for good homogeniser installation practices are shared here. Operators can save themselves a lot of headaches if they: • Always check for the minimum inlet pressure required for proper homogeniser operation and make sure there is a pressure switch installed to monitor the pressure and – in case of pressure drop – protect the homogeniser by turning it off.

• Wherever possible introduce on the homogeniser inlet a transparent inspection, so they can have a visible control of the product stream flowing into the homogeniser.

• Make sure that the installation on the suction side of the homogeniser is free from areas where air pockets could easily form (siphoning, dead legs).

• While operating with a suction tank, always make sure that there is a vortex breaker and also a minimum level control installed.

• Wherever possible before adjusting pressure to the homogenising valve try to circulate the product for a while, so that any potentially trapped air can be evacuated.

The leader in the field of homogenisers and at the same time the inventor of the technology is APV Diagram of the homogenisation process (presently part of SPX Flow) with its two homogeniser product lines – Gaulin and Rannie – with For more information: This article was written by Krzysztof a history reaching back to the early Doroszkiewicz, Sales manager at 1900s. In Poland, Russia, Ukraine, Bulgaria, Tapflo Poland. Visit: www.tapflo.pl Romania, and Latvia these products are distributed by the Tapflo Group, which Bibliography: supports operators in getting most out APV Homogenizer Handbook/ Issued: 04/2009 3005-01-06-2008-US of these fine pieces of technology. z

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Extra safety in one neat package

VALVES

The challenges of implementing double-block-and-bleed valve systems and the benefits of specifying single-unit designs Right along the oil and gas supply chain – from extraction through to delivery to the end user – safety is the number one concern. When an operator wants to isolate a pipeline, whether this is part of the routine operation of a facility, to carry out maintenance, or in response to a potential crisis, it is critical that the valve used is 100% effective.

Sometimes isolation valves are installed purely as a safety measure and may never need to be closed. They may sit inactive on a pipeline for many years before being urgently required, at which point operators need to be sure that they will perform as expected.

To isolate pipelines in oil, gas, and petrochemicals applications, doubleblock-and-bleed (DBB) valve systems have been mandatory since 1990, following the events of the Piper Alpha disaster, which killed 167 people on an oil platform. These arrangements feature two independent valves in the pipeline itself with a third valve allowing

operators to drain the space in between the two valves. The benefit of such an arrangement is that if the first valve in the system leaks, any material getting through will escape through the open “bleed” valve, rather than continue down the pipeline to the area where it might potentially become a hazard.

Today, more than 90% of isolation systems used in the oil extraction process worldwide are DBB configurations.

Conventionally, in order to achieve a

A DBB instrumentation valve from Oliver Valves

DBB system, two standard isolation ball valves are installed along with a separate facility for bleeding the pipework in between. However, there are downsides to these traditional installations.

Leak paths The first is around fugitive emissions – the small amounts of material that leak out through the flange connections between separate components. These are a major cause of concern across the industry, particularly for onshore facilities where the material may be escaping into populated areas.

Any seal between two separate pieces of material constitutes a potential leak path. Inside a ball valve, the contact seal between the ball and the seat insert presents a possible means of escape for high-pressure media, and valve manufacturers have invested a great deal of time and effort into reducing the possibility of these leaks, employing technology such as sprung seats and trunnion-mounted balls.

Potential leak paths are also presented by any join in the pipework, whether this is a connection between a pipe and a component or two separate sections of pipework. Therefore, increasing the number of joints required for a valve installation significantly increases the likelihood of media escaping from the system. If the additional potential leak paths created by installing three valves are multiplied instead of one for isolation duties across an entire oil refinery, it is easy to see how it could present a substantial issue.

Size and weight

Precision engineering a valve

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The second challenge is that more components will take up more space FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

VALVES and add to the weight of an installation.

Requiring an additional valve unit to be installed, as well as a T-section to allow the intervening pipework to be bled, more than doubles the space required compared with a single valve system, which can be an issue where space is of the essence.

This significant size increase can often make the installation unfeasible, especially where multiple valves along the line need to be upgraded. One area in which this is a particular concern are floating facilities, where space and weight are at a premium. In the world of upstream oil and gas production, these facilities have gained a lot of ground against traditional oil and gas platforms as they allow energy companies to access increasingly remote locations more cost-effectively.

Floating production, storage, and offloading facilities are a particularly popular approach. These typically re-purpose the hull of an existing vessel, such as an oil tanker, to house the production facilities, which are connected by submersed pipelines to the wellheads on the sea floor. These applications require a large amount of equipment to be housed on the facility, which has a finite amount of weight and space available. Therefore the physical dimensions of all installations have become a critical concern and engineers are keen to shave off size and weight wherever possible – needless to say, without compromising on safety levels.

Single-unit DBB valves

A Twinsafe valve in situ, demonstrating the reduced face-to-face length required for installation

6D and ANSI B16.10. Not only does this mean the system can be easily installed into an existing system without any re-working of the surrounding pipes, but also that the space required for a DBB system is reduced by more than half. This frees up room for other equipment and easier personnel access and, in the case of floating facilities, saves critical weight and space.

Oliver Valves pioneered the single-unit DBB valve, called Oliver Twinsafe, in the early 2000s and, since then, the range of sizes and designs of single unit DBB valves available has grown rapidly. The company recently manufactured its 200,000th DBB valve, demonstrating the popularity

To tackle the inherent challenges of a traditional DBB system – which requires three times more connections than are needed for a single unit – a potential solution is the single cartridge DBB valve manifold. Incorporating all three valves into a single housing increases the safety of the system by removing connections between separate units, resulting in fewer potential leak paths. The volume of the cavity between the valves is also reduced, allowing operators to evacuate the space and establish a safe isolation more quickly – a potential benefit in emergency scenarios. This reduction in volume also makes for less waste, reduced handling, lower costs, and easier disposal.

Another key advantage is that the whole system can be built to have the same face-to-face length as a standard single isolate valve, as specified in the relevant international standards API

they have gained across the industry.

As global energy businesses face challenges such as increasingly inaccessible oil and gas reserves and the need to reduce fugitive emissions, technological innovation at ground level will play a central role in delivering solutions. Single cartridge DBB valves are just one example of how the valve industry has developed in recent years in response to industry needs. z

For more information:

This article was written by Paul Shillito, engineering director at Oliver Valves. Visit: www.valves.co.uk

An Oliver Twinsafe pipeline isolation valve

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 19

VALVES

Easy selection, powerful performance Pneumatic pilot-operated valves can be deployed in safety applications with multiple advantages over traditional pressure relief valves Pilot-operated pneumatic valves are used in a huge array of industrial applications, from simple on/off operations to those using multiple inlets and outlets for more complex logicbased control architectures. In many instances, their method of operation has remained the same for several years, with body and flow designs coupled with advances in materials providing the differentiating factors.

One area in which they are used very successfully is in processing environments, such as those found in the oil, gas, and chemical industries. As well as offering a number of physical advantages over incumbent and traditional technologies, their method of operation is also safer from a fire risk perspective thanks to their use of a pneumatic infrastructure.

In just about every industrial and processing environment, over-pressure is a dangerous phenomenon that has to be managed precisely and, in many cases, quickly. Even with generous safety factors built into pressure and storage vessels, pressures must not be allowed to go above certain installation specific levels.

The good old way?

Traditionally, the role of managing pressure in vessels or pipes has been the job of pressure-relief valves. Basic

The SMC VFA3130 air-operated pilot valve

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pressure relief valves are highly simplistic, deploying a spring to hold a valve closed until the pressure of the medium being contained is high enough to overcome the force of the spring and open the valve, until the force of the spring is once again greater than the opposing pressure and able to close the valve.

The closing force in relief valves is often adjustable to a certain degree, using variable spring compression, but this is not an exact science as over their lifetime the springs can relax or compress, resulting in variable holding forces.

Pressure relief valves are also fettered by the need to be physically large enough to resist higher pressures. Higher pressures mean bigger springs, which in turn mean bigger valve bodies. In today’s modern industrial environment where real estate is at a premium and ‘clutter’ is not tolerated, more suitable options are required.

Enter the pilot This is where pilot-operated control/ relief valves come into their own. By using the pressure of the fluid they are controlling against, they can be much more compact. Indeed, they are positively diminutive in size compared to some similar-performance relief valves.

In operation, a small feed pipe is routed from the side of the system under pressure and this is sent via a control pilot to a piston, which is used to cut off the flow from the pressure side. The sealing is achieved by the fact that the small feed pressure is applied to a larger surface area behind the piston than that faced by the fluid under pressure.

This means a greater force is applied on the reverse of the cylinder, even though the supply pressures are the same.

When the pilot valve experiences a set pressure level it opens to atmosphere, venting the small feed tube, which

immediately removes the closing pressure on the cylinder, allowing the main system to vent. Once the pressure is below a certain safe set point, the pilot reseals and the system pressure once again closes the valve.

There are many benefits of using a valve of this design, including its smaller overall envelope and greater flexibility with regards to control options and remote mounting. It also provides a better seal due to the system pressure never quite reaching the closing pressure, as it is in direct correlation but always slightly lower.

Options here, options there Pilot operated pneumatic control valves form the mainstay of many pneumatic control solutions and designers are spoilt for choice when it comes to variants and suppliers. Leading suppliers include Asco Joucomatic, Bosch Rexroth, Crouzet, Legris, Norgren, Parker, and SMC and when it comes to variants, one look at the website of RS Components, an equipment distributor part of the USbased Electrocomponents, confirms that over 4,780 products are available from these suppliers and others.

However, the number of options available automatically helps cut this huge range down to more manageable chunks, giving designers the freedom to narrow in on their exact requirements from a smaller choice of units.

In the first instance, the mounting solution is probably first on the list of options to consider as the valves can be installed either on their own or on manifolds/sub-bases – both on machine or remotely. The second consideration will be to look at material types for all parts of the valve as this will, to a certain degree, be determined by the application and its environment. As an example of whittling down the options,

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

VALVES by simply choosing a manifold mounted, aluminium-bodied valve, the list of 4,780 variants is cut to just 31 products.

Once the mounting style and material choice is available, the next option is the primary function of the valve based on the number of ways (paths) and ports. There are multiple options available including two-, three-, four- and five-way valves with various port configurations depending on the type of venting/supply required.

Connection types and operating pressures are next on the list, but as these are generally standard across international borders, chances are that there will be very little specialisation and that standard sizes/pressures will suffice.

The body materials give some hints about specialist applications, with users given a choice of basic steel or aluminium metal construction through specialist alloys and plating options. The designer can then move into brass and brass/alloy combinations before hitting the realm of the specialist high-strength engineering plastics for very specific application

requirements.

Internal components can also play a large role in the functionality and longevity of valves.

Spool and seal materials can affect speed of operation and sealing efficacy coupled with resistance to aggressive The SYA range of air-operated pilot valves from SMC substances, thus prolonging their life.

In all instances, as long as designers application is not unique. Suppliers know what they want the valve to such as RS are also able to provide achieve, the environment in which it 3D CAD models making the design is to operate, how it will be mounted, process even more straightforward. z and what supply parameters they have, selection can be extremely straightforward. All suppliers will be able to For more information: This article was written by Paolo help with exact specifications and even Carnovale, category marketing manager specialist applications will often be readily for automation and control, at RS Components. Visit: www.uk.rs-online.com considered, as chances are the specialist

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 21

PUMPS

Drop the shovel, use a pump

Jump JH38 Double peristaltic pump on mobile unit

Installing a peristaltic pump has helped one French food company save time, energy, and back muscles while processing fruit puree A food industry company based in northern France was looking for a solution to transfer fruit puree from barrels to a heated mixer.

Fruit puree is a food product composed of finely ground fruits, in which sugar is added in different quantities depending on its use. Sugar is mainly used for preservation during storage, but it also enables the producer to fix colour irregularities, preserve the flavour of the fruits, and make the final product creamier.

At this stage, the company transfers the fruit puree directly from its suppliers into barrels, which are then stored at about 4°C. The barrels are carried to the mixer, where the puree is processed into different end products, such as yogurts, compotes, and other such foodstuffs.

In order to maintain the high quality and consistency of the product, the transfer process of the fruit puree has to be handled with care, but as quickly as possible. At this temperature, the product needs to be processed quickly to avoid thermal shocks and sanitary risks.

Until now, the transfer was made manually by the operator by using a shovel and raw manpower. This method for unloading the barrels was extremely time consuming and physically very hard for the operator. Therefore, the company decided to install a pump to do away with this archaic operation. The new equipment to be implemented had to reduce manual work and increase the efficiency and productivity of the operator and the speed of unloading, while simultaneously reducing the amount of puree remaining in the barrels and causing product loss.

Jumping at a solution Jump, a French fluid transfer solutions provider, was asked by the food company to find a solution for this specific application. Jump identified three determining factors that affected the selection of the right pump for the job: • Viscosity: Generally, fruit purees are thick, smooth products which have been processed in such a way that the insoluble fibrous parts are broken up to the point that the puree is able to fit through a fine sieve. In some cases, the puree is pasteurised to reduce microbiological loading and increase shelf life.

• Particle size: Fruit puree is composed of fruit pulp particles that have to be taken into account when choosing the processing pump, as not all technologies can accommodate such chunky material.

• Installation, pressure, and charge losses: Considering the viscosity and the installation, the pump needs to have strong suction and compression power to reach the flow rate needed.

Regarding this application, Jump proposed to use its JH38 Double 22

peristaltic pump to empty the mashed fruit of about 100,000cPs in viscosity from the 200L barrels to the mixer, thus reducing the need for manual work. The technology was chosen due to it being well-suited for the application. The pump would help reduce the operator’s workload and fatigue, and it is quick to install with reduced maintenance time and ease of use.

The food company was satisfied with this new solution and the results. The pump proved successful in handling the fruit puree based on a combination of several factors, such as preserving the quality of the product due to a low shear rate, strong suction, and compression power. The pump reduced the need for maintenance time and cleaning, improved work conditions, and increased the food company’s productivity.

Technical features The JH38 Double pump consists of two flanged mounted bodies with a suction and discharge port that increases its flow rate capacity while reducing pump size and space requirements.

Adapted to the fruit puree processing application, the JH38 Double is able to transfer the fruit puree at a height of 2m. The pump is able to empty a barrel of puree in less than five minutes.

The product loss is less than 1% due to the pump’s suction and compression power. The pump is safe to operate and the operator no longer needs to handle barrels during the transfer operation. Manual work at the processing facility has been reduced to a minimum. The pump is installed close to the mixer and the operator only has to carry the barrels to the mixer station.

Designed and manufactured by Jump, the JH series pumps combine several pumps into one through a system of embedded bodies. The pumps’ design provides up to 70% lower pulsation with three bodies compared to a single peristaltic pump, reduced space requirements while providing a transfer capacity of up to 300m3/h in the triple version, reduced energy consumption by 70%, and adaptable flanges that offer the possibility of transferring, mixing, or dosing several products with a precise volume flow.

The JH Series pumps can be used in many fields of applications, such as food, energy, chemical, or cosmetic industries for pumping a variety of fluids with or without high solid contents. They are selfpriming, dry running, and reversible. Jump offers hoses in different materials according to the pumped products’ compatibility, the selection including natural rubber, Buna, and EPDM. z

For more information:

This article was written by Sophie Denicant, communication manager at Jump. Visit: www.jump-pump.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

PAGE HEADER

STAR CONSTELLATIONS.

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 23

PUMPS

Nao is the time

Solving the pumping challenges in pharmaceutical applications requires innovative solutions The main factor driving the market of pumps today is the increasing use of sophisticated devices both for individual and industrial use. The challenges faced by the industry are two-fold, including the high level of accuracy in delivery with pulseless flow whether delivering a small or large dose of fluids, and the cost of the disposable pump head and driving unit. Simply put, the market is asking for the best solutions to overcome issues encountered when using peristaltic and syringe pumps. Therefore, modern pumps have to be easy to set up and to use, be accurate, and of low cost.

Within such context, Switzerlandbased consultancy and industrial engineering company Swissinnov Product has set to meet today’s market challenges and increasing demands.

Swissinnov develops different proprietary technologies of disposable pumps to provide solutions for very specific technical requirements, sometimes termed as “technological challenges�, from various industries, including medical, pharmaceutical, veterinary, and food.

Masterflex drive in an open position with a NaoStedi pump

What makes it tick To provide a solution to these challenges, Swissinnov has developed the NaoPump.

The pump possesses fairly simple technical characteristics, allowing it to be easily fitted into any device or equipment requiring pulseless flow delivery at a certain level of precision, whether in small or large volume.

The pumping system consists of two pistons moving specifically and alternatively into a rotor, ensuring a linear and constant flow rate. The flow delivery correlates proportionally with the speed of the motor and the delivered volume to its rotation angle. The system is similar to the peristaltic pumping system, but the differences become relevant when looking at the results. One motor revolution in a NaoPump gives +/-1% accuracy of delivery independently of the inlet and outlet pressure and over time.

24

One of the main advantages of the NaoPump is that there is no need for a flow sensor or any controlling balance in the system. Furthermore, the flow delivery remains constant during the lifespan of the pump parts. Several

The market is asking for the best solutions to overcome issues encountered when using peristaltic and syringe pumps

tests conducted on the NaoPump have confirmed that it does not suffer from any drift, which usually appears in pumping system after a certain amount of time and operation. Designed to be fitted in any pumping device, the NaoPump can be mounted with any standard motor, offering the possibility of use in a large variety of applications.

Good medicine Recent applications of the pump technology have been specifically in medical and pharmaceutical fields. For a medical application, the NaoPump has successfully achieved the technical challenge requested for a drug dosage

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

PUMPS

The NaoStedi was found to be compact, lightweight, silent, simple to set up and use, and – most importantly – economical in a blood circuit. Swissinnov’s client was faced with an issue of finding a pumping system able to deliver accurately and constantly small and large flows that change intermittently. The whole system had to be capable of working without any sensor installed into the dosage circuit. Additionally, the pump itself had to be of a compact size, easy to set up, and able to deliver a drug accurately into a blood circuit during a couple of hours. Finally, the solution had to come in the form of a disposable pump that could be integrated into a portable device.

Against this backdrop, peristaltic pumps were considered but found to not be the best fit for the application.

Certain shortcomings in the peristaltic pumping system did not allow an accurate delivery of drug dosage, therefore requiring a dosage sensor, which had been ruled out by the application requirements. Diaphragm pumps could not match the technical challenge either, since diaphragm pumps not only produced a high level of noise, but they also could not ensure proper dosage when pressure in the main circuit varied.

NaoStedi, a NaoPump model, on the other hand was found to be a suitable solution for the medical application. It delivered the requested accurate dosage without a flow sensor for calibration, and the torque required to operate the pump remained relatively low as compared to peristaltic pump. The pump’s adaptability to different motor types was seen as an advantage, offering many options to the client when integrating the system into a portable device. The NaoStedi was found to be compact, lightweight, silent, simple to set up and use, and – most importantly – economical.

very short time frame and low cost.

The challenge faced by SwissInnov’s client was to find a disposable pump able to rapidly fill multiple vials simultaneously during several hours of operation, while ensuring accurate dosage in each vial.

The client selected the NaoStedi as its preferred choice solution due to its ease of use and compatibility with Masterflex drives. These features allowed testing to be carried out within a short time. Subsequently, the client was able to capitalise on its existing training system, which has resulted in reduced integration costs for NaoStedi. The solution also offered the possibility to remove the calibration phase, which is usually required in peristaltic pumps. The elimination of this start-up phase can further reduce the cost of operations and subsequently increase the overall productivity of the whole process.

In order to offer a complete solution for this specific pharmaceutical application, Swissinnov also provided its services in designing the fluidic circuit to simultaneously fill multiple vials. Only one specific component had to be added to deliver a prototype in just few days.

These two recent cases illustrate the application spectrum offered by the NaoPump. The flexibility in the pump design and confirmed performance of the pump, combined with the additional services, are the key factors in solving specific technical challenges or issues faced by a diverse industry looking for pump solutions. z

Jet vacuum systems Process-integrated solutions for many types of vacuum system

Jet pumps form the core of steam jet vacuum pumps, steam jet cooling plants and heating/cooling units. They are used in many different processes for conveying, recompressing and mixing gases, vapors and liquids and for evacuating tanks by drawing off gases, vapors and solvents. Consult our Online Product Catalogue on our website and get inspired by the variety of information and application examples.

Pumps & Valves, Antwerp Expo, Belgium 20 – 21 April 2016, Stand F4040

The pharma filler For a pharmaceutical application, Swissinnov has successfully provided a full and complete solution, including the design of an associated fluidic circuit to a pumping system within a

For more information:

This article was written by Florent Junod, managing partner at Swissinnov Product. Visit: www.naopump.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 25

A bit of bitumen

PUMPS

Sliding vane pumps have proven to be an efficient choice for pumping harsh viscous liquids Transferring road surfacing products from bulk holding tanks to road tankers demands pumps that are not only capable of handling the liquid, but are also wholly reliable to ensure that products are readily available on demand. When Axflow, a London-based pump manufacturer, was requested to recommend pumps capable of handling viscous, sheer sensitive bitumen emulsion products at temperatures of 260°C, the company’s answer was to specify its Blackmer N and SNP sliding vane pumps for the task.

Blackmer sliding vane pump types employ a number of vanes that are free to slide into or out of slots in the pump rotor. When the pump driver turns the rotor, centrifugal force, push rods, and/or pressurised fluid causes the vanes to move outward in their slots and rub against the inner bore of the pump casing forming pumping chambers. As the rotor revolves, fluid flows into the area between the vanes (pumping chambers) when they pass the suction port. The fluid is transported around the pump casing until the discharge port is reached. At this point the fluid is squeezed out into the discharge piping.

Using this combination of methods means that Blackmer vane pumps can run at slow speeds, thereby enabling them to handle viscous fluids while subjecting them to very little disturbance. These are highly important characteristics when handling bitumen emulsions.

As positive displacement pumps and due to the push rods that maintain the pressure of the vanes against the pump housing, the volume of liquid transferred by the pumps remains constant irrespective of the viscosity of the liquid and the life of the pumps. The pumps can also be used to handle clean, non-corrosive industrial liquids and petroleum products.

Typical applications include fuel oils, lube oils, aviation fuels, edible oils, and a variety of solvents and thinners.

The operating principle of the positive displacement free vane pump. The rotation of the rotor and vanes transfer the liquid from the positive suction side to the discharge side within the pump chamber in a continuous movement.

blends, which was why sliding vane pumps were considered. Emulsions do not like shearing as it has an adverse effect on the viscosity of the product.

The NP4 pumps are used for bitumen loading and the stainless steel SNP3 model for transferring highly corrosive emulsions. The original pumps installed were fitted with packed glands, but with the introduction of further gantry loading facilities the new pumps were fitted with flushed mechanical seals to give higher integrity. The steam quenched seals also maintain the product temperature and protect the seals from seizing up.

As the pumps draw a variety of emulsions and bitumen products from storage tanks, product crossover is a potential problem. A significant benefit of the Blackmer NP4 and SNP3 pumps is that they can be reversed for a short period, enabling the pipelines to be cleared at the end of operation. Reverse pumping the products back through the lines prevents swivel joints on the loading lines from seizing up. In addition, where the single pump is taking separate product from three different tanks, product in the lines can be pumped back into the tanks thereby reducing the possibility of product cross-over.

The installation of the emulsion loading facilities led to the introduction of sliding vane pumps for bulk liquid transfer at the plant. These have proved to be a successful answer to what can be a challenging duty, given the nature of the products. The design of the pumps means that maintenance is low and operators at the plant only need to carry out vibration and sealing gland checks. At the end of the production season the pumps are given a short flush and steam clean before shutting down for the winter. z For more information:

This article was written by Bryan Orchard, an independent international journalist working in the areas of pump and valve technologies, for Axflow. Visit: www.axflow.co.uk

Possible issues According to Malcolm Walker at AxFlow, the client had expressed concern in respect of shearing problems with some of the more complex bitumen emulsion 26

Blackmer SNP3 sliding vane pump

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

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Don’t miss your chance to appear in the May/June 2016 issue of Fluid Handling International

For editorial suggestions contact: Ilari Kauppila, ilari@woodcotemedia.com +44 (0) 208 687 4146 For advertising information and prices contact: Georgina Barry, georgina@fluidhandlingmag.com +44 (0) 208 648 7092

Next issue features include: Industry focus: water & wastewater Vacuum pumps Butterfly valves Safety valves Ultrasonic flowmeters Leak detection

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Don’t throw the baby out with the bath water!

FLOWMETERS

Even a grizzled veteran of a flow element can get a new lease on life with a fresh flowmeter installation A large UK water company works to supply drinking water to the city of Manchester from the Longdendale Chain of reservoirs in northern Derbyshire. Originally conceived in the late 1800s, the water treatment process has seen many changes as technology and processes have improved. One such water treatment plant is based on a process installed in the 1960s. It delivers drinking water to approximately 72,000 people.

The water treatment process adds chemical flocculating agents to bind together impurities, which sink and are later removed in sedimentation tanks.

In addition, lime is added to remove manganese and the water is further filtered and chlorinated before being allowed into the water network.

One of the key parts of the process is being able to automatically control the amount of chemicals that are added.

By measuring the volume of water being passed through the treatment plant, the amount of chemicals can be automatically controlled in proportion. So, being able to rely on a flowmeter that can produce repeatable readings adds to the consistency of the control and the quality of the water being delivered from the process.

The existing flowmeter The existing flow measurement solution at the treatment plant is a differential pressure primary flow element (FE), which is installed in the incoming 60” water

The basement housing the old FE is prone to flooding

28

main. Access to the FE is arranged via ladders and gantries, and in addition the basement is prone to flooding. There is also a risk that water levels could rise above the FE, if there was a pump failure.

There are two differential pressure (DP) transmitters that are connected to the FE, and until recently operations personnel had confidence in the signals that these devices were providing to the control room.

But this confidence suffered when one of the two DP transmitters failed and signals from the second one became erratic.

So what is the problem? Without consistent and reliable meter readings to automatically control the dosing rate of chemicals during the process, it would require a continuous manual operation, which is both time consuming and costly.

Investigations A team from a leading flowmeter manufacturer was called to the site to investigate a possible solution.

Their observation was that: • No technical drawings or flow sizing details were available for the flowmeter • It is more than 60 years old • The exact type of flowmeter is not clear from external examination • No physical access to replace the existing FE is possible due to the basement location Their proposed solution: • To leave the existing meter in

line and cap off the tapping’s to the DP transmitters • To quote for a new 1,500mm electromagnetic flowmeter • To dig a new metering chamber outside of the current building footprint • To shut down the water treatment plant to facilitate the cutting of the main feed pipe so that the new meter could be installed in the new chamber While there is nothing technically wrong with this proposal from a metering point of view, it would cause a severe disruption to the water supply for some 72,000 people and incur costs in excess of £250,000 (€323,900).

The alternative Coulton, a UK flow solutions provider based in Christchurch, provided an alternate solution. The company’s metering and control specialist attended the site and worked through the guidance given in BSEN 7405:1991 “Selection and application for flowmeters for the measurement of fluid flow in closed conduits”. The process of elimination suggested the following considerations, with the intended outcome being to identify the appropriate metering technologies for the application: • Performance • Installation • Fluid properties • Environmental • Economic

Seiko flow element engineering meeting

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

FLOWMETERS Fuji Electric V5 flow and pressure transmitters

production would have to be considered.

Coulton recognises that BSEN 7405 is in need of updating. Nonetheless, it still provides useful guidance on the selection process, and in particular for keeping an open mind with regards to technology, as what is available on the market changes at an incredible pace.

The solution

The installation was a critical consideration in the selection of the most appropriate solution. The existing location had limited straight runs of pipework, no access for lifting, and the possibility of flooding.

It was clear that for control purposes, reliability and repeatability were more important performance criteria than absolute accuracy. The performance of the existing FE had been satisfactory for more than 60 years, so it was unreasonable to reject the existing flowmeter based on the technology. The performance of the existing FE would, however, be tricky to verify without drawings and sizing calculations. And this was not to mention the inevitable wear and tear that 60 years of service would have created.

The fluid properties were of a lesser concern because water is reasonably well understood and documented.

It is stable and the fluid of choice for many calibration flow rigs. It therefore placed few restrictions on the selection of flowmeter technology. Environmental conditions were not too challenging either, although Ingress Protection to IP67 or even IP68 had to be considered to cope with the threat of flooding. Otherwise the environmental conditions did not restrict the selection of meter type.

Economic implications in the selection of a flow metering solution are often critical. However, users should be aware that price is no indicator of performance.

Often the cost of correct installation will be a major consideration in meter choice and this application is a clear example of this. In addition, the cost of lost production and/or the cost of alternative

Two technologies were shortlisted, largely because they met the installation limitations. The first solution proposed was to keep the original primary FE, to renew the differential pressure transmitters, and to verify the meter flow coefficient using operational data from the water treatment process. In effect, Coulton planned to calibrate the meter in situ. The second device to make the list was a clamp-on ultrasonic flowmeter. This technology has seen huge improvements over the past 10 years with the clear advantage of not having to cut into the pipe to install it.

Both technologies were proposed to the customer, with additional support for the installation, commissioning, and verification of readings included in the proposal. This would require the additional cost of Coulton instrumentation engineers attending site. In the end, the customer chose to proceed with the first option.

The technology DP flow devices still represent 40% of the installed meter population, and unlike newer technologies they are the subject of well-established international standards.

In control or general flow monitoring applications where reliability and repeatability are of the highest importance, fixed geometry DP devices are a hard act to follow. They are commonplace in many process applications. Also, being fixed in construction and having been

Fuji Electric flow transmitter

calculated for practical pipe flow rates gives DP FEs a solid foundation on which flow metering systems can be built.

Today’s DP flowmeters also benefit from a new generation of DP transmitters.

Advances in DP transmitters has led to density flow calculations, square root extraction, local digital displays, and even impulse pipe blockage detection being available in the transmitter electronics. It is now practical to expect a differential pressure transmitter accuracy of 0.06% over a turndown of 100:1, giving orifice plates, Venturis, flow nozzles, and pitot tubes a new lease on life.

Some critics will refer to the pressure drop caused by the restriction of the flow element. But they then, conveniently, forget to mention that 40% is recovered downstream, or that an alternative vortex meter, if installed correctly, will introduce reduced bore pipe work, causing an equivalent pressure drop.

The product Coulton recognises that Fuji Electric is not the only manufacturer to provide reliable DP transmitters of this level of performance. In this instance, the customer purchased a DP flow metering “solution”, based on Coulton selecting the most appropriate technology, whilst working to internationally recognised standards.

The solution was made possible through the practical application knowledge and support of Coulton engineers. Such a complete solution package can be considered a product in itself. In addition to DP flowmeters, Coulton offers flowmeters for all liquids and gasses in hazardous, hygienic, or general process applications. z

For more information:

This article was written by Malvern Jones, managing director at Coulton Instrumentation. Visit: www.coulton.com

Customisable engineering units via push buttons

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 29

Picking the perfect magmeter

FLOWMETERS

What to consider when choosing a magnetic flowmeter and why Since their introduction in the 1950s, electromagnetic flowmeters have become one of the most widely used flowmeter types for measuring water and other liquids.

Also known as Magmeters, magnetic flowmeters, or induction flowmeters, they function with conductive fluids to measure flow across a controlled magnetic field. The magnetic flowmeter design offers some very important advantages especially with regard to reliability and accuracy, which have helped encourage uptake, making the Magmeter the most common inferential velocity device used for flow measurement.

For a start, there are no moving parts to wear and become unreliable. As a result, there is nothing to affect the flow stream, which makes measurement far more reliable, giving greater accuracy between 0.5 to 1%. Additionally, there is virtually no pressure drop, as even the insertion magnetic flowmeters have only a very minor drop in pressure.

Magmeters can be used in pipes of almost any size and handle flows with a high level of solids, which often cannot be measured with other types of flowmeter.

They can support a variety of liners that enables the meters to be used for a range of specific applications, such as sanitary liners for hygienic applications or inert liners for corrosive liquids. They are relatively insensitive to fluid viscosity, specific gravity, temperature, and

Icenta Magnetic flowmeter operating principle

30

Preparation of Magflo with remote display prior to installation on buried water supply pipe

pressure, but there are a small number of specific limitations. Magnetic flowmeters will work with laminar, turbulent, and transitional flows and respond well to fast changing flows. They also have relatively short straight-run requirements.

Limitations As with all flow meters, the Magmeters do have their limitations: • Magmeters’ use is restricted to liquids where conductivity is at sufficient levels to induce measurable voltage, i.e. magnetic meters are unable to measure the flow of hydrocarbons due to their low conductivities • For the Magmeter to be effective, it typically requires a pipe full of flowing liquid • Magnetic meters cannot be used to measure gas flow • The pipe must normally be grounded (failure to properly ground the pipe can result in fluctuating flow signals) Due to the significant advantages of magnetic flowmeter technology, the

Magmeter can handle a wide variety of applications. It is commonly used in the water and wastewater industries, along with liquid food, beverage, and pharmaceutical industries where there is a requirement for sanitary flowmeters. It is also suitable for very corrosive liquids, such as corrosive acids, process chemicals, electrolytes, and brine. Its suitability for flows with high level of solids has led to applications in the pulp and paper industries, mining slurries, sludge, and other solid bearing fluids.

Considerations for selection To help operators choose a magnetic flowmeter that is right for their application, there are some key things that should be taken into consideration: 1. What type of fluid will be measured?

2. Is the fluid conductive or water-based?

3. Is the fluid or slurry abrasive?

4. Is an integral display or remote display required?

5. Is an analogue output required?

6. What is the minimum and maximum flow rate for the Magmeter?

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

FLOWMETERS necessary replacement water supplies to be provided.

Icenta specified IP68 electromagnetic flowmeters and data loggers with remote displays from Siemens (Magflo 8000 series) for this project. The meter specification had to meet strict criteria. Key concerns for ERS were suitability for drinking water application, and any potential impact (perceived or real) of the flowmeter on the supply flow and pressure and ease of use. The Magflo met all necessary requirements, allowed the operator to exactly match a flowmeter to water supply pipe diameter whilst using a single type of flowmeter, and the battery operation and remote display allowed the flowmeters to be installed both on buried water supply pipes and in confined environments such as pump houses.

Furthermore, the Magflo meters were easy to connect to off-the-shelf pulse data loggers to allow flow recording at

Installation of Magflo with remote display on buried water supply pipe

7. What is the minimum and maximum process pressure?

8. What is the minimum and maximum process temperature?

9. Is the fluid chemically compatible with the Magmeter’s wetted parts?

10. What is the size of the pipe (mm)?

11. Is the pipe always full?

12. Does the product have to be ATEX approved?

13. How will the Magmeter be fitted – new pipe installation or fitment to existing pipe?

What to choose There are two different types of Magmeters, namely in-line and insertion meters. These types of meter primarily differ in how they are fitted to the pipework.

In-line Magmeters are supplied flanged within its own section of “pipe” that can be connected to the pipes already in location on-site. Once installed, the inline Magmeter operates smoothly and provides an accurate and reliable flow measurement instantly and without fuss.

These meters are typically fitted to as part of a new installation of pipework.

The insertion Magmeters by contrast are typically retrofitted to an existing section of pipework by drilling a hole into the pipe, inserting the Magmeter into the hole and fixing it to the pipe to prevent damage or loss of performance. It is due

to the retrofit nature of the insertion meter that a minor pressure drop could occur.

As mentioned, Magmeters are used in many industries and sectors. An example of how Magmeters have been used in the supply of water in Scotland is how ERS Remediation used meters supplied

by Salisbury-based Icenta Controls.

15 minute intervals for the duration of the project. One challenge was ensuring a straightforward and compliant (both in terms of hygiene and assembly) installation in the field, at sites which were sometimes remote. This was achieved by fabricating fixed length spigots with suitable fittings (to ensure pipe linearity) and preassembling all flowmeters, grounding rings, remote displays, and data loggers in the workshop prior to field deployment. z For more information:

The Scottish case

This article was written by Paul Gentle, managing director at Icenta Controls. For more help in choosing a meter and useful guides and tools, visit: www.icenta.co.uk

In 2013-2014, Icenta partnered with ERS to install 24 electromagnetic flowmeter at With acknowledgment and thanks to ERS Remediation for the Scottish case properties around Aberdeen, Scotland, study, illustrating magnetic flowmeters in UK. These properties were located along application. Photos © ERS 2013-2016 the path of the proposed Aberdeen Western Peripheral Route (AWPR), and relied on private water supplies as they were not connected to the mains water network. ERS was appointed by the local authority to install monitoring equipment and undertake a oneyear programme of monthly monitoring and sampling before the road construction started, in order to establish the baseline water flow and water quality at each property, and allow for any An example of an in-line flowmeter

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 31

Accuracy defined

FLOWMETERS

Considering how flowmeters define their accuracy will help in selecting the right meter for the job Municipalities that are looking to accurately measure their water flow rates often fall into one of three categories.

One, they may want a flow control valve that has the ability to vary flow rates over time, but would rather not to have to install a flowmeter, a valve with an actuator and positioner. Two, when filling a reservoir they might like to know how many gallons have been used. Three, they would like to install a conventional flowmeter in their control valve station but do not have the space.

The common choice in the municipal world to date has been the electromagnetic flowmeter due to cost, reliability, and turndown, among other factors. Unfortunately these meters require straight runs upstream and downstream prior to the meter, typically five pipe diameters upstream and two diameters downstream to give reasonable accuracy. There are other technologies available, but they also require straight runs and in many cases even more than the magnetic flowmeter.

Regardless of the flow technology chosen, if using the flow signal for control, there is still the task of tying this into a control valve, with all of the programming and additional equipment

Singer Valve SPIMV point insertion flowmeter

32

that this entails. Alternatively, there are “in-valve flow measuring” technologies, which fall into three main categories: 1. In-valve turbine meter 2. In-valve insertion vortex metering 3. Calculated flow measurement using position transmitters and differential pressure transmitters that calculate the flow rate from a known position on the valve C curve.

Each of these technologies is not without merit, but also has its problems.

Turbine meters require clean water and maintenance. Vortex meters are prone to suffering from vibration effects (giving a flow reading when there is actually no flow) and plugging or damage due to foreign objects in the line. In utilising the flow calculation method, accuracy is dependent upon having an accurate valve Cv curve and due to the number of instruments required – differential pressure transmitter and position transmitter – there is also the risk of compounding of errors. This is also the least accurate of the three measurement types.

What is ‘accurate’?

Accuracy should always be considered with all of the mentioned methods.

The current in-valve technologies are meters that are typically rated with a percentage of full scale accuracy. But when their accuracy percentage is given as, for example, 2%, what does that really mean? While the number quoted is important, equally important is the statement after the percentage sign. A percentage of full scale meter, while being accurate at full flow, can be dramatically different at low flow rates, which one would expect to see in a control valve scenario.

As figure 1 demonstrates, a 2% of full scale meter can still be within specifications at eight to 12 units, which at a reading of 10 units is +/-20% accurate.

This makes for a big difference from the 2% that was initially expected. A better flowmeter would be a meter that has a percentage of reading accuracy, as shown in figure 2. This example indicates that this meter is accurate from 9.8 units to 10.2 units, which is a much better proposition for accurate control.

New solution Singer Valve and McCrometer joined forces to create a single point insertion electromagnetic flowmeter that is installed into a control valve, the SPI-MV. This 2% of reading flowmeter has been flow profiled and tested in McCrometer NIST traceable flow laboratory in Hemet, California. This means that the unit is guaranteed to be accurate to 2% of reading throughout the specified velocity range, and, as it has already been profiled to match the valve, it works right out of the box.

The insertion probe extends into the flow stream in one of the valve inlet connections and protrudes into the valve, equivalent to 1/8 of the valve diameter size. With a bullet nose to the flow, its clean profile eliminates clogging and build-up. The unit can be installed on any of the Singer Valve models from 4” to 36” valve sizes. It can be installed on either side of the valve on the inlet connection and only requires three pipe diameters upstream clearance.

The sensor is rated for continuous submergence and is removable. It only protrudes from the valve 4.6” to 6.3” and only requires 8-12” clearance for maintenance. It is supplied with a convertor that not only gives an LCD readout screen, but also gives a 4-20mA output along with four programmable digital outputs. The meter can provide capital savings when compared with a conventional magnetic flowmeter on the large sizes.

A case in Colorado A city in Colorado needed to determine the flow through each of its three separate

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

FLOWMETERS 2% Full Scale Performance

10

Percent 0 Rate Error

Protecting your equipment makes sense

Flow

-10 Flow (units) 100 50 25 10

Absolute Error (2% Full Scale) 2% of 100 = 2 units 2% of 100 = 2 units 2% of 100 = 2 units 2% of 100 = 2 units

Figure 1: Demonstration on 2% of full scale accuracy

10

2 Percent Rate Performance

Percent 0 Rate Error

Flow

-10 Flow (units) 100 50 25 10

Absolute Error (2% Rate) 2% of 100 = 2 units 2% of 50 = 1 unit 2% of 25 = 0.5 unit 2% of 10 = 0.2 unit

Figure 2: Demonstration of 2% of reading accuracy

valve chambers to determine whether the water load was shared equally among the valves. By measuring the flow rates, the operator is able to use the data to determine whether there is a need to adjust the pressure set points on any of the pressure reducing valves in each vault. As there was no power source and limited space in the station, the city specifically wanted a portable flowmeter that could be shared between three valves in the three separate chambers.

Pipestone Equipment’s Dave Buchwald suggested the SPI-MV as it could be inserted into their Singer valve to measure flow and then removed and moved to a different valve. The SPI-MV was combined with a data logger and a 12VDC lithium battery to allow the operator to leave the probe unit in the vault for a month to acquire and save the flow data. A USB was then used to

extract the data off the logger and the battery was recharged before the unit was simply installed into one of the two additional vaults and the cycle repeated.

Installation was straightforward. Once the SPI probe is removed, the ball valve is closed, allowing the valve to continue to run as normal. The probe is then moved to another vault and inserted into another pressure reducing valve. As the unit only protrudes 8” from the valve and requires 12” for clearance, it fits easily in to all the chambers. With a 2% accuracy of reading throughout the specified velocity range, the utility is now able to confidently monitor the flow rates of their valves and compare loads to ensure equal flow. z

Rely on Rotork Choose the Client Support Programme that suits your needs

• Protect your investment

• Increase plant availability

• Maximise productivity

• Reduce your cost of ownership Get the facts, find your nearest Rotork office or more information about the Client Support Programme at www.rotork.com T +44 (0) 1225 733200

For more information:

This article was written by Mark Gimson, business development and marketing manager at Singer Valve. Visit: www.singervalve.com

E information@rotork.com W www.rotork.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 33

FLOWMETERS

Choosing the right flow measurement technology Tips for selecting the right option for your application Flow measurement instrumentation options are many, and the challenge of picking the right one for a particular application can be daunting. Many experienced plant personnel default to one they have used before – or perhaps count on a supplier to help them select among the available technologies. Instead, they should probably start by getting answers to a few key questions about measurement specifics for their application. The answers will help determine the most important criteria to assess available choices for their circumstance, since many flow technologies may apply.

Next, operators should review how different flow measurement technologies work to determine which one fits the process needs best. Finally, the pros and cons of the available options should be compared. These are the first steps on the right path to successfully choosing a measurement device.

Know thy measurement needs Of all the questions to be asked, the key one has to be: ‘Why is the measurement required?’ Is it to control or optimise the process, to meet state regulations, or for monitoring or indication? Is it done as a safeguard or to warn of a process upset?

For example, if measurement is to control a batching process, such as adding ingredients to a food product, accuracy and repeatability would probably be the most important considerations. Adding the same measured amount of vinegar to a wing sauce or raspberry flavour to an iced tea is critical to producing the same taste to the consumer every time.

Other key questions to ask include: • What is the expected result of the measurement?

• How much is this instrument going to cost?

• What modifications will have to be made to process piping or at the receiving device 34

such as the PLC or DCS? • How accurate or repeatable does the measurement need to be?

• What is the expected lifespan and maintenance requirement?

Before selecting a technology for making the measurement, operators should make sure to thoroughly define the process and the desired measurement.

Flow measurement choices There is a wide range of choices for flow measurement solutions.

Each meter technology has advantages and drawbacks. Main device categories include: • Differential pressure with primary flow elements, for example orifice or Venturi • Mechanical devices, including variable area, turbine, or positive displacement meters • Electronic flowmeters, including magnetic flow, vortex, ultrasonic, and Coriolis mass First, the available flow measurement options have to be reviewed. Knowing at least in brief detail each device’s method of measurement, along with the applications they are best suited for, will help in making the decision.

or Venturi meters. Other flow elements may include nozzles and pitot tubes.

A differential pressure meter must be mounted in the pipe, so using them incurs installation costs. Regular maintenance is necessary for calibration and inspection, as well as cleaning the taps and the pressure devices. These devices are best suited for measuring single phase products, either all liquid or all gas with a single composition.

They are also ideal for measurement of natural gas (for example, methane) or liquids such as light hydrocarbons or chemicals used in water treatment.

These devices require a secondary device to measure the pressure.

Positive displacement flowmeters Positive displacement (PD) meters directly measure volume of flow using cavities (also called chambers) that hold a known volume of fluid. They pass the fluid from the meter’s input to its output.

Each progression of the fluid produces a pulse – usually from a magnetic pickup – and each pulse is equal to the cavity’s volume. The process can be likened to

Differential pressure devices with primary flow element A differential pressure measuring device is placed into a flow stream with a primary flow element that produces a pressure drop proportional to a flow rate.

The most popular flow elements are orifice plates

1

2

3

4

16

The operating principle of a positive displacement meter

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

Doppler Ultrasonic Magnetic flowmeters must be installed in the pipe, so installation costs must be added to the cost of the meter. These flowmeters are usually maintenance free and require no regular recalibration. An example of such a device is the Krohne Optiflux 4300C. Magnetic flowmeters require that the process fluid being measured has a minimum conductivity.

In most cases this is around 5μS/cm. In the case of liquids such as demineralised water, the conductivity needs to be slightly higher, around 20μS/cm.

Vortex flowmeters A vortex meter is a device that infers a flow rate based on velocity and cross sectional area of the measuring chamber. Vortex meters measure the vortices produced when a product flows around an obstruction. Picture a flag waving in the wind or water in An example of a variable area flowmeter

ladling a sauce or gravy from a pot – the ladle holds the same volume each time it is filled and then emptied onto a plate.

There are numerous types of PD meters, including: • Rotary vane • Rotating disk • Nutating disk • Oscillating piston • Sliding vane • Oval gear • Bi-rotor • Rotating paddle Heavy viscous products such as crude oil are measured extremely well by the positive displacement meters listed. When measuring less viscous fluid, the meters may experience an effect known as slippage, in which a small amount of the liquid being measured passes through the sealing of the chambers and is not measured, causing inaccuracies. This measurement technology is also generally not suitable for gaseous state products.

Electromagnetic flowmeters Electromagnetic flowmeters (MID’s) use Faraday’s Laws of induction to make the measurement. When a conductor (water or other process fluid) flows through a magnetic field, it generates a voltage, which is directly proportional to the conductor’s velocity. With a known cross sectional area of the meter body, the velocity is directly proportional to the volume flow rate.

a stream going around a rock. The vortices caused by the obstruction have a frequency, which is proportional to the velocity of the product moving through the measurement chamber.

Vortex meters are installed directly into the flow stream and require insertion into the process piping. Some also include a pressure and temperature measurement to output mass flow.

Variable area flowmeters

FLOWMETERS Limit switches can be added to signal an alarm during high and low flow rate conditions. The meters can be supplied to measure flow moving from bottom to top, from top to bottom, or horizontally.

Turbine flowmeters These mechanical meters also work by measuring velocity and are considered quite accurate and repeatable. The fluid passing over the turbine moves a set of blades, and each blade rotation indicates a specific product velocity.

Normally these units require no power as the output is a frequency or pulse that is generated by a magnetic pick up.

Turbine flowmeters also require insertion into the flow stream, so installation cost must be added to the meter price.

Since they are mechanical, turbine meters are subject to wear, which means over time they will lose accuracy, on top of which they can require frequent recalibration. However, the cleaner the application, the less wear and tear there will be on the meters, so recalibration is not required as frequently.

Ultrasonic flowmeters Ultrasonic meters come in two configurations, referred to as clampon and spool piece. The clamp-on meter is attached to the outside of the process piping. The spool piece requires cutting the process pipe and installing the meter in the flow stream.

Ultrasonic measurement relies on either transit time or Doppler technology.

With transit time a sound wave is sent across the pipe from one transducer to another with the flow. A sound wave is

Unlike the other flowmeters discussed so far, variable area flowmeters require no power to operate. They measure fluid flow by allowing the cross sectional area of the device to vary in response to the flow, causing some measurable effect that indicates the rate. The measurement tube is of a tapered design, with a smaller diameter at the inlet and larger diameter at the outlet. Inside the measuring chamber is a float that is designed to match the density of the product being measured.

As the flow increases, the float moves higher in the chamber. If the tube is transparent, a scale is printed on the measuring tube. If the measuring tube is armoured, a magnetic pick is used as an indicator. These meters can also be powered and report on a 4-20mA loop.

Cutaway of a turbine flowmeter

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 35

FLOWMETERS

Sensor

are higher amounts of suspended solids or entrained gases. It requires something to ‘bounce’ back the signal.

Sensor

Sensor

Sensor

Coriolis mass flowmeters Coriolis mass flowmeters work on the Coriolis Effect, which describes forces generated in oscillating systems when a liquid or a gas moves away from or towards an axis of oscillation. A Coriolis device measures a frequency at no flow conditions. Then, when flow begins, there is a shift in the phase of the frequency that is proportional to the rate of mass flow. The frequency the meter sees changes with the density of the product in the measuring tubes. A less dense product causes a higher frequency and a more dense material causes a lower frequency. Coriolis meters are the fastest growing flow measurement product.

Transit Time Ultrasonic Transit Time Ultrasonic Transmitting Transmitting Element Element

Receiving Receiving Element Element

Flow Direction Flow

Reflectors

Direction

Reflectors

Comparing the options

Doppler Ultrasonic Doppler Ultrasonic Operational principles of transit time and Doppler measurement then sent in the opposite direction. The flow causes a change in the time it takes the sound wave to travel across the pipe.

Travelling with the flow takes less time and travelling against the flow takes a longer time. The difference in time is proportional to the velocity of the process fluid.

With Doppler technology, a sound wave

is sent into the product. The device looks for a return, which bounces off particles in the flow stream. It then measures a frequency shift to determine flow velocity.

Transit time works best for a cleaner product, with low suspended solids and entrained air. The Doppler technology is designed for processes where there

This brief overview of available options provides basic information on how each technology works and a general idea of what each technology is best for. The below table offers an overview matrix table to compare the pros and cons of each technology. z

For more information:

This article was written by Rich Lowrie, local industry division manager – water and waste at Krohne. Visit: www.krohne.com

Comparison of available flow measurement options Technology

Price

Notes

Products

DP measurement $$$ Generally 10:1 Dependent upon 10D upstream unobstructed

the pressure device requires secondary device

to make measurement

Reynolds number influences/pressure loss maintenance of pressure device

Oil, water, hydrocarbons, gases, most any clean liquid or gas not affected by pressure drop

Magnetic flow $$ 100:1 or better .5% (nominally) 5D upstream and 3D

downstream

Must be conductive fluid best above 2 FPD velocity

Water, acids, bases, chemical feed in WTP and WWTP, slurries

Vortex

20D upstream unobstructed

Lower viscosities

Steam, water, gases, air

Variable area $ 10:1 generally 1% nominally

Flow from bottom to top on most models

No solids, low viscosity

Gases, water, chemicals, air, ozone, methane

Turbine meters

10-20D upstream unobstructed

Frequent calibration required

Gases, water, fuel oils, air

$$$

$$$

Turndown

10:1 generally

20:1 or better

Accuracy

1-2% nominally

0.2%

Installation requirements

Ultrasonic $$ clamp-on, 100:1 or better .3% nominally 5-10 upstream unobstructed, Flow profile and Reynolds

$$$ spool (non-CT spool piece 3-5 downstream dependent piece meters), 1-2% clamp-on meters

Gases, water, fuel oils, air, chemicals, crude oil

Coriolis $$$$

High viscosity low flow can cause some meters to have errors

Slurries, gases, chemicals, polymers, fuel oil, hydrocarbons

Frequent calibrations subject to slippage with lower viscosity fluids (process slipping through seals)

Crude oil, fuel oil, water, polymers, thick viscous fluids

Based upon 1 bar pressure drop over device

.12% normally of Depends upon manufacturer, mass and mass flow most have none

Positive $$$$ 20:1 or better .15-.2% None displacement

The advantages and disadvantages of different flowmeter types

36

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

EVENT PREVIEW

Tank World Expo 2016 boasts major names The latest developments and opportunities in Middle East and Africa for oil and fluid handling will be revealed in Dubai at Tank World Expo 2016 Tank World Expo, the definitive tank storage event for the Middle East and North Africa regions, will take place on 12-13 April, 2016, at the Dubai World Trade Centre. The two-day event brings together the best and brightest from the Middle East and African bulk liquid storage industry, opening its doors to suppliers and key decisionmakers from across the region.

Easyfairs, organiser of Tank World Expo 2016, has announced that His Excellency Eng. Suhail Mohamed Faraj Al Mazrouei, the United Arab Emirates (UAE) Minister of Energy, will open the show and deliver its keynote address. It has also confirmed that the show will be officially supported by The UAE Ministry of Energy.

Nick Powell, StocExpo & Tank Storage Portfolio Event Manager comments: “When we acquired Tank World Expo and made the decision to merge it with Tank Storage Middle East, we established the largest bulk liquid event for the region. Having His Excellency Eng. Suhail Mohamed Faraj Al Mazrouei opening the show and The UAE Ministry of Energy on board as a government supporter, is simply fantastic and really strengthens the position of our show.”

Tank World Expo also boasts many other major show supporters, including Horizon Terminals, ENOC, Fujairah Oil Terminal, Gulf Petrochem, and Star Energy Oil Tanking, as well as some of the world’s leading suppliers including

Emerson Process Management, Kanon Loading Equipment, BORSIG Membrane Technology, Atexor, and Endress+Hauser.

Exhibition hall Many exhibitors will be using Tank World Expo 2016 to launch new innovations and technologies to the Middle East and African markets. For instance, Arflu Industry Valves will be presenting its dual expanding plug valve. Easy to operate, the valve requires little maintenance and offers a verifiable double block and bleed service, plus a long lifetime.

Fort Vale Engineering will demonstrate its MK3 Safeload semi-automatic bottom loading coupler, with extended “wrap

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 37

EVENT PREVIEW around” trigger design that follows the profile of the loading adaptor, covering over 60% of the adaptor circumference.

Alma-Carbovac will be showcasing Flexicompt, its portable gravity flowmeter for petroleum products. This portable and compact MID-certified metering system enables precise measuring of quantities. It features advanced Adriane turbine technology, which quickly and easily monitors the volume delivered to each gas station. It also shows any discrepancies between the actual amount delivered and the amount invoiced, meaning a rapid return on investment.

Knowsley SK will be displaying its latest foam mixing technology – the Turbinator.

Designed to accurately mix foam concentrate liquid, with either fresh water or seawater, the Turbinator is suitable for use in fixed systems or mobile units. Its design makes it inherently self-priming, plus the gear type foam pump creates strong inlet suction, leading to a reliable and uninterrupted foam concentrate supply.

Loadtec Engineered Systems will be highlighting its wide range of tanker loading arms. It will also present its portfolio of fall prevention systems, designed for safe access to road, rail and marine tankers.

Mascoat, a global producer of thermal insulating coatings, will be demonstrating its latest coating, the Mascoat Industrial-DTI. The multi-purpose coating solves insulating and corrosion under insulation issues. It is capable of thermally insulating up to 190°C, fulfilling niche temperature-focused market areas, on all types of substrates.

Elmac Technologies will be exhibiting

Tank World Expo opening ceremony

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The Dubai WTC metro station will serve visitors and exhibitors at Tank World Expo

its range of flame arrestors, designed to prevent the spread of pipeline explosions at the earlier stage, when flame velocities and associated pressures are at their lowest. Also on show will be its pressure and vacuum relief valves, emergency valves, gauge hatches, and bursting discs.

Implico will be revealing details of the latest version of OpenTAS, the terminal management software for tank farms and refineries. The company will also be demonstrating its cloud solutions, such as iGOS (Implico Global Operation Services), which helps tank terminal operators migrate their entire supply chain to the cloud along with the interface to their collaborating partners. The system offers low costs and improved data quality.

Emco Wheaton will be showcasing its range of supporting arms, including its marine break-away coupling, which

has been robustly designed to withstand harsh marine conditions. Also on show will be the Gantry Access Equipment, Tank Truck and Safety Release Systems. The latter provides automatic disconnection of a loading arm or hose in the event of a tanker accidentally driving away.

Emerson Process Management, which helps businesses automate production, processing, and distribution, has solutions for applications in control and safety systems, custody transfer, overfill protection, terminal management, tank gauging, and tank farm management. Its services improve safety by sending more data to the control room, reducing manual rounds and streamlining environmental compliance by monitoring overfill, leakage, and tank blanketing to control emissions.

Endress+Hauser will be displaying its latest inventory management solution – Endress+Hauser II AG – which helps reduce inventory costs, improves customer satisfaction, and increases productivity.

The system handles the monitoring of tanks and silo levels through to accurate custody transfer, tank gauging at tank farms, and the automation of terminals.

Omnivalve will be presenting its OmniSeal double block and bleed (DB&B) expanding plug valve. OmniSeal is a single valve solution that simultaneously blocks both the upstream and downstream flow, while allowing the user to verify seal integrity using a manual or automatic body bleed system.

Mesa Engineered Tank Products will be exhibiting its vapour-guard gauge pole covers, which reduce emissions from above-ground storage tank slotted

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EVENT PREVIEW gauge poles. This reduces product loss for tank owners, whilst meeting all environmental regulations.

TTK will be showcasing its FG-OD hydrocarbon leak detection cable. This sense cable is addressable, re-usable, and has a fast detection. The TTK leak detection system ensures a continuous protection of areas where storage tanks or distribution pipes are located. The sense cable is available in standard, pre-connected lengths, or cut-tolength reels for long-line applications.

Conference programme Tank World Expo 2016 will also feature a two day-conference programme led by 18 leading industry figures from organisations such as The UAE Ministry of Energy, OTTCO, Oiltanking Odfjell Terminals Oman, Dubai Mercantile Exchange,

The two-day Tank World Expo bring together the best and brightest from the middle East and Afrcan bulk liquid storage industry Burgan Cape Terminals, and CITAC Africa.

In 2015 the show focused primarily on Fujairah, but the 2016 conference programme reflects the changing market place, with an increased focus on the UAE and Greater Gulf Cooperation Council region, which is currently developing the world’s largest terminal.

With this in mind, Said Al Mawaali, project director at OTTCO, will be presenting

Major companies will exhibit their latest innovations at Tank World Expo

Latest developments at the region’s largest storage facility in Oman.

Maintaining this focus will be Roderick de Rooij, commercial manager at Oiltanking Odfjell Terminals Oman, who will be looking at the future outlook for the storage market in Oman. He will discuss how to capitalise on the trade routes between Asia and Europe, whilst analysing the region’s demand for storage capacity. He will also explain how best to increase the terminal’s efficiency and explore Oman’s future growth ambitions.

The growth of Fujairah is still a key driver in the Middle East’s continued rise. It is the second most productive region in terms of bunkering capacity and the third largest oil storage and products trading centre in the world. In light of this, Malek Azizeh, commercial director at Fujairah Oil Terminal will discuss the region’s crude oil storage position as a strategic regional hub for products and crude.

The recent merging of Tank World Expo and Tank Storage Middle East, creating one ultimate show, has also allowed a greater focus on the African sector, with Muziwandile Mseleku, CEO of Burgan Cape Terminals looking into the opportunities within the African bulk liquid storage sector.

Following the African theme will be Gary Still, executive director at CITAC Africa, who will be presenting Assessing storage capacity and infrastructure across Africa in relation to product flow. He will analyse the African supply challenge, cover the regional demand growth, and discuss the investment in infrastructure.

For those looking for a more general overview, Paul Young, head of energy products at Dubai Mercantile Exchange will be looking at the impact of oil prices on the storage sector, predict how long the contango will last, and delve into crude supply and demand drivers in the Middle East. In a similar vein, Amrita Sen, chief oil analyst at Energy Aspects will present Regional supply, demand, trade flows, and downstream capacity across the Middle East and North Africa. z

For more information:

Visitors engaging in conversation

On exhibiting, free fast-track entry when visiting, or becoming a media partner, contact event manager Nick Powell at nick@stocexpo.com. Visit: www. tankworldexpo.com

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PHARMACEUTICALS

Sensor technology takes infusion pumps to the next level by making failure detection reliable, even for infiltration

Liquid infiltrating tissue surrounding a vein

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Listen to your heart Every day millions of patients worldwide receive intravenous (IV) infusion therapy, many times assisted by a smart infusion pump. These pumps provide wellcontrolled drug delivery over a prolonged period of time and are of tremendous help for hospital staff. However, they fall short when it comes to reliable failure detection.

Today’s infusion pumps lack the technology to directly measure the flow rate of the drug inside the tubing, which results in two main problems. First, there are failures that remain undetected, and second, over-sensitive pumps generate a high number of false alarms. The ECRI Institute, a medical and pharmaceutical industry watchdog, named alarm fatigue and infusion pump medication errors as number one and two on their list of top 10 health technology hazards for 2014.

Typical failures during infusion therapy

include occlusion, air-in-line, free flow, cross-flow in multi-infusion settings, and infiltration or extravasation. While all of the above failure modes are very well known to hospital staff, today’s infusion pumps can at best only detect the first three. New liquid flow sensing technology enables smart infusion pumps to detect not only these failures, but also reverse flow, crossflow, and even infiltration errors reliably.

Infiltration and extravasation Infiltration and extravasation describe the leaking of IV fluid into the tissue surrounding the vein. With infiltration, the IV fluid is a so-called non-vesicant agent leading to irritations, while extravasation describes the efflux of vesicant agents that can cause damage to the tissue.

Potent drugs used in chemotherapy, for example, are such vesicant agents. The damage can extend to involve nerves, tendons, and joints and can continue for months after the initial incident. If treatment is delayed, surgical debridement, skin grafting, and even amputation may be the unfortunate consequences. Potentially severe consequences strengthen the need to include disposable liquid flow sensors for enhanced reliability and safety in infusion therapy.

The frequency of complications caused by extravasation is hard to establish clearly, varying heavily between different hospitals and tending to be generally underreported. However, the estimated incidence rate published in literature is between 0.1 and 6% for patients receiving chemotherapy. Extravasation causes harm to patients and inflicts heavy costs on the healthcare system, while both of them could be prevented. The costs following an extravasation injury can be enormous, including extended therapy and a longer

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PHARMACEUTICALS housing which features all mechanical, electrical, and fluidic connections needed to smoothly integrate it into, for example, an infusion set.

Integrated into an infusion set, Sensirion’s disposable liquid flow sensor communicates the flow rate inside the tubing in real-time, allowing for enhanced reliability and safety for infusion therapies. Occlusion, for example, can be detected within a few seconds by noticing a decrease in the flow rate even in ultra-low flow ranges. Users no longer have to wait for 45 minutes before an alarm is triggered by an infusion pump.

Drops in primary infusions due to cross-flow errors from secondary lines can be detected quickly, so that corrections can be made without impacting patient therapy. The sensor also features bubble detection to identify air inside the infusion tubing.

Sensirion’s liquid flow sensor is sensitive

Sensirion flow sensor in a drug dosage application

hospital stay, as well as legal costs.

The leakage of IV fluid into the surrounding tissue can be caused by many reasons, including damage to the vein’s backside during catheter insertion.

However, one of the most common reasons is the puncture of the vein wall by mechanical friction of the catheter needle. This is typically preceded by an occlusion. With a traditional infusion pump, the occlusion may remain undetected until the pressure in the tubing reaches a certain threshold level, triggering the alarm through a pressure sensor many minutes and sometimes close to an hour later. Detecting the occlusion quickly and reliably and consequently stopping the infusion pump can prevent the rupture of the vein and the subsequent leakage.

Sensitive care Sensirion, Switzerland-headquartered sensory solutions provider, delivers sensor technology for medical devices based on more than ten years of experience in measuring very low flow rates using advanced CMOSens components that combine MEMS and CMOS portions on a single monolithic silicon chip. By integrating this tiny flow sensor chip into a variety of packages, Sensirion has successfully improved diagnostics, automation, and semiconductor industry processes around the world. The same

Reading of a heartbeat through an IV sensor

proven technology can be applied to infusion applications and medical devices to increase patient safety and support hospital staff during their daily work.

The measurement method is based on a micro-thermal principle by which a microscopic heating element introduces a negligible amount of heat into the bypassing liquid. The shape of this “heat cloud” is monitored by two temperature sensors and is directly related to the flow rate inside the fluidic channel. By using this principle, Sensirion’s liquid flow sensors can reliably and constantly measure the low flow rates typical for medical applications. Every sensor is fully calibrated and provides a linearized, digital output to ensure the highest accuracy.

CMOSens technology is scalable and allows sensor solutions to be technically as well as economically feasible. The sensor chip is packaged into a plastic

enough to detect the smallest changes in the flow rate. For instance, it can detect the regular peaks in the infusion flow rate produced by the oscillating back pressure of the patient’s venous pulse – the sensor can feel the patient’s heartbeat.

Detecting the heartbeat on the flow rate is a direct indication of an intact connection of the infusion cannula to the vein of the patient, while absence of the pulsation on the contrary indicates an interrupted connection.

Possible causes may include kinked, disconnected, or ruptured tubing or a dislodged infusion cannula, which may in turn lead to infiltration. By evaluating the sensor signal, Sensirion’s sensor solution offers the possibility of detecting infiltration quickly and preventing harmful consequences to the patient.

Most medical device manufacturers – familiar with the art of infusion therapies – are aware of the challenges inherent to the technology of smart infusion pumps. Integrating a liquid flow sensor into infusion tube sets will take the infusion therapies a great step forward and allow for a controlled drug delivery on a much broader scale than today. Failures that go by completely unnoticed can be detected or even prevented. This will lead to an increase in patient safety and well-being, a reduced workload, and less stress for hospital staff, as well as overall savings in the healthcare system. z For more information:

This article was written by Jonas Horn, application expert - medical for liquid flow sensors at Sensirion. Visit: www.sensirion.com

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PHARMACEUTICALS A multi-modal platform at a production plant

Tanker loading challenges in the pharmaceutical industry Technology used in tanker loading has changed little in the past 20 years and some age-old problems still persist In the last 20 years, the design and technology used in tanker loading and unloading systems in the pharmaceutical industry has changed surprisingly little. Tankers are still between 3.2m and 4.2m high, and their conditions fluctuate greatly. Tanker walkways are widely variable and, occasionally, just not there. Solvents are still dangerous, flammable, toxic, or pose environmental hazards. Tanker driver competence is as variable as ever, and concrete remains very hard and humans very soft.

What has been interesting is that while design and technology has changed very little, documentation, accreditation, and surveillance has grown to be a major factor in cost and time. The warning signs are still all there and remain the focus for the need to change or improve access for the operator and handling of the liquid.

What has changed?

But even if some things are never expected to change, the inevitable flow of time is bound to bring on other changes. The aforementioned increase in 42

documentation and regulation has caused the following changes to come into effect: • In 2005 the Work at Heights Regulations were implemented throughout Europe. More of which later.

• ISO 9001, ISO 14001, and a number of other ISOs have been brought into play.

• Pharmaceutical companies with longserving and experienced engineers have now moved to contracting out their engineering resource to third parties.

This is not necessarily good or bad, but it is a factor. A project based in London, for example, may see companies working with detail engineering teams on the other side of the world.

• A number of companies have preferred sub-component manufacturers. This becomes interesting when a tried and tested package of equipment has to be reconfigured to meet the site specific needs for valves, switches, and solenoids.

• Documentation has increased exponentially. Despite nearly 20 years of supplying virtually identical systems, the growing trend for expediting and micromanagement by clients has created a huge increase in cost and time.

Now we have climate controlled rooms and terabytes of data. Twenty years ago project data files consisted of a couple of ring binder folders on a shelf behind the engineer who bought the equipment. Is there a clear benefit to the client in this detailed acquisition of “knowledge” or is it a consequence of the litigation culture that invades every aspect of our lives?

Of course, equipment suppliers need to be mindful of this. A client either accepts an offer based on the standard componentry and quality assurance, or makes it very clear from the outset of a project that suppliers will need to source specifically pre-approved components.

The difference in cost between a standard and proven scope of supply, versus one with high surveillance and client specified components can be more than double.

How does this affect a client’s decisionmaking when it comes to developing a scheme? A number of agents in the pharmaceuticals industry are taking the seemingly bold stance of filling all tankers from ground level. This is partly due to their interpretation of the Work at Heights Regulations (which suggests it is

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PHARMACEUTICALS

A tanker being filled

a good thing, but does qualify that with a “wherever practical” caveat) and the perception that this will be a cheaper solution. The majority of chemicals moved globally are in sea containers. To maximise volume, the design of the ISO tank in the vast majority of cases is not equipped with vapour return facilities at ground level.

Bottom or top loading?

The pharmaceutical business transfers a great deal of clean solvent and, consequently, waste solvent. These chemicals require precise handling that safeguards operators and the environment. Bottom unloading arms have been utilised extensively over the years and they allow operators to manoeuvre the pipe into position, prepare the tanker, and make a secure and repeatable connection, without having to carry a heavy hose and leave pharma grade couplings laying on the floor.

But what happens when an operator wants to bottom fill? Is there a vapour return line at ground level? Statistics suggest there is not, unless the operator has rented a more expensive tanker with a reduced payload. Thus, vapour return will be at the tanker top, presumably via the manhole, because the other feature that will be needed is a high level device. There is a need to fit a vapour return line at a high level with a built-in high level device. Due to weight and handling, this is clearly best served in the form of a loading (vapour) arm. But then the primary issue remains.

How does one get an operator onto and off of the tanker in complete safety?

The simple folding stairs with safety cage has been the go-to solution for a long

Multi-modal platforms can increase safety in pharma operations

time. But with the tightening of legislation and the variation in tanker profiles and walkway configurations, folding stairs, forever the “vanilla” choice, are no longer the obvious solution. Customers want “tutti frutti” systems that provide greater security, flexibility, and range.

The solution is the multi-modal platform, a vertically elevating platform that can be between 4m and 15m in length. It travels through a standard 1.5m range or more with a built-in floor that is removable wherever access to the tanker top is needed. Multi-modal platforms also come with the added benefit of being able to tilt to match the slope on a tanker top.

These systems have been sold successfully by Loadtec Engineering Systems since 1996 all over the world, with December 2016 seeing the company’s 20th anniversary. Multi-modals are utterly reliable and provide fool-proof safety with ease of operation. They are manufactured

to globally accepted standards and are used by virtually all blue chip pharmaceutical companies. Furthermore, they are relatively cheap considering the lifespan and advantages they bring.

So, when an enquiry arrives, it is essential to establish whether the client wants a reliable system that works using tried and tested components, or whether they want to reinvent the wheel and cost themselves a small fortune. Clients seem to be diverging into two distinct camps. Those who want a system that is necessarily simple because the total project cost is consumed by bureaucracy, and those who want a future-proof, feature-packed system that is globally proven for the same cost. z

For more information:

This article was written by Alec Keeler, managing director at Loadtec Engineering Systems. Visit: www.loadtec.co.uk

A tanker loading package in Russia, including a loading arm, tanker enclosure, and metering skid

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Moving liquids with sound PHARMACEUTICALS

New sound-based handling technology enables pharmaceutical producers to transfer miniscule amounts of fluids with great accuracy Acoustic droplet ejection (ADE) moves liquids with sound. When a pulse of ultrasonic energy passes through a liquid and is focused at the meniscus of the fluid, a droplet of fluid can be ejected upward from the bulk fluid (figure 1).

The initial work on the physical and biological effects of ultrasound was published in the early 20th century, but it was not until the 21st century that the process of ADE was incorporated into a commercially available instrument.

The commercial Echo liquid handling systems – produced by Californiabased liquid handling equipment maker Labcyte – eject droplets of two different volumes, either 2.5nL or 25nL. Droplets are ejected from a reservoir rapidly at up to 500 droplets per second. The reservoirs holding the transfer solution are usually multi-well plates that meet the ANSI SLAS 1-2004 microplate footprint dimensions. Free movement of the acoustic transducer that produces the acoustic pulse and the destination that collects the transferred materials means that any volumes of liquid (in 2.5 or 25nL increments) can be transferred from any well of the source reservoir to any position of the destination.

The destination is usually a multi-well plate, but it can also be a microscope slide or other structure. The freedom to transfer any fluid in the source reservoir or plate to any spot in a destination plate or surface means that it is easy to set up dose-response experiments, drugcombination screening, low-volume genotyping, protein crystallisation, synthetic biology, personalised medicine, direct injection into a mass spectrometer, and other applications. Despite the freedom of the fluid transfer, ADE is very rapid, with the transfer of 384 44

different samples to 384 different assay wells taking less than 90 seconds.

Precision work While the precision of traditional liquid handling apparatuses tends to get poorer as volumes are decreased, users of ADE have found that its precision remains constant, often less than 3% coefficient of variation (CV) even at transfer volumes as low as 2.5nL. Traditional pipette or pin-tool based techniques tend towards CV an order of magnitude worse for these low volumes. This result can be accomplished even with very viscous materials that would normally clog a pipette or nozzle.

Since traditional liquid handling techniques come into physical contact with the fluid being transferred via pipettes or nozzles, solutes dissolved in the solution can adhere or be affected by the tip itself even beyond the

complete loss of precision and accuracy.

Compounds including plasticisers and mould release agents in pipette tips can be leached into the assays and seriously degrade results. It is also possible for solutes in the solution to bind to surfaces during transfer and dilution processes, leading to a significant loss of material.

One pharmaceutical company noted that drug potency could be in error by more than two orders of magnitude when serial dilution using pipettes was used, compared to ADE with direct dilution. These results were further analysed and indicated that the samples treated by serial dilution with pipettes generated results that were not predictive of future compounds and suggested pharmacophore structures that were incompatible with the pharmacophores generated by ADE and by X-ray crystallography. Errors of this sort can cost pharmaceutical

Figure 1: Operational principle of ADE

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PHARMACEUTICALS companies millions of dollars as they pursue false leads down cul-de-sacs.

It is important to ensure that the ejected droplet travels true to the expected location and that there is no possibility for it to reach the wrong well.

ADE is capable of providing pinpoint drop-on-drop transfer, but a more intuitive example is shown in figure 2, where droplets of dimethyl sulfoxide (DMSO) are transferred into a glass capillary after they have passed through the eye of a needle. Transfer of small droplets by other techniques, including flow cytometry, can result in the formation of aerosols.

Using the polymerase chain reaction (PCR), researchers have shown that there is no cross-contamination of materials at even the parts per billion range.

What’s on the plate?

A system for completely touchless, highly miniaturised liquid transfer provides users with financial benefits. While individual disposable pipette tips are relatively inexpensive, the aggregate cost can be substantial. Tip costs are further aggravated by waste disposal costs and – if the tips are washed between uses – the cost of the solvents used for washing and their disposal as hazardous waste must be considered. More importantly, miniaturisation of assays both conserves samples and increases confidence that the amount of solute being transferred is precise and accurate. This means that assays can be reduced in volume dramatically. For example, a linear reduction in volumes from a 96-well plate to a 1536-well plate cuts reagent costs by as much as 93%. Indeed, many users

of transfer of different concentrations of glycerol, where all the samples are transferred from the same source plate and all changes in power are determined by the instrument in real time.

Gentle handling

Figure 2: Transferring DMSO droplets through the eye of a needle

have noted that they have recouped the cost of the instrument in a few months simply by reducing assay volumes.

When the fluid of each well in a source plate is identical in both composition and volume, it is easier for traditional systems to transfer solutions with precision and accuracy. This hypothetical state is not of use to many users, who would like different samples in different source locations. As volumes may differ due to evaporation and cherry-picking, a useful system needs to be able to adjust the acoustic focus at the changing meniscus level.

Multiple real-time measurements are made of the fluid depth and the energy needed to successfully transfer a droplet from each well immediately before transfer. These measurements take only milliseconds and ensure that solutions that differ substantially in total volume, surface tension, and viscosity can be transferred successfully. Figure 3 shows the precision and accuracy

The fluids and solutes transferred by ADE are extensive and include many millions of drug-like compounds in DMSO or DMSO/water solutions, serum, plasma, whole blood, cells, DNA, and RNA. Successful transfers have also been recorded with pure water and solvents, both neat or as mixtures with water including ethanol, methanol, isopropanol, acetone, dimethylformamide, acetonitrile, N-methylpyrrolidone, acetic acid, trifluoroacetic acid, a variety of room temperature ionic liquids, and glycerol. Detergent solutions are easily transferred despite low surface tension, while salt solutions including buffers are transferred with the same precision and accuracy as water despite the significant change in the speed of sound.

ADE is gentle to the samples being transferred. The energy density is mild and no more than might be used in fetal ultrasound imaging. ADE transfers both cells and polymers, including DNA with no noticeable effects. Transfer of cells

by ADE allows the user to set up assays with a smaller number of cells, preserving biological samples for more experiments.

ADE, a new technology embodied in the Labcyte Echo liquid handlers, provides rapid and flexible transfers of nanoliter to microliter volumes of fluids with high precision and accuracy. It is compatible with a wide range of fluids, for which it automatically self-calibrates in milliseconds. The gentle technique is fully compatible with the transfer of fragile samples including live cells and genomic material and other polymers.

The completely touchless format ensures that there are no leachates to harm sensitive assays and that solutes are completely transferred without loss to the liquid handler. Recent expansion of the technique to new areas including direct sample introduction to mass spectrometers suggest that the future for this technology is bright. z For more information:

This article was written by Joe Olechno, senior research fellow at Labcyte. Visit: www.labcyte.com

Figure 3: Transfer accuracy of glycerol at varying concentrations

For references, visit: www.labcyte.com/ recources/references-olechno

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COUPLINGS

Coupling into the future Learning from existing technologies has enabled a UK coupling manufacturer to build new innovations

Rubber-in-compression couplings provide failsafe operation, protecting both staff and machinery. Torque is transmitted through compressed rubber blocks, which dampens vibration and eliminates backlash. When rubber is loaded in compression, it is inherently stronger than alternative options, such as rubber-in-shear or tension,s where the slightest scratch in the rubber can lead to catastrophic tears and complete coupling failure.

Such failures often result in downtime in both machinery and productivity.

In addition to the safety and reliability features, rubber-in-compression couplings also save time and money when it comes to maintenance. They are “fit and forget” and do not require lubrication or adjustment of any kind.

The only serviceable items are the rubber blocks, which in the majority of cases are good for over 10 years (although it is recommended to check them after five years), meaning that rubber-incompression couplings also provide the lowest lifetime cost, when compared to rubber-in-shear or tension alternatives.

Building on the old UK-headquartered machinery manufacturer Renold Couplings has recently developed the Hi-Tec RBI coupling, which improves upon the company’s existing RB range. Renold’s team of engineers has worked to completely reconfigure the profile of the compressed rubber blocks, with the ultimate objective of increasing the torque

Renold Hydrastart hydraulic coupling with Renoldflex technology

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throughput currently offered by the RB. Finite element analysis (FEA) was conducted, in order to create an optimum shape for the rubber blocks to increase the torque transmission that could be produced when compared to the existing Hi-Tec RB rubber-in-compression coupling. This new block shape allowed for a harder grade rubber to be used, going from the SM70, which was used as standard in the previous range, to an SM80, which is the new standard in the RBI. The FEA had indicated that the combination of this new block profile, coupled with the harder SM80 rubber grade and some modifications to the metalwork, would allow for higher torque.

Subsequent testing of the new Hi-Tec RBI has confirmed the findings of the analysis and torque has been increased by 50%, when compared to its predecessor the RB.

Renold Hi-Tec RBI coupling

majority of cases, there will be no bespoke machining needed and the new Hydrastart range will be available from stock and can be dispatched straight away. Teaming the Hydrastart with the Renoldflex for the new modular system makes it a maintenancefree option and also extends the life of the coupling. These features enhance the previous Hydrastart model, which is also suitable for use with V pulleys.

Waking the hydra Cardiff rising The Renold Hydrastart hydraulic coupling is used for the “soft start” of high inertia machinery. The soft start nature of the coupling allows for the motor to accelerate to full load torque (FLT) before kinetic energy is released to start up the driven machinery at a reduced current, so saving energy costs.

Renold’s engineering team has designed a new “modular” coupling, which combines the Hydrastart with the torsionally stiff Renoldflex coupling, and new flanged mounting plates have been developed to accommodate this. The new modular Hydrastart system has many advantages over the existing range. By incorporating the Renoldflex, the turbine housing can be replaced by “dropping into” the existing coupling halves mounted to the input and output shafts, allowing the drive assembly to remain in place.

The Hydrastart can be used as a retrofit for transfluid couplings and the drop-in feature would simplify this process.

Historically, lead times on the Hydrastart have been high, due to the level of machining that has been required.

Renold’s engineering team has redesigned the sleeve, end plate, and adapters for the Hydrastart, meaning that in the vast

The new product lines follow on from Renold’s announcement of significant investment in the future of its Cardiff manufacturing facility earlier this year. The investment centres on the installation of new machines, to increase production and reduce lead times of couplings manufactured at the site. Two of the machines are now fully operational, with a further two to follow later in 2016.

“With the DMG Mori-Seiki NCX2500 and NTX2000 replacing legacy equipment, it will allow us to produce components that are fully machined and de-burred with no additional operations required,” says manufacturing engineer Tim Phillips. “This is a vast improvement on the previous setup and will not only streamline the production process, but also ensure that the parts are also manufactured more accurately and to a higher quality.”

Renold Couplings will be on stand D338 at the Drives and Contols exhibition, which runs at Birmingham’s National Exhibition Centre in the UK on 12-14 April, 2016. z For more information:

This article was written by Tom Hattersley, commercial director at Renold Couplings. Visit: www.renold.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

Proactive: not just a buzzword

HOSES

Knowing the signs of hydraulic hose degradation will save operators time and money It is often thought that hydraulic hose failure cannot be predicted, and as a fairly inexpensive component, many production managers accept failure as unavoidable. Equally, it is common for hydraulics users to pre-emptively replace hoses which are still in safe working order, utilising unnecessary time and money. But the low cost of the hose itself belies the considerable expense associated with oil clean-up and replacement, while a runto-fail policy also fails to take into account the significant health and safety hazard posed by burst hoses. There is always an indicator that a hose will fail, enabling maintenance engineers to act in time.

Hydraulic systems can contain as much as 2,000l of oil, which – due to high pressures – can completely drain out of a damaged hose within just 20 minutes. Even a small pin-prick sized hole can quickly compromise an entire system as, due to pressures exceeding 100 or even 200 bar, a tiny hole can split or expand to the size of a golf ball within a very short space of time.

While many modern hydraulic systems sit within a bund to collect waste oil, bursts can be unpredictable. The oil may spurt out at an angle, missing the bund

Common hydraulic power unit condition

Hydraulic hose equipment

altogether and damaging surrounding equipment or – even worse – causing significant and even life changing fluid injection injuries to individuals.

Due to all these factors, the cost of a leak is not limited to the price of the replacement hose, which could be as little as £10 (€12.9). Simply replacing 2,000l of oil could run to £1,000 or more, and this may not be accomplished immediately as few lubricant suppliers keep the volumes required in stock and oil from different sources should not usually be mixed. There is also therefore the cost of downtime to consider, as well as the cost of cleaning up and safely disposing of oil.

Should oil escape down drains, environmental fines may also apply, as well as the cost of compensation or fines if an individual is injured as a result of a leak.

It is easy to imagine how the £10 cost of a replacement

hose could spiral into several thousands of pounds, meaning “run to fail” is neither an economic or safe option.

How to predict Failure can be predicted either by calculating usage, through the use of monitoring tools, or visually. Most hoses will last for around a million cycles, and so by analysing the run time of a piece of machinery, the average life span of the hose should be easily calculated. Alternatively, various monitoring systems exist which can be installed within a hydraulic hose assembly to detect dangerous levels of wear and send an alert at the point at which a replacement is required. Often based on RFID or infrared technology, monitoring systems offer a high degree of reliability, as they are not based solely on calculations and so account for any unpredictable wear caused by misuse.

Where monitoring technology is not used, a combination of calculations and visual inspection should be implemented.

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016 47

HOSES exposing parts which can corrode, wear, or rust. As hoses of 6-8m in length and 1” in diameter are not uncommon, they are typically very heavy and without support, which will put pressure on the crimp and fitting at one end or both. Persistent pressure can distort and break a crimp, and oil drips can quickly become a jet under normal operating conditions. When installing supports for hydraulic hoses, it is recommended to replace the hoses at the same time to account for previous wear and tear when unsupported. Any twists or tight bends should be inspected for damage and, in the case of twists, care should be taken not to overtighten the fitting as this itself can cause pressure.

When replacing a hose, engineers should ensure it is within its “best before” date. Products should show the date of manufacture of all components along with the date of assembly, as hoses have a shelf life. The nitrile rubber casing loses its effectiveness after around five years due to UV exposure, so care must be taken to ensure the hose is within date and professionally swaged to ensure components have not been changed or replaced.

Brammer’s fluid power solutions team has been established for more than 20 years and has extensive experience in the inspection, design, and repair of hydraulic hose assemblies. z

Hydraulic pressure hoses system

Before undertaking full inspection – either planned or as a result of spotting a potential fault – the hydraulic power pack should be shut off and depressurised.

Interpreting the signs A hose consists of an inner metal braid, connected to the ferrule at either end via a robust crimp, and protected by an external rubber sleeve. Should the braid be visible due to rubber wear, the hose should be replaced as this could be indicative of damage to the inside of the hose and leaves the braid open to rust and abrasion. This damage can be caused by excessive pressure exerted on the hose, such as being driven over by forklifts or trapped under other machinery.

Where the rubber casing remains intact but the inner braid is damaged, a tell-tale sign is blistering or swelling of the outer coating. Here, oil is seeping through the braid and travels between the two materials, meaning it is only a matter of time until the rubber housing gives way. Another cause of blistering could be an incompatibility between the hydraulic fluid and the hose materials, again pointing to replacement.

A hard, brittle rubber casing is indicative of its maximum operating temperature being regularly exceeded, meaning it should be replaced with a more suitable product. Conversely, a tube exposed to temperatures below its optimum level will remain soft and flexible but display hairline cracks, in which case either the system temperature should be raised or the hose replaced.

Frays or loose wires at either end of a hose point to excessive hose movement, which may be the result of vibration, 48

Hose in poor condition

pressure surges, or too short a hose. If vibration can be identified as the cause, then clamps or dampers may be required to support the hose if re-routing is not an option. An amount of slack should always be allowed as assemblies shrink when pressurised, so a longer hose may be required. Hoses should always be specified with a higher maximum operating pressure than the system itself to account for surges. However, spiral reinforced hoses are available specifically for severe pulsing applications if necessary.

Hoses often need to be supported by fittings to prevent them being bent out of shape or exerting pressure at weak points. Fraying can occur as a result, A hydraulic system

For more information:

This article was written by Terry Davis, national technical manager at Brammer.

Visit: www.brammeruk.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2016

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