Fluid Handling International May/June 2016

HELPING TO KEEP YOUR BUSINESS FLOWING

JULY/AUGUST 2016

Through heat and ice Butterfly valves powering through varying weather

MRO procurement made simple Realizing cost savings through supplier partnerships

Issue 4 Volume 4

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COMMENT & CONTENTS

Contents July/August 2016

2

Latest news

7

Product showcase

8

Where two become one The conversion of oil volume to weight is a crucial part of petroleum product transfer where computerised systems are essential for maintaining accuracy

ISSUE 4 • VOLUME 4

Woodcote Media Ltd Marshall House 124 Middleton Road, Morden, Surrey SM4 6RW, UK www.fluidhandlingmag.com MANAGING DIRECTOR Peter Patterson Tel: +44(0)20 8648 7082 peter@woodcotemedia.com 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 Russell Priestley Tel: +44 (0)208 6487 092 russell@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 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.

10 MRO procurement made simple

Tackling MRO complexity to realise the benefits of supplier consolidation – an opportunity for manufacturers 14

Preventive maintenance through particle analysis An online particle counter helped a Finnish paper mill discover impurities in its process fluids and avoid expensive damages and downtime

16

Tackling complex geometries How an FPSO vessel solved its issues with corroded pipeline bends, straights, and tees with a composite wrap

18

Integrating leak detection and custody transfer for pipeline monitoring

20 22

Sizing for diaphragm actuated control valves

29

Long live the globe Extending the service life of globe valves through innovative coating application

31

It’s the little differences Using alternative peristaltic pump designs can bring operators significant cost savings when pumping slurries and corrosive substances

34

Centrifugal pumps in a nutshell Nutshell filters are used to separate oil from water, but without a properly engineered pump the process will not be optimal

36

Conveying wave technology Bridging the gap between peristaltic and diaphragm pumps

37

A historic partnership A French-German ceramics company enhances its 267-year history with the assistance of innovative AODD pumps

40 Unlocking energy saving potential 42

Event preview: Tank Storage Asia 2016

44

Magnesium oxide in tertiary oil recovery Thermal fluids are challenging good old steam’s supreme position in heat transfer applications

Supplying Filanovsky A UK company delivered valve solutions to one of the largest crude oil finds in decades

24

Through heat and ice Butterfly valves actuated through several means provided a solution to an operator based in an area with highly fluctuating weather conditions

26

Safety first In liquefied natural gas facilities, whether they be on land or sea, process safety equipment should be the thing to consider

46

A design challenge A multitude of hardships and challenges need to be taken into account when designing steam trace systems

48

Events

HELPING TO KEEP YOUR BUSINESS FLOWING

JULY/AUGUST 2016

Issue 4 Volume 4

Through heat and ice Butterfly valves powering through varying weather

MRO procurement made simple Realizing cost savings through supplier partnerships

Drilling Rig Equipment in the russian oilfield. ©A.Zaytsev. Picture from bigstockphoto.com

Comment Dear reader, The last time we at Fluid Handling International reported on the oil industry, the situation was… Let’s call it less than stellar. Now, though, the market seems to be doing better, with oil’s price per barrel bobbing up and down somewhere around the $50 mark (slightly under it at the time of writing), and according to the latest update by MarketWatch, has gone up $2.

We’re yet to see what kind of a shakeup the UK’s recent and – dare I say sudden? – exit from the EU will give the European liquid handling equipment market, but for the time being the industry seems to be doing alright. The global valves and manifolds market, for instance, is expected to grow by an annual 6.5% for the next five years, with ball valves leading the development.

And even if European markets would go down somewhat, Asia is raising its head as the prime hunting ground for equipment manufacturers. Looking at the water pump market in Thailand, just as an example, the country’s developing agriculture segment should drive growth to an annual 6.3% until 2021. The Asia-Pacific region is also looking good for intelligent flowmeter manufacturers, due to the area’s growing demand for high quality energy-efficient devices and rapidly developing industrial infrastructure.

You can read more on the industry’s latest developments in this July/August issue’s news section, where we tell you, among others, about company acquisitions, supply contracts, and of course the most interesting new products. The features section kicks off on page 8 with an interview with Implico’s managing partner Stephan Buhre. Brammer sheds light on how to optimise MRO equipment procurement on page 10, while Wilden tells us on page 37 why a 267-year-old German company needs AODD pumps.

But that’s of course not all. As usual, the rest of the magazine is filled to the brim with articles relating to our oil focus, without forgetting other applications, such as butterfly valves and conveying wave pumps. I wish you pleasant reading moments!

Best wishes,

Ilari ISSN 2057-2808 1

VALVE NEWS

Asco introduces zoned safety capabilities in Numatics 503 series valve manifold Asco has introduced the capability to integrate multiple safety zones within a single Numatics 503 series valve manifold.

This new zoned safety approach helps the design engineer satisfy the Machinery Directive 2006/42/EC and comply with ISO 13849-1 while eliminating the components and complexity found in discrete safety circuits.

“With this functionality, the original equipment manufacturer (OEM) and end user can easily and cost-effectively configure up to three safety circuits in a production machine using a single Numatics 503 series valve manifold with G3 fieldbus electronics,” said Robert W. Kemple, Jr., executive VP of sales and marketing for Americas at Asco.

The zoned safety concept is an integrated approach to machine safety and control that greatly simplifies the design of a redundant pneumatic safety circuit with a manifold system.

The Numatics 503 series can create up to three independent electro-pneumatic safety zones, while also allowing independent non-safe sections to co-exist within one manifold assembly.

The operator does not have to shut down the entire machine by releasing compressed air through a redundant safety/control dump valve.

Instead, the Numatics 503 series valve manifold can be configured to shut down air and power only to the group of valves that controls the machine’s motion in the operator’s vicinity.

“Because zoned safety capability is designed into the standard Numatics 503 series valve manifold platform, no redesign is required and the user has optimal choices when selecting valve options, accessories, and flow requirements,” said Kemple.

“The flexible approach also significantly reduces safety system cost and allows valuable machine space to be saved for other purposes.” z

Humphrey unveils new line of iDP liquid valves Humphrey Products, a US-based fluid handling producer, is targeting its new range of iDP liquid valves at the medical and analytical markets.

The company’s new products are a series of inert media separation valves, specifically designed for aggressive liquids and gases.

According to Humphrey, the 300 and 350 Series iDP models are efficient two-port valves constructed of material suitable for bodily fluids, aggressive chemicals and cleaners, and elevated liquid temperatures.

The flexing diaphragm-poppet isolates media from the solenoid within an inert body material, the company said.

The valves were developed and marketed by South Bend Controls for several years, and moved to Nogales, Mexico, when they were acquired by Curtiss-Wright.

After Humphrey acquired the products in 2015, the manufacturing moved to Humphrey’s Kalamazoo, Michigan, facility. z

2

Pentair launches first API 2000 compliant pressure and vacuum relief valves Pentair Valves & Controls has introduced the new Anderson Greenwood 4000 Series of pressure and vacuum relief valves, compliant with the latest API 2000 standard.

Developed alongside the industry standard, the valves are the first high capacity full lift valves verified to meet the requirements of the seventh edition of API 2000, which covers normal and emergency vapour venting requirements for bulk liquid storage tanks.

The 4000 Series pressure and vacuum relief valves are engineered to provide increased flow capacities and will fully open at 10% overpressure, helping protect tanks from physical damage caused by internal pressure fluctuations.

As a result, the valves can be set more closely to a storage tank’s maximum allowable working pressure (MAWP) or maximum allowable working vacuum (MAWV), enabling users to fill and empty tanks more quickly, and operate them at higher pressures.

The 4000 Series valves remain closed longer and enhance flow capacity, resulting in increased productivity and reduced evaporation – a key benefit amid the oil and gas, water, power and food and beverage industries’ focus on emissions and wastage.

“With verified 100% API 2000 compliance, customers can be fully confident that they are working with products that meet the latest standards,” said Stuart Brooks, tank protection product manager at Pentair.

“There is strong demand from operators for equipment that can enhance efficiency to increase productivity and save costs. The new Anderson Greenwood 4000 Series vacuum and pressure relief valves extend our tank protection offering to deliver these benefits thanks to their optimised design.”

The valve range is available in weight or springloaded designs and comes in 2-12” sizes.

In accordance with API 2000, the valves have been tested on a square-edge flange connection and are available in a variety of coatings, such as PTFE and ECTFE, for protection from extreme temperatures and corrosive media. z Pentair is the first to release fully API 2000 compliant full lift valves

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

PUMP NEWS

Börger to New KSB high-pressure pump supply rotary for a powerful performance lobe pumps to Northumbrian Water wastewater facility Following a six-month trial at Howdon Sewage Treatment Works in the UK, Northumbrian Water is set to replace a total of four pumps with FL776 rotary lobe units made by Börger.

Initially, a Börger pump with optimum rotors was put to work in the heavy rag application, transferring sludge from a holding tank to an AD plant.

Colin Davison, mechanical maintenance team leader at Northumbrian Water, said: “We wanted to improve this part of our process with a pump that would perform with suitable effectiveness, but also be far more reliable and easier to service than what we were using”.

“Over a sustained six-month period, the Borger FL776 proved conclusively that it is more than capable of handling this tough application, with the bonus that its maintenance-inplace design makes it much easier and far less time-consuming to service than other pumps,” he continued.

To help reduce costs for Northumbrian Water, Börger will be reusing the 30kW drives from the original pumps. z

German pump manufacturer KSB has launched its Movitec 125 pumps as an addition to its current range of vertical high-pressure pumps.

The multistage centrifugal pumps are designed for fluids such as water, coolants, condensate, and mineral oils.

They are well-suited for industrial recirculation and fire-fighting systems, cooling water circuits, and washing plants, as well as for boosting pressure in general process applications.

The efficiency of the new pumps with a full impeller diameter is greater than 80%, and the type series handles flow rates of up to 192m3/h at 60Hz at heads of up to 125m.

The permissible fluid temperature ranges from -20°C to 120°C, and as standard, the new pump sets are driven by twopole IP3 motors of 15 to 45kW. Fitted with product-lubricated plain bearings made of tungsten carbide, cast bases, and torsion-resistant pressure shrouds sealed by confined O-rings, the pumps are robust and reliable.

Corrosion-resistant hydraulic components made of stainless steel further add to these qualities, KSB says.

Several material variants and flange connection options provide users with flexibility when it comes to installing and operating the new pump sets.

With standardised cartridge mechanical seals complying with the EN 12756 standard, the Movitec 125 pumps provide simplified maintenance and longer service life.

As an option, the pump can be operated on a frequency inverter and combined with high-efficiency motors to increase the system’s efficiency and match the New KSB Movitec 125 pump flow rate to actual demand. z

Wilden releases HS430S AODD pump in aluminium

Wilden’s high pressure HS430S pump is now available in aluminium

Wilden, part of PSG, a Dover company and a worldwide air-operated doublediaphragm (AODD) pump developer, has released an aluminium version of its HS430S Advanced FIT High Pressure 1-1/2” (38 mm) AODD pump.

Well-suited for applications that require high head pressures, such as viscous and solid-laden slurries, the HS430S high pressure aluminium pump comes equipped with the FIT wetted path.

This design feature minimises the number of fasteners and allows for single socket reassembly for faster, easier maintenance.

The new pump also provides high flow rates, is easy to maintain, and increases plant profitability, Wilden says.

The HS430S has been designed for

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

high-grade containment, is a direct replacement for existing 1-1/2” (38 mm) high pressure aluminium pumps, and does not require any repiping during installation.

The pump features a Simplex design, which means that one liquid chamber is used to pump fluid while the other is used as a pressure amplification chamber.

With a 2:1 pressure ratio, the pump generates 17.2 bar and does not require costly external boosters or amplifiers to achieve this discharge pressure.

FIT high pressure aluminum pumps are fitted with the energy-efficient ProFlo Shift air distribution system (ADS).

This innovative ADS provides up to 60% reduction in air consumption compared to some other AODD pump technologies. z 3

PUMP NEWS

Grundfos India releases new pump with aims to double market share Grundfos Pumps India has launched a new product, the BMS hs AC high-speed booster pump, used for reverse osmosis and ultra-filtration applications in pharmaceuticals, food, electronics, and desalination industries.

According to Grundfos Pumps India sales head Saravanan Panneer Selvam, the new pump ensures high efficiency and energy savings of up to 10-12%.

The high-pressure booster pump market in India is worth INR1.5 billion (€19.8bn), and with the new release Grundfos plans to double its share in this segment to 3% in 2016-17.

“With increasing demand for sustainable and energy efficient pumps in the water treatment segment, our new pumps are specifically designed to improve efficiency for high flow and pressure applications,” Selvam said.

In addition to increasing its market share, Grundfos also aims to double its sales during this year. z

Hytek upgrades Alpha pumps with easy-to-use display Hytek, a UK-based equipment manufacturer, has begun fitting its Alpha pumps with an improved display to increase the ease of use.

The upgraded pumps feature a simpler and faster configuration and electronic calibration sequence, an easy to read display with improved viewing angles and LED backlighting, and larger 30mm high main characters and 12mm characters on the lower line facilitating clearer instructions and error messaging to be shown.

Operators are also able to personalise the display to incorporate their company name and branding.

In addition to the new display, Alpha pump have also been ATEX certified for use with diesel. z

AxFlow acquires Esspump in ‘strategically important’ move AxFlow, a Swedish positive displacement pumps and fluid handling systems specialist, has acquired its compatriot pump distributor Esspump.

With 570 employees and sales of €175 million, AxFlow is the largest distributor of industrial fluid handling equipment in Europe and South Africa, but the company still lists the acquisition of Esspump as strategically important.

Fred Lindecrantz, managing director of Axflow, believes the two companies “complement each other well”. ”Both AxFlow and Esspump are known for their products technology and application knowledge. Our expertise and strong customer and supplier relations give us a strong market position in Sweden,” Lindecrantz said.

Niklas Holmstedt, managing director of Esspump, is enthusiastic about the acquisition. ”The synergy of complimentary products, strong technical and application knowledge resulting from this acquisition, and the international resources available from AxFlow will bring considerable benefits for our customers and new business prospects,” he said.

AxFlow was established in 1991, and since then it has established itself as a major distributor in the chemical, mining, pulp and paper, water and wastewater, food, and pharmaceuticals industries.

The acquisition of Esspump makes AxFlow one of the largest distributors of positive displacement pumps in Sweden. z

Xylem optimises wastewater pumping efficiency with compact Flygt pump controller Global water technology company Xylem has launched a compact plugand-play pump controller with advanced monitoring and control capabilities to optimise wastewater pumping efficiency.

Xylem’s Flygt FGC400 is a self-contained, intuitive controller with pre-programmed functionality, which enables the operator to install and configure the unit to match specific wastewater pumping needs.

The Flygt controller can be connected to one or two pumps and offers the pump operator high flexibility, including the ability to alternate between pumps, track information on pump performance, and undertake maintenance actions.

Energy measurement, data loggers, 4

and level monitoring are all built into the compact unit, eliminating the need for complex electrical cabinets, which makes for a cost-efficient monitoring solution.

In addition, integrated motor protection functionality automatically monitors and protects the pump motor against voltage phase failure, overload, and voltage fluctuations.

Preventative maintenance and trouble-shooting information alert the operator to potential pump problems before they occur.

Magnus Lindberg, director of monitoring and control at Xylem, said: “No two wastewater pumping facilities are identical, and operators’ pump

requirements change constantly.

Xylem’s Flygt FGC400 is designed to give pump operators maximum flexibility with minimal effort, improving performance and boosting efficiency with a single, easy-to-use interface.”

The Flygt FGC400 is capable of controlling pumps up to 5.5kW, or larger pumps using external contactors, and is equipped to synchronise with external controls systems like SCADA systems.

The unit can be configured via PC, USB, or the controller’s own humanmachine interface, which can be mounted next to the controller or used as a handheld device and provides a wealth of actionable real-time data. z

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

FLOWMETER NEWS

Smart meters and evolving water systems expected to drive global flowmeter market The global flowmeter market is projected to grow at a comfortable CAGR of 11.45% between 2016 and 2020, according to a new market report.

Heavy industry analysts from market researcher Technavio highlight the emergence of smart meters and evolving sustainable water management systems as contributing to the growth of the market.

Smart meters are replacing analogue and other old technology meters, as these intelligent meters offer characteristics like real-time data management and remote access.

Smart meters are being promoted in the residential, commercial, and industrial sectors to record the real-time consumption of the utility services.

The meters also help end-users in

analysing their consumption pattern and cost, thus enabling them to optimise the daily consumption of these services and reduce cost.

Smart meters, as opposed to traditional “dumb” models, offer better utility management, personalised reports, reduction of cost incurred by human error, real time monitoring, and accurate billing due to increased measurement accuracy.

Improved water systems Countries across the world are facing the problem of water scarcity, partly because of the increasing losses associated with the water pipeline systems, such as leakages and illegal tapping.

For instance, the aged water supply and

Krohne introduces ultrasonic flowmeter for superheated steam Krohne has introduced the Optisonic 8300 ultrasonic flowmeter for superheated steam, which delivers 1% measuring accuracy, high repeatability, and a large dynamic measuring range with maintenance-free operation.

The two-beam ultrasonic flowmeter is capable of handling high flow rates of superheated steam, making it wellsuited for power plant boiler and plant efficiency monitoring, energy balancing, and inter-company steam billing.

As downtime of steam pipes is very costly, the Optisonic 8300 was built for long term use and it features a full bore flow sensor without moving parts or obstructions and an overall sturdy and robust construction with no cables or sensitive parts exposed.

The highly accurate flowmeter can maintain its measuring accuracy without maintenance or subsequent calibration for up to 20 years, while keeping operating costs at a minimum.

Verification of the measuring accuracy can be achieved by using the flowmeter diagnostics without removing the flowmeter itself, reducing the need for costly downtime.

The Optisonic 8300 is available in nominal sizes ranging from DN 100...1000 / 4…40” and is particularly suited to high flow rates.

The flowmeter is rated for pressure up to 200 bar and temperature up to 540°C, with higher rated units available on request.

Temperature and pressure sensors connected to the device provide the integrated flow computer with data to calculate steam mass flow, eliminating the need for an additional flow computer.

The flowmeter’s wide measurement eliminates the need for a dual range measurement setup, simplifying installation, operation, and maintenance. z

Krohne’s new Optisonic 8300 flowmeter helps reduce maintenance and installation costs

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

storage system in the US has resulted in the wastage of billions of gallons of water every year, according to Technavio.

The installation of smart meters can help vendors detect leakages in pipelines and thereby take appropriate measures to reduce water losses, which has in the US led to 20% reduced water consumption and 30 % lower energy consumption, the company says.

“To meet the high water demand, many countries are implementing smart meters in the water management system and improving the efficiency of wastewater treatment plants, so that the processed water can be reused for alternate purposes,” said Gaurav Mohindru, a lead analyst at Technavio for research on test and measurement. z

Yokogawa Electric releases new mass flowmeters Yokogawa Electric Corp., a Japanese electrical engineering company, has announced the global release of a new portfolio of four-wire Coriolis mass flowmeters called Rotomass Total Insight.

This new Coriolis mass flowmeter product platform was developed based on a ‘Total Insight’ concept that seeks to optimise operations and reduce maintenance costs at all phases of the product lifecycle.

Of the two main types of flowmeters that are in use today – the volume flowmeter and the mass flowmeter – the latter is generally more accurate as its measurements are less susceptible to variations in temperature and pressure, Yokogawa said in a statement.

Coriolis mass flowmeters are versatile and highly accurate instruments whose utility extends beyond mass flow, inline density, and temperature measurement.

They have evolved into multifunctional devices that can measure concentrations, function as net oil computers (NOC), and even measure heat transport, the company said.

“Our customers expect first-class performance from these instruments in demanding process control applications that involve liquids with high viscosity, entrained gas, and two-phase flows,” it added. z 5

OTHER NEWS

Emco Wheaton launches new break-away coupling Emco Wheaton has released a new Todo emergency breakaway coupling for bottom loading applications that reduces incident risk and improves operator safety.

The tried and tested Todo 4” aluminium break-away coupling has been specifically adapted for bottom loading arm applications with the addition of a TTMA flange.

The device can be applied on new loading arms, while it also means the break-away can be retrofitted to bottom hose loading arms that currently incorporate this type of flange in their construction.

The addition of the flange and use of the break-away coupling gives operators peace of mind knowing that should a drive-away incident occur, the break-away will disconnect and minimise risk of product loss.

Equally important, the breakaway would take the force of the incident, thereby protecting the API coupler and loading arm.

By keeping the design concept simple, the break-away coupler can be reset on site after an event with an easy-to-install kit, leading to reduced downtime.

Holly Damude, Emco Wheaton North American product manager for Todo, said: “The consequences of drive-away incidents are very serious without break-away protection. Our new Todo TTMA break-away coupler removes the human error element when transferring dangerous fluids.”

The coupling consists of two identical halves joined together by a series of 3mm break-pins, allowing the break-away to be configured to separate at a defined load.

Should an excessive load be placed on the loading arm, the pins break and the break-away separates, automatically closing the internal valves.

This new variant of the break-away coupler is designed to operate reliably in hazardous conditions, ensuring that liquid is delivered without spillage or contamination, at all times protecting the driver and the environment. z 6

Hayward releases new CPVC high-accuracy level sensor for corrosive liquids Hayward Flow Control has released a new high-accuracy HLS level sensor line that is not affected by foaming, waves, or head space vapours.

With a complete CPVC housing and construction, the HLS is well-suited for corrosive fluids and environments where metals cannot perform.

The HLS level sensor measures hydrostatic pressure and converts the reading to an analogue 4-20mA signal, which can be displayed on a wide range of indicating transmitters or taken directly into a PLC. The sensor’s all CPVC housing features FPM or EPDM seals, and it comes with a large ceramic diaphragm that ensures accuracy and repeatability.

The cable entry into body is triple-sealed, and the PFA-coated cable, available in

30ft and 49ft lengths as standard, offers superior chemical compatibility.

The sensor is capable of handling 0-15ft and 0-33ft water measurement ranges and 0.25% accuracy full scale.

Additional accessories and options from Hayward for the HLS series include moisture protection volume, NEMA 4X enclosures, ceramic sink weights for high specific gravity fluids, and the new HLST200 indicating level transmitter with configurable display and separate temperature channel.

Typical applications or installations include, but are not limited to, waste and water treatment, chemical storage, transfer and processing, sump level control, cooling towers, chlorination systems, aquatic and animal life support systems, and metal plating and surface finishing. z

Fluiten develops mechanical seals for extreme operating conditions Italian seal manufacturer Fluiten has temperature, it is difficult to find a material released double cartridge TRHD seals with for secondary gaskets (usually elastomeric metal bellows, developed specifically O-rings) that withstands high temperatures for pumps used at high temperature. without losing the necessary elasticity to Fluiten’s R&D team designed the seals to accommodate the movement of the shaft. be able to withstand temperatures of over Metal bellows are able to absorb this 176°C, as stipulated by API standards, and movement even at high temperatures as they are also able to prevent any leakage they do not include dynamic O-rings. of dangerous liquids into the atmosphere.

Elastomeric materials exposed to high During the refining process of crude temperatures undergo an irreversible oil, the desulphurisation of naphtha is chemical transformation which makes them one of the high temperature processes solid, crumbly, and subject to cracking, which run considerable risks. making mechanical seals therefore unsuited The chemical reaction takes place for use in high temperature conditions. at a temperature of about 260°C The new Fluiten metal bellow seals are with a pressure of 25-26 bar, with able to function in these challenging cobalt-molybdenum as catalyst. operating conditions in which elastomeric At this temperature the sulphur molecules gaskets are impracticable, while complying are removed from the naphtha with the with the API 682 4th ed. standards. z use of hydrogen, which produces highly dangerous sulphite waste.

In heavy duty applications the mechanical seal is subject to axial and radial movement, and when the process liquid to be sealed Fluiten TRHD double cartridge metal bellow seals exceeds a certain FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

PRODUCT SHOWCASE EASY-CLEAN, QUICK-STRIP PUMPS FOR FOOD AND PHARMA DUTIES

EFFICIENT COLORIMETRIC ANALYSER HELPS MONITOR TROUBLESOME MINERALS IN WATER

n Transferring liquids in food, brewing, pharmaceutical, and other similar hygienic process applications requires reliable, easy-to-clean, and easy-to-maintain pumps. Liquids handling specialist Pump Engineering offers a range of CSF CS, CSA, and CSM centrifugal pumps capable of handling capacities from 1 to 550m3/h at heads up to 155m.

CSF pumps are manufactured in investment cast AISI 316L stainless steel, with stainless steel for all wetted parts. They are designed for clean-in-place to ensure the absence of dead areas and feature electro-polished finishing of all surfaces. Depending on the duty CSF-CS and CSA pumps can be supplied with an internal or external single mechanical seal or flushed double mechanical seal for handling high temperature liquids, or those with a tendency to crystallise.

n The easy-to-use and economical CA6 Colorimetric Analyser from Electro-Chemical Devices provides accurate and reliable measurement of manganese (Mn) or iron levels in municipal drinking water production, food/beverage processing, and other high purity water processes. A sequence of sampling, analysis, and results processing is performed and repeated using colorimetric methods. This technology relies on an LED light source and a heated colorimetric cell designed for measuring trace amounts of manganese, iron and other analytes in water.

The CA6 precision online sequential sampling analyser is lightweight and easy to install.

Weighing less than 40 pounds, it can be wall mounted or simply set on a bench using the optional bench top stand. After the sample, waste and reagent lines have been connected to the analyser and provided with power, the CA6 will begin its pre-programmed analysis sequence.

FLOWMETER FOR METERING VISCOUS FLUIDS n Built for metering viscous fluids, such as hydraulic oils used in heavy machinery, at pressures of up to 700 bar and temperatures up to 150°C, the Titan Enterprises OG2-700 bar flowmeter is designed to be fully IP67 / NEMA 4 compliant. With a standard flow range from 0.03 to 4.0l/min on 30Cstk oil, the flowmeter is able to routinely achieve high accuracy (0.5%) and repeatability (0.1%).

Combining robust 316 stainless steel design, durable construction materials, and proven technology ensures the OG2-700 bar flowmeter provides reliable, accurate operation over an extended product lifetime.

EFFICIENT INSULATED PIPING SYSTEM FOR CHILLED MEDIA n Asahi/America’s Coolsafe is a cost-effective complete pre-insulated piping system for chilled media, consisting of a polyethylene inner layer, polyurethane insulation core, and polyethylene outer layer. The PE-inner by PE-outer design allows the system to be simultaneously butt welded, saving installation time and providing a safer installation.

Coolsafe components are moulded and insulated to strict tolerances to ensure easy installation and long-term insulation of chilled media. It provides thermal conductivity better than 0.026 W/m-K (0.015 Btu-ft/h-ft2-F).

Coolsafe is available in sizes of 32mm-250mm and it includes a complete range of fittings. Asahi/America’s Type-21 ball valves and Type-57 butterfly valves can be incorporated into the Coolsafe system to control flow.

Suitable applications for the Coolsafe piping system include commercial refrigeration, brewery and winery chilling, secondary cooling of food production, cold storage facilities, and central plant HVAC systems.

Want your product here? Email russell@fluidhandlingmag.com FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

7

INTERVIEW

Where two become one

The conversion of oil volume to weight is a crucial part of petroleum product transfer where computerised systems are essential for maintaining accuracy When petroleum products are traded, volumes have to be converted into weight, and vice versa. It is vital for this calculation to be performed correctly, because even the smallest inaccuracy will affect key processes in the supply chain of oil and gas companies – from the safety of the loading and warehousing operations through to the computation of tax liability. Stephan Buhre, managing partner at downstream software specialist Implico, told Fluid Handling International about the pitfalls that await the unwary and about the role that software solutions can play in the conversion process.

Fluid Handling International (FH): How much does the conversion of quantities matter in petroleum logistics?

Stephan Buhre (SB): A wide range of products are produced from crude oil – from petrol to liquid gases to aromatics.

The volume and density of all these materials change – and at different rates – at different temperatures. Whenever oil products are transported, different units of volume have to be converted into units of weight and vice versa. This makes the issue both complex and relevant for the logistics processes. Industry uses huge quantities of oil products, and even the smallest temperature fluctuation can result in substantial differences in quantities, leading to marked fluctuations in value.

FH: Can you explain the physical context?

SB: As already mentioned, the volume and density of petroleum products are temperature dependent. For example, if you load a tanker truck with 30,000l of fuel at an outside temperature of 25°C and later unload the same tanker at 10°C, the measured volume will be significantly less. The recipient thus receives a smaller 8

be calculated at 15°C and this value is then used throughout the supply chain.

This ensures that same amount is always referenced throughout the transportation process, from the refinery to the tank terminals and finally to the consumer.

amount through no fault of the seller. The only way to be sure of knowing the correct quantities at different temperatures is to take into account what is known as the volume correction factor (VCF). Using this, you can convert the volume at the current temperature to the volume at a reference temperature. You can also use the volume correction factor to calculate the density of the substance at that temperature.

And this is important when performing the volume-weight-volume conversion.

FH: So, with the aid of the VCF, the contracting party has a reference point that allows everyone to refer to the same quantities when, for example, litres are being converted into kilograms and vice versa.

SB: Exactly. And the reference point of petroleum products depends on where you are. It is 15°C in Europe, 20°C in warmer southern countries, and 60°F (appr. 15.5°C) in the US. For specialty products like bitumen, the reference point is 25°C. The density of the 30,000l of fuel in our example would

FH: There must be some basis for this calculation because specific density varies from one substance to the next.

SB: That is why the specific gravity is determined at the refinery where the crude oil is processed and the product is assigned to a particular class. These are A for crude oils, B for refined products, C for special substances, D for lubricating oils and E for LPG. These classifications were developed by the American Petroleum Institute (API) and form part of the recognised industry standards of organisations such as the American Society for Testing and Materials (ASTM), the German Institute for Standardization (DIN) and the British Energy Institute (EI).

These standards contain the specific densities and the temperature versus density curves for all substances based on oil, together with the relevant conversion formulas. Everyone in the oil and gas supply chain needs these, as they provide a universal reference for doing business with petroleum products.

FH: Can you give us some examples of when these conversions play a particularly important role in the oil and gas supply chain?

SB: Let’s use the example of the tanker truck. Bulk liquid cargo is normally measured in units of volume – usually litres. But as soon as the tanker travels on a public road, national road traffic regulations often insist that the weight of the load has to be determined and

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INTERVIEW automatically, eliminating potential errors and improving the efficiency of the petroleum logistics processes.

FH: So, compared with 25 years ago, when shippers, schedulers, and quantity bookkeepers were busy copying figures from tables, these processes now run fully automatically. Could you give us an overview of how this happens?

SB: At Implico, we developed OpenTAS QCM to take care of quantity conversion.

The name stands for Quantity Conversion Module and it is integrated into our OpenTAS tank terminal administration system, among others. OpenTAS QCM contains all the data from the tables and standards mentioned earlier and calculates the required values automatically. We make sure that the data is always up-to-date and that it includes all international conventions.

All that the shipper has to do is enter the

Stephan Buhre, managing partner at Implico

documented to ensure, for example, that the vehicle’s maximum permissible axle weight is not exceeded. Then the regulations on the transport of dangerous substances require that sufficient space is left in the tank to allow for expansion caused by a rise in temperature. The carrier must therefore not only ascertain the weight of the cargo, but must also know how its volume expands at different temperatures. If the tanker truck discharges its load at a higher temperature, more litres will be discharged than were originally loaded – even though the weight has remained the same.

FH: And for which the customer will not wish to pay for.

SB: It does not matter from which side you look at it. Both parties have an interest in ensuring that there are no discrepancies and that the agreed quantity is actually delivered. Moreover, companies trading in petroleum products are not the only ones with a stake in this – the tax authorities also want to know that the figures add up.

FH: Tax – that is an important word.

Petroleum products generally attract different levels of tax.

SB: That is certainly one of the distinctive features about petroleum products. Since they are subject to different and often very high taxation rates, traders are keen to transport and store as much untaxed

product as they can. This allows them to minimise the capital they have tied up prior to the point of consumption. Traders are often not required to pay tax until they actually sell their products. Take Germany, for example. There is a basic requirement to pay energy tax on all movements of petroleum – even if you are just moving your own product from one tank terminal to another without any change of ownership taking place. You can suspend this tax liability under certain conditions, by operating what is known as a “tax warehouse”. The German customs must receive prior notice of any movement of goods out of the tax warehouse. And here again it is very important to be able to precisely and consistently determine how much product is being shipped.

FH: You have been dealing with this issue for over 25 years. What is different now compared with when you started?

SB: A lot! Refineries and tank terminals used to work out the quantities of petroleum products on a calculator, and then manually transfer the figures from one delivery note, invoice, and tax form to the next. It was all very time consuming and prone to errors. Everyone involved not only had to determine the correct data, but also to accurately convert and update the quantities involved each time the product was moved. Today, with the right software, this happens completely

type of product and the initial values for each bulk movement. This avoids the kind of errors that can become very costly in the downstream process. What is special about our solution is that OpenTAS QCM can be integrated into the entire end-toend petroleum logistics process chain, from the refinery to the end customer. The module communicates with other systems and automatically outputs the correct data right up to quantity bookkeeping and invoicing in ERP systems such as SAP. FH: So OpenTAS QCM can provide solutions for the entire supply chain?

SB: That is indeed what is unique about OpenTAS QCM. Companies can use the system as a standalone solution to convert individual volumes. We also supply a free web-based calculator or an Excel addin. The module can also be integrated into SAP ERP systems. To do this, we use a remote function server, which carries out the necessary calculations. It is a particularly attractive option for oil and gas companies working with SAP IS Oil, SAP Secondary Distribution Management for Oil & Gas, or SAP Retail Fuel Network Operations. When it comes down to it, however, we can integrate OpenTAS QCM into any other environment, such as other TAS systems or logistics software.

FH: Mr. Buhre, many thanks for your time.

For more information:

Visit: www.implico.com

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MRO procurement made simple

Tackling MRO complexity to realise the benefits of supplier consolidation – an opportunity for manufacturers For most manufacturers, procurement strategies for direct spend items – such as raw materials and items forming part of the finished product – are carefully planned and scheduled to ensure value for money, high levels of availability, and optimal inventory holding. With indirect items such as maintenance, repair, and overhaul (MRO) products and industrial consumables, however, the procurement process is typically far more unpredictable and ad hoc.

Purchasing from multiple local suppliers, holding excessive amounts of inventory due to unpredictable usage, and thousands of order and invoice transactions are common occurrences for many manufacturing companies.

As the cost for each individual item is generally relatively low, rationalising procurement is not frequently prioritised – and when it is, the task at hand can be complex and daunting.

Take, for example, a manufacturer holding 10,000 stock-keeping units (SKUs), being purchased by numerous individuals from stores staff to engineers, technicians, managers, and production staff, and with no regulation over supplier choice or frequency of ordering. A single high use item – perhaps an abrasive disc, spanner, or disposable glove – could be purchased by different people, from different suppliers, at different prices, at the same time, and without consideration of stockouts or overstocking.

Across one plant this could prove a minefield, but across a multi-site organisation, standardising the brand, model, price, and stock could seem an insurmountable challenge. It is generally recognised that whilst spend on MRO and industrial supplies can 10

represent around 15 to 20% of total spend, this category can equate to 80% of purchasing transactions.¹ Procurement challenges Optimising the MRO procurement process can therefore not only deliver significant savings in terms of pure product cost, but also in administrative costs, a reduction in inventory, and supply base. In a study by the Aberdeen Group², a survey summarised the key challenges cited by those tasked with procuring industrial and MRO supplies.

Lack of visibility into spend was highlighted as a significant challenge faced by organisations aiming to streamline and optimise MRO procurement, closely followed by an inability to ensure compliance with supplier contracts. Where multiple individuals are empowered to

purchase, duplication of orders is highly likely as teams work in local silos and there is no centralised control over ordering, leading to a lack of accountability for MRO procurement.

Within multi-site organisations, buying practices at site level often result in individual loyalty to local, niche suppliers, meaning hundreds of companies may be issuing invoices to a single site. While the niche supplier may not be charging a premium for the products to which individual buyers feel loyal, using a large amount of such suppliers increases the administration time associated with ordering and receiving goods as well as processing payments. These suppliers often have a relatively small share of the company’s overall spend and are therefore unlikely to invest in delivering value adding initiatives.

A lack of traceability also leads to an inability to create accurate purchasing

Instead of holding great stocks, companies can outsource their MRO procurement

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MAINTENANCE plans and strategies, as organisations rarely have a true picture of the volume of items used and the correct amount to be held in stock to maintain optimal service levels. The unpredictable demand of MRO items can lead to holding “just in case” stocks, which ties up cash in inventory and – as there is often a lack of traceability and a large number of people responsible for procurement – further stock could continue to be ordered due to a shortage in one area when large supplies are available elsewhere.

The survey also highlighted the challenge of gaining year-on-year cost savings. This problem can be exacerbated where a company sources its indirect items from a large number of suppliers and each vendor is providing only a small number of products sourced by the company. In this instance, it is virtually impossible to drive meaningful year-on-year savings. There is often little or no incentive for an individual supplier to offer price reductions for leveraged volume, or for them to dedicate resources to cost savings or continuous improvement activity.

A huge waste of money The implication, therefore, is an excessive number of MRO parts and SKUs supplied by hundreds of local suppliers with no incentive to negotiate on price, a high volume of transactions expending unnecessary administration time, lack of standardisation and best practice amongst the supply base, and high obsolescence of MRO part numbers that

Total cost elements of MRO and industrial supplies

may be frequently recreated despite high volumes of stock already in place.

The complexities of MRO procurement mean that the costs associated with procurement and inventory management are greater than the product item price, increasing the total cost of ownership many times over. In fact, in a typical cost profile of MRO and industrial supplies, only 40% of the total product spend can be attributed to the product itself. Some 35% is down to the cost of inventory – storage, handling, and obsolescence costs – while the remaining 25% is accrued through the cost of procurement.

This includes the hours of work associated with selecting products, ordering and receiving, and making payment, as well as the cost of errors.

This means that for every £100,000 (€127,705) of annual spend on MRO and industrial supplies products, the total cost of ownership is around £250,000 or more when all factors are considered.

The Aberdeen Group study also showed

Good communication between responsible parties ensures timely and low-cost maintenance

that “best in class” companies were successful in achieving cost reductions of 19% by taking a considered approach to MRO and procurement. However, the benefits were not purely financial – best in class organisations also achieved a 14% reduction in parts inventory, reduced supply base by 17%, and recorded a reduction in administrative costs of 18%.

The study, based on a benchmark of 150 companies, found that the organisations performing poorly could only record savings of 2-3% across each of the above categories, while even average companies noted a saving of between 7 and 9%, pointing to a clear opportunity for the majority of organisations.

The best of the best So what constitutes “best practice” in MRO and industrial supplies procurement, and how are cost and production efficiency benefits really achieved?

A number of factors, which regulate people, processes, and systems, contribute to best practice. To extract the greatest value, each facet should be seen not as a standalone concept but as a cog in a wider machine, linking to other aspects of procurement and bringing people and processes together to ensure everything – and everyone – operates uniformly.

Product optimisation and inventory management are closely related, for example. Organisations should regularly review usage of both original equipment manufacturer (OEM) and substitute parts to ensure the most suitable products are purchased and in stock, while applying lean and 5S principles helps avoid overstocking, obsolescence, and stock-outs within an engineering stores environment. Product optimisation

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 11

MAINTENANCE ensures that the same or similar items are not being purchased through multiple suppliers, reducing the supplier base.

Meanwhile, rationalising the design and layout of the stores facility simplifies inventory management on site.

Applying best practice to MRO can also contribute to enhanced energy efficiency and even health and safety.

Careful analysis of personal protective equipment (PPE) needs can help avoid over-specification and the associated overspend while maintaining correct protection for employees. Similarly, reviewing energy-intensive assets such as motors, drives, and pumps to ensure the most efficient models are available – as well as implementing a robust repair/ replace policy – can cut costs through reducing energy consumption.

In terms of processes and systems, best practice in accounts payable and e-commerce are also linked.

Both online ordering and receiving consolidated invoices electronically cuts down on transaction costs as well as saving employees’ time, freeing them up for value-adding projects.

Efficient category management, meanwhile, through implementing supplier service level agreements (SLAs) and scorecards, should aim to achieve in excess of 80% contract spend consolidation compliance.

To further optimise efficiencies among production or maintenance employees, lineside supply is an important factor to consider. It involves making high volume industrial consumables available close to the point of use, rather than a long “walk and wait” trip to stores. This approach improves plant productivity by ensuring employees remain at or close to their work stations.

Let someone else handle it Best practice, however, cannot be implemented successfully without being aligned to clear goals. Joel Roth, in his book The 20% Solution: A practical guide to dramatic cost reduction in MROP procurement, notes that: “When asked for their MRO goals, many procurement managers offer vague statements like ‘lower costs, better service, higher quality.’ Or, ‘I’d like to cut prices by 10%.’ Goals that are general are useless; they must be specific and measurable.

Moreover, goals must be related to activity levels: it is probably unrealistic to expect a 20% cost reduction if 12

Brammer’s Insite solution delivers operational cost savings

production volume is increasing by 20%.”

The following examples of SMART – specific, measurable, achievable, realistic, and timely – goals applied to the optimisation of MRO procurement help to demonstrate this principle: • Improve signed-off operational cost savings by 25% over 3 years through vendor consolidation and partnering with strategic suppliers • Reduce purchase to pay costs by 20% through the application of consolidated invoicing and vendor reduction • Reduce working capital tied up in inventory by 10% over two years through the use of vendor managed inventory and consignment stock • Reduce product consumption by 25% for fast moving consumables by implementing industrial vending • Reduce the number of MRO related SKUs by 25% over three years through product standardisation and OEM conversion Developing strategic relationships with a smaller number of suppliers can help achieve all of these objectives, as stronger partnerships lead to the delivery of valueadding services. By replacing a large, fragmented supplier base with fewer, longer-term relationships, organisations can leverage reductions in transaction costs and operational cost savings as the vendor is as motivated as the company itself to not only achieve savings, but add value through close collaboration.

With fewer suppliers also comes more streamlined ordering, a reduction in the number of invoices, and less time spent on administration and stock handling.

Returning to the concept of best practice in MRO procurement, one additional factor can be implemented

which has the potential to impact all other aspects – from product optimisation to category management – and manage the setting and measurement of goals: vendor managed inventory.

Choosing to outsource the management of industrial supplies and MRO is a strategy recognised by the Aberdeen Group as part of its 2006 report.

For organisations operating at “average” level (that is, undertaking some best practice activity but recording savings of only around 7-9% compared to the 19% possible), the report recommends outsourcing specific areas of MRO procurement and management as one method of improving performance. The report notes that as external providers understand market dynamics, they are therefore able to leverage more favourable agreements, and also focus on more strategic cost reductions.

Far from considering MRO procurement a box ticked for companies ranked as best in class, the report recommends outsourcing key elements to maintain savings and make further gains in cost and efficiency benefits. With the outsourcing of elements of MRO through vendor managed inventory and the use of on-site supplier personnel recognised within the industry as a viable tool for increased cost savings and enhanced efficiency, identifying a trusted supplier with whom to collaborate is just stage one of a multi-faceted partnership.

Know your friends A suitable value adding supply partner must have excellent relationships with the manufacturers of MRO products and industrial consumables, able to not

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MAINTENANCE only leverage buying power, but also benefit from technical expertise, exclusive product ranges, and OEM support. The supplier must be able to demonstrate past results, validated if possible by independent third parties, detailing the cost savings achieved alongside customer testimonials. They should have a track record of successfully implementing lean engineering stores and vendor managed inventory solutions, demonstrated by their own best-in-class supply chain, and show how their activities have delivered added value over and above pure cost savings.

One of Brammer’s key solutions for MRO procurement and management is its Insite service – effectively a dedicated Brammer branch housed within a customer site geared entirely to meeting the needs of that organisation.

By dealing with only one supplier, ordering is rationalised and purchasing power is leveraged. Without each local site ordering from their preferred supplier with different costs and codes, time spent processing paperwork is vastly reduced. Only one invoice per month can be produced, covering all items consumed, meaning organisations do not have to tie up resources in nonvalue adding activity – a major benefit of supply chain consolidation. When orders are received, they can be shipped as part of a consolidated delivery, creating further handling efficiencies as well as economies of scale.

Brammer has a strong track record of delivering operational cost savings for customers, many of which have been facilitated by the use of Insite service.

Brammer’s Insite service adds a dedicated Brammer branch to a facility

In the UK, for strategic customers, these efficiencies represented around 14% of their total purchasing spend. More than 100 Insite locations are in operation across the UK, covering both single and multi-site organisations, delivering cost savings and efficiency improvements on a daily basis.

To maintain and improve plant uptime, having the correct MRO products available at the time of need is imperative. While it is tempting to keep high inventories in stock, bringing on board a strategic MRO supplier can drive down unnecessary inventory and

the associated costs. Effective MRO partners will often be able to deliver critical parts within one or two working days, therefore eliminating the need to hold these products on-shelf in stores.

By reducing the amount of customerowned inventory and replacing it with in-house consignment stock, paid for only once used, customers are able to reduce the amount of working capital tied up in stock. But, for a partnership with an MRO supplier to be successful, a number of prerequisites must exist.

Responsibilities for each party must be clearly defined, with standards and objectives agreed at the outset. As this is a partnership approach, rather than a traditional supplier-customer model, regular reporting and reviews at the appropriate level must also be conducted to both communicate successes and highlight development areas – especially across multi-site organisations. z

For more information:

This article was written by Richard Raybould, head of site based services at Brammer. Visit: www.brammer.co.uk

References:

Confusion in parts ordering is avoided by limiting the number of suppliers

1. The 20% Solution: A practical guide to dramatic cost reduction in MROP procurement – Joel Roth, 2008.

2. The Maintenance, Repair and Operating Supplies Benchmark Report: Strategies for Improved MRO Spend Management – The Aberdeen Group, 2006.

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MAINTENANCE

Preventive maintenance through particle analysis

An online particle counter helped a Finnish paper mill discover impurities in its process fluids and avoid expensive damage and downtime Lubricating oil systems rely on clean operating fluids, and are subject to failures due to contamination. Particles in lubricating oil systems might lead to system failures or machine downtime. The sources for such contaminations are various, as particles can enter the system either from outside or can originate from the system itself.

Contaminants may enter the system from outside through badly covered patches (e.g. particles in environmental air or sediments on piston rods). Incorporated dirt particles derive from the manufacturing process, and stay in the system unless they are carefully removed (e.g. casting sand of core manufacturing, scales, rust, welding sputter, or textile fibre).

Finally, metallic or non-metallic pieces of abrasion may enter the liquid during machine operation due to ageing processes (e.g. wear material or abrasive particles). All these contaminants may cause severe problems for the lubricating oil system. It is therefore essential to continuously monitor the condition and cleanliness of the operating fluid.

Automatic particle counting Automatic particle counting helps to prevent contaminationrelated damage. With the aid of an online particle counter, the operating fluid can be permanently monitored. The fluid particle counter detects particle number and the size of each individual particle via an optical measuring technique. As soon as a pre-defined limit is exceeded, the online particle counter instantaneously raises an alarm.

In case of an extraordinary number of large particles, it is likely that wear and abrasion have occurred. Abrasive

Equipped with eight or more size channels, automatic particle counters are able to detect bearing failures in lubricating oil systems at an early stage

particles often derive from defective components, which must be exchanged or repaired to prevent machine failures or complete downtime. Large abrasive particles, however, can be detected only with specially equipped monitoring instruments.

Unlike standard contamination monitoring devices, the integrated sensor of an automatic particle counter is equipped with more than three size channels. With at least eight integrated size channels, a particle counter provides much more detailed information on the particle size distribution than a contamination monitor could do. Larger particle sizes >70µm(c) can be distinguished from smaller or medium particle sizes.

The following application example shows that the knowledge on larger particle sizes and their size distribution is of paramount importance in lubricating oil systems. An above average particle population of large particles casts light on abrasion issues in the application.

Eight take on three

Defective roller bearing in a Finnish paper mill

14

In a Finnish paper mill, the operating fluid of a roller bearing was monitored simultaneously with two measuring instruments for four months. On one side, the monitoring was performed on a contamination monitor comprising three size channels, and on the other side on a particle counter equipped with eight size channels. As per ISO 4406, the contamination monitor provided information on the particles in the sizes of >4µm(c), >6µm(c), and >14µm(c), whereas the automatic particle counters reported on the contamination level in eight size channels between >4 and >70µm(c).

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MAINTENANCE

Abrasive particles often derive from defective components, which must be exchanged or repaired to prevent machine failures or complete downtime The comparison of measuring results showed that the triple channel monitor did not suffice to identify the quality of the lubricating oil sample. During the complete measuring interval, the contamination monitor declared the oil to be clean with low triple codes as per ISO 4406. The automatic particle counter with its eight size channels, however, reported alarmingly high particle numbers in the size channel >70Âľm(c). A further examination revealed that mechanical components of the roller bearing had been badly damaged, resulting in the bearing having to be exchanged. If the machine abrasion had not been detected on time, a severe and costly machine failure or complete downtime would have been the consequence.

The use of an automatic particle counter was therefore crucial in this application example. Only thanks to the differentiation of particle numbers in eight size channels, and in particular in the channel >70Âľm(c), was it possible to clearly

show the real degree of contamination. The high number of larger particles highlighted an abrasion issue and provided insight on a failure in the system (i.e. a defective bearing in this case). If such abrasive particles are detected on time, proactive and preventive maintenance operations can be undertaken to repair the failure and to limit downtime.

Conclusion Condition monitoring of lubricating oil systems requires an early detection of failures, so that they can be quickly repaired and consequential damages can be prevented.

The application example proved that a differentiated particle analysis of at least eight size channels is required to detect abrasive particles. A contamination monitor reporting triple codes as per ISO 4406 does not provide any information on the real size distribution of larger particle sizes.

Contamination monitors cannot detect these large particles and hence are not adequate for condition monitoring of lubricating oil systems. An online particle counter with eight or more size channels is more suitable for early detection of bearing failures, as it provides information on the particle size distribution also for larger particle sizes. z

For more information:

This article was written by Sandra Suresh at Pamas Partikelmess- und Analysesysteme. Visit: www.pamas.de

Precision - Made in Germany Schubert & Salzer Control Systems is a medium-sized company in the Schubert & Salzer Group focusing on the development of innovative solutions in control technology for liquid and gaseous media flows.

Schubert & Salzer UK Limited P hone: +44 / 19 52 /46 20 21 Fax : +44 / 19 52 /46 32 75 E mail: inf o@ schubert-salzer.co.uk

www.schubert-salzer.com UK_Fluid Handling issue JANUARY-FEBRUARY H135 x 190 mm 3mm bleed.indd 1

11.01.2016 09:29:01

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 15

MAINTENANCE

Tackling complex geometries How an FPSO vessel solved its issues with corroded pipeline bends, straights, and tees with a composite wrap

In April 2015, a Norwegian floating production, storage, and offloading (FPSO) vessel requested a solution to rebuild, strengthen, and protect corroded pipes. A series of pipes on board the North Sea FPSO were displaying signs of corrosion between both the pipe and support, in some areas registering thin wall defects with up to 35% wall loss. Not only did this represent a severe containment issue, but it also threatened the vessel’s operation.

Impressively, FPSOs combine facilities for production, processing, and storage all in the same place. Often viewed as safer and more economical than permanent platforms, with the ability to relocate to another development, these vessels have become the foremost system for offshore oil and gas production. They receive material from subsea reservoirs, which is then processed before being stored on board until it is possible to offload elsewhere via a tanker or through pipelines.

Thin-wall corrosion up to 35%

16

These pipes often suffer severe corrosion at support points due to abrasion and/or galvanic corrosion. This can have destructive effects on the wall’s integrity, quickly developing into thin and even through-wall defects.

In this situation, the customer highlighted how the 6” pipe system was suffering from corrosion between the pipe and support. Significantly, the hazardous part of the project was lifting the pipes because of internal pressures. Therefore, in order to eliminate the associated risks, the project needed to be executed offline.

In order to limit the downtime of the FPSO, the asset owner assigned a limited shutdown period, totalling seven days.

An unorthodox solution Because welding was not an option, the application required a unique cold-applied solution due to the total number of irregular pipe geometries.

The solution had to further incorporate a well-engineered design for both Tee junctions and sharp bends.

Consequently, the customer selected Belzona SuperWrap II due to the composite wrap’s versatility and ability to conform to complex geometries.

Having previously worked with the Norwegian Belzona distributor CAN Technology, the customer received a precise timeline for the applications, overall guaranteeing an efficient and structured process. Within this timeframe, five of the days were allocated for the design and installation of all six repairs, whilst the remaining two days allowed for curing and demobilisation of all equipment and personnel.

The application was carried out in accordance with ISO/TS 24817 and ASME PCC-2 Article 4.1., certifying the composite wrap system is in line with equipment and piping repair regulations for petroleum, petrochemical, and natural gas industries.

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MAINTENANCE Prior to the installation, heavy equipment necessary for lifting the large sections of pipe was rigged into place, consistent with engineering designs. Notably, some areas needed the use of rope access techniques, requiring an overall team of five operators, including riggers, inspectors, and product specialists.

Installation In order to determine the extent of the defect, ultrasound equipment was used to inspect the status of the damaged pipework. Eventually this revealed areas where more than a third of the substrate had succumbed to thin wall corrosion, thus demanding reconstruction of the pipeline surface before the application of Belzona SuperWrap II. As a part of the plan, the installation team assembled tarpaulin housing around the specific pipe defects for grit blasting and climate control purposes.

Each wrap application followed the same procedures, beginning with grit blasting in accordance with Standard SA2.5, thus removing any foreign corrosive matter. Ultimately this provided an optimum substrate surface profile of 75µm, ideal for successful application of the Belzona SuperWrap II. Once the surface was primed, corrosion resistant Belzona 1111 (Super Metal) was used to rebuild the metal substrate. The versatile adhesive properties of the resurfacing epoxy-based composite, particularly on carbon steel substrates, created a level surface for the next stage of the process.

As mentioned earlier, the complex pipe geometries included bends, straights, and tees, necessitating a tailored design for the Belzona SuperWrap II application.

The two-part, fluid grade resin system

works in conjunction with a bespoke hybrid reinforcement sheet based on fibre glass and carbon fibre. The fibre glass offers flexibility, in addition to serving as a wet-out indicator, which ensures effective application of the reinforcement sheet.

Interwoven with carbon fibres, the reinforcement sheet provides the composite wrap with the strength it needs to retain Ceramic shim plates take the load off high pressures and loads.

Belzona was able to cut the reinforcement sheets to match the installation was finished within six hours, unique pipe dimensions in the form of leaving sufficient curing time for each reinforcement jackets for the tees, whilst application. Once the entirety of the utilising specifically measured strips for repair was completed, it was necessary the bends. Before each application, for pressure testing to be carried out. After the substrate was wetted with the fluid successful assessment indicated that pipe grade resin system, maximising the pressure had been restored to original bond between the carbon steel and levels without any irregularities, the pipe Belzona SuperWrap II. Covering lengths system was set back into production. Due of 690mm, applicators used seven to the initial planning, combined with spirals of reinforcement around each the correct equipment and application defect, creating a tapered profile of management, there were no issues during 14mm at the densest section. Finally, this the project timeline, consistent with the was consolidated by tightly wrapping customer’s specified shutdown period. release film around the composite Primarily, all phases of the project wrap, which was later removed after were handled by one contractor, the curing process was complete, allowing for a consistent approach that allowing the repair to securely adhere. ensured the application was successfully Following the completion of the Belzona achieved within the allotted schedule.

SuperWrap II installation, a new solution Furthermore, this was significantly was implemented to place the pipes aided by the ease and speed in which into position, fit for purpose. Belzona Belzona’s composite wrap system 1311 (Ceramic R-Metal) was adapted could be applied. Since installation, by applicators to create irregular load the customer has indicated that the bearing shims between the pipeline and application is functioning well and is set support. Often used for metal repair and for periodic inspection, in line with the protection against the effects of erosion specified design life of 20 years. Between and corrosion, 2010 and 2015, a total of 48 Belzona these reinforced SuperWrap applications have been plates were commissioned by the customer, across installed to various offshore oil and gas platforms. transfer the load This figure has subsequently risen, after of the pipe, three repairs executed in August 2015 demonstrating were completed, serving as an indication the material’s of the product’s strength and the high compressive customer relationship developed. z strength.

Results

Belzona SuperWrap II tackles complex geometries

Including the grit blasting of defected areas, each Belzona SuperWrap II

For more information:

This article was written by Thomas Belli, marketing assistant at Belzona Polymerics. Visit: www.belzona.com

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METERS

Integrating leak detection and custody transfer for pipeline monitoring

Using Coriolis flowmeters not only provides accurate measurement data, but can also help detect leaks The importance of pipeline integrity is growing in the oil and gas industry.

New regions of oil and gas production and growing demand are driving the construction of new pipelines and reversals of existing pipelines. Older pipeline systems are still in operation and often running at capacity. 41% of US oil pipelines were built in the 1950s and 1960s. A report that was prepared for the Interstate Natural Gas Association of America in 2012 indicated that there are even pipelines that were installed prior to 1920 (nearly 100 years ago) that are still active.

Pipelines can be operated safely with a long lifetime as long as proper maintenance, operation, and inspection practices are employed. Valuable natural gas liquids (NGLs) with high Reid vapour pressure (RVP) are being transported at higher volumes than ever. This often results in the need to comply with regulatory requirements that were not applicable before. In order to comply with these requirements, there is a greater need than ever before for qualified personnel to operate, monitor, document, and maintain the pipeline and the ageing infrastructure.

Regulatory requirements aside, it is important to consider the huge impact of a leak, in terms of personnel safety, clean-up costs, civil penalties, loss of product and revenue for the shut-down of the pipeline, and the risk of damaging the environment. As an example, a California pipeline leak of 143,000 gallons of crude 18

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oil in 2015 will cost at least $250 million (€224m) in clean-up and other costs. It is estimated that clean-up of a typical pipeline spill will cost between $10,000 and $100,000, depending on whether the spill is on dry land or near water.

Detecting leaks Leak detection systems (LDS) are of paramount importance to give operators the tools they need to ensure pipeline integrity and have the confidence they need that even small leaks will be quickly detected. There are several types of LDS, internally or externally based, depending on the measured characteristics. Some examples of external methods are line patrol and hydrocarbon sensing via fibre optic, dielectric cables, etc. Even satellite surveillance is used in some cases.

In-line inspection (ILI) tools, such as smart pigs, can detect irregularities in the pipeline like corrosion, cracks, or deformations. Internal methods are based on the hydraulic characteristics of the product flowing inside the pipeline, namely pressure, temperature, density, viscosity, and flow rate. Examples of internally based systems are: • Mass/volume balance • Real time transient model (RTTM) • Acoustic pressure wave analysis

• Statistical method These systems have different characteristics in terms of reliability, sensitivity, accuracy and, of course, complexity and cost. More than one system can be applied for a higher level of security and back-up protection.

In addition to the LDS itself, other modules can be added such as: • Training simulators, to ensure operator competency and confidence • Performance analysers for sustainable performance • Schedulers for managing traffic RTTM represents one of the more sophisticated and widely used leak detection methods. It gives high confidence to the customer on the ability to detect very small leaks and their location. It uses physical laws like the conservation of mass (such as the balancing method), momentum, and energy. It compares measured data for a segment of pipeline with the predicted conditions from the model: • Calculated pressure-flow profile of the pipeline overlapped onto the actual data profile • An intersection of the profiles indicates a potential leak and provides the location The ability of RTTM to detect small leaks and their position (and to do it quickly) is heavily dependent on the accuracy

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

METERS

Flow rate is a fundamental measurement input for RTTM, so flowmeters have a very important role. It is no surprise that custody transfer meters can also offer the best performance for RTTM. The size of the minimum detectable leak, correspondent to the system sensitivity, is a function of the flowmeters’ accuracies and output resolutions – the higher the meter accuracy, the smaller is the leak that can be detected.

Another important meter characteristic is stability, especially in liquid pipelines that move different products. When product batches and/or flow rates are changed, it is important to avoid false alarms from the LDS. The meter must thus guarantee stability of the meter factor under changing process conditions. This is also important for minimising ongoing proving and calibration costs of the meters.

Emerson’s Micro Motion Coriolis meters

Scan Rate

The role of custody transfer meters

fulfil the mentioned B A requirements of the characteristics needed to /HDN 'HWHFWLRQ perform well in any LDS, 3HUIRUPDQFH &XUYHV in terms of high accuracy for all types of fluid, measurement stability, reduced maintenance, and calibration operations that result in lower operating costs.

0HWHULQJ $FFXUDF\ Moreover, for liquid pipelines, the density Time to Detect measurement gives the Diagram of the relationships between meter accuracy and detected oil and gas producer the leak size added benefit of precision interface detection, requires accurate and reliable mass enabling them to make improvements flow measurement technology to work to product cuts that reduce the amount properly. The best software in the world of slop that needs to be reprocessed. For cannot solve the problem of a poor and these reasons, Coriolis meters are widely unstable flow measurement device. z used by the most sophisticated LDS. While the LDS software is of paramount For more information: importance for efficient and effective This article was written by Rossella Mimmi, pipeline oil and gas industry manager, and leak detection, it is not the only element.

Marc Buttler, oil and gas industry marketing No matter how good the software is or manager for midstream at Emerson Process Management. Visit: www.emerson.com whose software is used, leak detection

Leak Size (% of design flow rate)

and stability of the flow, pressure, and temperature instrumentation.

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 19

Sizing for diaphragm actuated control valves

VALVES

Thorough consideration of application characteristics will help designers make more educated valve selection choices There are many options and several conditions that need to be considered when purchasing the right valve for a job. The more information from the field, the better the choice will be.

The ultimate goal is to have the best valve for the job required at the most economical price. While it is not rocket science to do this, there is some fundamental information that needs to be taken into account to ensure the proper valve is chosen.

Some key questions to consider are: • What is the purpose of the valve and what do we want the valve to accomplish?

• What are the required flow rates? Both minimum and maximum need to be considered.

• What type and size pipe will the valve be located on?

• Will the valve be used continuously, intermittent, or momentary?

• What are the operating pressures that the valve will be subjected to?

manually using the Cv method, using performance curves, or using the tables in a manufacturers’ catalogue. To measure the flow through an open valve, the following formula can be used: Q (gpm) = Cv x Square Root of pressure differential Cv = Q/Square Root of pressure differential Cv is the flow across a valve when there is a 1psi pressure differential across a fully open valve. This value can be determined by looking at the performance curves of the particular model of valve and following the straight line of the performance curve until it hits the 1psi intersection of the x axis. For any model and size of valve, the Cv of the valve is the y-axis at the 1psi intersection.

Figure1 provides an example of a performance curve.

Other considerations are the different valve options to ensure the valve has a long operational life. Choosing valves with special features may cost a little more at initial purchase, but will be more cost-effective in the long run due to longer life, easier maintenance, and fewer parts requiring replacement.

The initial cost of a valve versus its true cost over its lifetime can vary significantly if valve options are not considered carefully.

Sizing valves The ultimate goal is to choose the smallest valve that can do the required job, which in turn will minimise costs. Sizing is a very important aspect to get right when attempting to achieve this goal. To begin with, procurers need to determine the operating conditions that the control valve will be expected to endure, as well as the maximum and minimum flows that the valve will see. In many cases the person choosing the valve does not take into account the low flow requirement, which can be dramatically different from manufacturer to manufacturer. A valve working below its minimum flow requirement may hunt and fluctuate, causing pressure spikes downstream, which can lead to pipe bursts.

Valves require a pressure differential to work correctly.

A good rule of thumb is to have a 5psi pressure differential between the inlet and atmosphere if the valve bonnet is being vented to the air, or 10psi if the bonnet cover is connected to the downstream. This is why it is important to know the operation pressure in order to be sure the valve will work as required with the pressures available.

There are several ways to properly size a valve. It can be done 20

Figure 1. Performance curve for flat diaphragm valve

If the valve vents to downstream and differential pressure is low, then flow through the valve will be less than fully open. When the bonnet is at the same pressure as the downstream, there is no opening force from the diaphragm assembly. The weight of the inner valve and spring tends to close the valve. Flow starts when the differential is able to overcome the weight and spring. This increase in differential increases the opening force.

The valve is fully open at approximately 10psi differential. The drooping portion of the performance curve shows how flow increases as differential pressure increases from zero. When the droop hits the straight line of the curve, the valve is fully open. Not all valve manufacturers show the valve opening on their curves, but it is certainly a good feature to have.

Continuous, intermittent, or momentary flow When looking at the performance curve of Figure 1, each size of valve also has three letters located on the curve: C, I, and M. Any position to the left of the C allows the valve to be used FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

VALVES “continuously”, which means up to a maximum flow of 20ft/s.

Any position on the curve to the left of the I allows the valve to be used in a intermittent operation, or up to a maximum of 25ft/s. Finally, any position to the left of the M allows the valve to be used “momentarily”, up to maximum of 45ft/s.

Manufacturers have performance graphs for all models of valves. These differ depending on valve types, full port globe valves, reduced globe port valves, full port angle valves, and reduced port angle valves. In the following examples, graphs and charts from Singer Valve will be used for demonstration.

required. What size of valve should be specified?

The worst case scenario would be when the valve has the smallest pressure coming into the inlet of the valve, so the 70psi inlet pressure is chosen to size the valve.

Pressure differential = 70psi – 50psi = 20psi Flow required = 1000gpm

Sizing example: manual Cv method for a pressure reducing valve Requirements: To size a valve to handle 3500gpm maximum flow at an inlet pressure of 100psi and outlet pressure of 70psi. The process includes three steps: 1. Solving for Cv Pressure differential = 100psi – 70psi = 30psi Flow(Q) = 3500 gpm Solving for Cv = 3500 / √30 Cv = 639 2. Comparing Cv and flow frequency capabilities for full port (106) and reduce port (206) valves: Table 1. S106 full port valve bodies

Table 2. S206 reduced port valve bodies

Using this curve diagram we can run a few different scenarios.

With 1,000gpm at 20psi, by marking the spot on the graph it shows that any valve above that point will be the right size, so size = 6”. If a 4” valve size were to be used, we look at 1,000gpm and then drop down to the bottom to see that the pressure drop is 25psi, so while this choice would provide sufficient flow characteristics, it is not at the right pressure. This means more pressure will be lost through the valve than is need and at that flowrate it will only be able to provide 45psi (70-25). At this point the procurer will have to consider whether that slight variance in the downstream pressure requirement is acceptable.

Conclusion

3. Valve selection: Cv = 639, maximum continuous Flow = 3500gpm

In this example the 10” 206 body is the best selection, as it meets the Cv requirement and the application meets the continuous flow recommendation for this valve. While the 8” S106 body meets the Cv requirement, the continuous flow recommendation is below what is required for this application. If using the S106 full port body, the 10” size would be required as well. Full port valves cost more than a reduced port valve of the same size, and so using the 10” 206 meets all the requirements and is the more economical option.

Sizing example: using performance curves Requirements: A city main supplies water at varying pressures throughout the year, from 70psi to a high of 110psi. A large industrial user requires a water supply of 1,000gpm at 50psi, so a pressure reducing valve is

In order to size a valve correctly one must be sure to understand what the valve is required to do, what the system parameters are, and then use this information to pick the valve that will do a proper job while keeping the economic desires in mind.

The right answer is often to pick the smallest valve that can do the job properly. While in many instances making a valve larger than required is a safe choice, this is not always a good option, especially when sizing specialty valves such as surge anticipation valves, where oversizing can be very detrimental.

In any valve sizing exercise there is always an element of choice for the system designer. Is the flowrate given realistic?

Are the pressures given accurate and proven? As the person responsible for sizing (while graphs, charts, and even software calculators are necessary), having a clear understanding of the issues certainly makes for a more educated choice. z

For more information:

This article was written by Jody Malo, international sales manager at Singer Valve. Visit: www.singervalve.com

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 21

Supplying Filanovsky

VALVES

A UK company delivered valve solutions to one of the largest crude oil finds in decades

The Filanovskogo (Filanovsky) oil field, 50km offshore in the Northern Caspian Sea, was discovered in 2005. With reserves of 153.1 million tonnes of oil and 32.2 billion m3 of gas, the field is expected to reach maximum oil production at a level of 12 million tonnes by 2017 with maximum gas production expected to exceed 26 billion m3 by 2028.

The infrastructure at the Vladimir Filanovsky offshore field consists of a 15,200-tonne ice-resistant fixed platform (IRFP-1), a living quarters module platform accommodating 125 people and including a helipad, a 21,000-tonne central processing platform (CPP) to process and pipe the oil and gas ashore, and a risers block (RB) platform, all linked with connection bridges. Construction works include the laying of 330km of subsea and 350km of onshore pipeline.

6” class 300 and 12” class 150 ball valves full bore

For this major project, UK-based valve specialist Orseal won a prestigious contract to supply a range of valves – from 1/2” to 20”, manual and pneumatic, actuated and motor operated. Orseal supplied the valves in carbon steel to suit the specific temperature requirements of -30°C. All valves needed to conform to the Russian GOST certification standard.

The project included over 500 valves and the manual valve package included floating and trunnion ball, double offset butterfly, globe, and dual plate check valves.

What’s in the package?

20” class 150 trunnion mounted ball valve with electric actuator

22

The actuated packages comprise both electric and pneumatic actuator operated ball valves sized from 2” to 20”. Most of the valves were lagged for thermal insulation, and the design configuration was enhanced

with special stem and spindle extensions to ensure that the valves remain fully operable with the lagging in situ.

As the valves were manufactured outside of the UK, Orseal undertook full inspection on site, at the manufacturer’s base. Hydrotesting was carried out on both body and seat, and low pressure air testing was completed.

To meet the project specification requirements, Orseal supervised a range of further valve tests. Procedures carried out included 100% visual and dimensional checks, supply and fitting of the projectrelated tags, witness of the painting of the valves, and monitoring of the curing times. Due to a local monsoon, which caused severe humidity, the valve paint process “to strict technical specifications” was delayed several days to ensure the coating process was conducted correctly. Painting thickness was measured to ensure dimensional compliance, and full documentation packs were reviewed against project requirements. Orseal’s scope of supply included monitoring of the nondestructive testing as these valves are to be positioned within critical applications.

Due to the severe environmental temperatures that the valves would be subject to on site, Orseal arranged to have special low temperature impact testing of the raw materials.

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

VALVES Orseal’s consultancy on this project included the full supply chain – from the specification and supply of appropriate valves to the major logistical supply and support to final destination in Dubai.

Orseal packed the valves to suit sea freight standard requirements with case markings displayed as required. The scope of supply included freight forwarding with full shipment tracking direct to the skid fabricator in Dubai, which was successfully completed in a timely manner.

Orseal provides flow control solutions for all fluids and gases. The company’s products are supplied and in use worldwide in many varied applications from pneumatic control through to complex on- and offshore solutions.

They are supplied to navies throughout the world, as well as being used in chemical plants, fire-fighting equipment, natural and LPG gas applications, and both on and offshore applications. z

Internal inspection

This was tested independently at the Materials Testing Centre for Research Institute of Materials, at -30°C. All cast valves were 100% radiographed and dye penetrant tested to critical areas as per ANSI B16.34 – the results being checked and verified at the inspection stage. In addition, hardness tests were also performed with results recorded on the material certification. All related documentation was reviewed, approved, signed, and dated for acceptance.

Orseal specified and managed this comprehensive format of inspections, carried out at three off-site manufacturing locations worldwide and two sites within the UK. This enabled Orseal to ensure that all the products supplied to the client fully met the project specifications, both technically and commercially.

tests to all actuated valves, together with comprehensive checking of the piping and design layouts between the actuator and controls. Again, all related documentation was reviewed, approved, signed, and dated for acceptance.

For more information:

This article was written by Champak N. Fakira, contracts and sales director at Orseal. Visit: www.orseal.com

Actuated valves After completion of the site inspection, there were a number of ball valves which were required to be actuated.

These valves were automated at the actuator manufacturer’s premises. This stage involved assemblies comprising of the valve, an actuator, 2-off solenoid valves, an air filter regulator, and a switchbox with visual indication. Orseal carried out a number of visits to the manufacturer’s site and ensured that the full assemblies complied with the required standard and that there were no additional forces between the valve, coupling, and actuator. Orseal witness-inspected the final 100% function

10” class 300 ball valve

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 23

Through heat and ice

VALVES

Butterfly valves actuated through several means provided a solution to an operator based in an area with highly fluctuating weather conditions

It’s a fact! Electric and pneumatic actuators, positioners, and process controllers play a key role in modern process automation. They deliver reliable, hardworking, and truly effective solutions.

Take for example butterfly valves. Butterfly valves have expanded operators’ capabilities tremendously, providing one of the most effective solutions for process control. They are used in larger sizes in food, pharmaceutical, biotechnology, medical, water treatment, petrochemical, and oil and gas sectors.

They are generally a better choice for isolation above 4” due to their weight reduction when compared to other types of valve. This in turn makes them easier to handle and install. Lower torque means smaller actuators, resulting in further weight savings and reductions in cost. Butterfly valves can be offered in various body and liner options with sealing in resilient soft seat, double and triple offset in wafer, lugged, and double flanged pattern with PN and ANSI drilling.

Team these with electric or pneumatic rotary actuators and a range of options that include limit switches, solenoid valves, and positioners and you have a totally flexible solution for many process applications! The actuation of manual butterfly valves is still an integral part of modern process automation, as the following example demonstrates.

was control of dust emissions on-site.

The project had a number of elements that needed to be solved, not to mention the process application and location of the site. Untreated water from settling pools was being used, which was not suitable for conventional valves, such as ball valves or solenoid valves. When the water was moved, solids were mixed in, resulting in blockages and subsequent failure of the valves.

The location of the site was also a testing one. Hot and dry in the summer with a damp, freezing winter resulted in challenging conditions. The system needed to be able to handle 3 bar pressure and consists of 60 manual valves, 40 actuated valves, and 4” pipework.

A pneumatically actuated butterfly valve

The solution

actuator and the airline, unless substantial lagging or heat tracing was undertaken.

The answer was to install additional IP67 protected electrical economy actuated butterfly valves. These valves offer standard open and close electrical and optical indication, manual override, limit switches, and anti-condensation heaters. Perfect for cold, winter conditions! Solenoid valves that piloted the pneumatic actuators were housed in control panels with Burkert Type 5470 DIN rail mounted pilot 4/2-way valves supplied as part of the system.

Electric and pneumatically operated double acting actuated butterfly valves were offered for a number of reasons and in a variety of locations. Using air to power the valves is cheaper than electricity, but more importantly a supply of compressed air was already available on-site, as a compressor had been installed at the facility.

An additional problem that needed to be overcome was the remote location and extreme weather conditions components would be subjected to.

Pneumatic valves would not be able to be installed outside on the outlet discharge due to freezing of both the

In its element Another great example of the changing face of process automation has been

Burkert positioner and process controller

The problem A leading manufacturer of aggregate had a project that had not been budgeted for, but still needed to be implemented in order to comply with regulations and avoid potentially costly financial penalties. Namely, the issue 24

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

VALVES Burkert’s range of Element positioners and process controllers that have taken the design and operation of many automated processes, especially hygienic applications and those that benefit from a decentralised control structure, just that one step further.

Burkert continues to improve the functionality of its Type 869x positioners and controllers. Gary Hopkinson, technical director at Valves Online says: “At Valves Online we have seen Burkert’s Element range quickly become established as a control mechanism for Burkert’s own process range and third party process valves, especially within the food and beverage industry. They have become a leader in their field for this type of intelligent process control valve.”

Recent improvements to the range include ATEX and IECEx approvals for operation in zones 2/22 and 1/21, where potentially explosive atmospheres may exist, in addition to an extension to the ambient operating temperature range, down to -10°C. The latest diagnostic functions allow the status to be displayed using standardised symbols, according

Electrically actuated butterfly valve

to NAMUR recommendation (NE107) as well as the ability to output the diagnostic messages using binary signals.

LED lights provide an instant and more visible indication of valve status.

In terms of communication, Burkert’s Type 869x range has compatibility with AS-i, DeviceNet, and Profibus, allowing

controllers to be integrated into a selection of applications and process structures. Using this range of fieldbus protocols allows individual valves to be connected using just one or two cables to link back to a local controller or up a level to a factory-wide bus network.

“Burkert’s Element range has become an integral part of our solution for clients seeking modern process automation either as standalone products or as part of a complete system. It is definitely a hard act to beat,” says Hopkinson.

Valves Online is UK-based supplier of process valves, control solutions and systems. Its supplied products cover a variety of applications and are used by all industries including food processing, breweries, and water treatment as well as in process engineering and biomass technology.

The company employs specialist engineers who have comprehensive knowledge of its supplied products. z

For more information:

This article was written by the technical team at Valves Online. Visit: www.valvesonline.co.uk

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 25

Safety first VALVES

In liquefied natural gas facilities, whether they be on land or sea, process safety equipment should be the thing to consider The global liquefied natural gas (LNG) landscape has evolved dramatically over the last decade. Industry dynamics have been driven by new gas discoveries on the supply side, while shifting demographics and emerging economies have impacted demand. As a result, the number and size of new liquefaction facilities, both planned and currently under construction, have increased significantly. Although lower gas and oil prices have forced closer scrutiny of short-term capital investments, some industry experts anticipate an increase in demand of 65% by 20251, which will require more liquefaction capacity.

Geography is also key here.

Liquefaction plants are part of the delivery process catering to the growing demand for gas from energy-intensive economies, but their location also needs to be carefully considered. The feasibility to process gas at the best cost has seen the growing interest of floating LNG (FLNG) vessels over landbased facilities, which are often located in areas of environmental interest or

far away from existing infrastructure.

This new technology can present unique technical demands, while storing and handling LNG are challenging for plant engineers in relation to infrastructure. Cooled to and stored at -162°C, LNG requires specially designed and engineered equipment to perform safely under demanding conditions, which, combined with the substantial

Regardless of the type of LNG facility, reliable and high-performance safety integrated systems (SIS), control systems, and safety valves are designed to continually monitor the status of the processes. They react instantaneously to any mechanical, electrical, or operational failure that may lead to a critical process upset or overpressure event, resulting in the release of

energy potential and flammability of the gas, generate significant potential for hazardous events. These factors have led to an industry-wide focus on safety and standards.

flammable and toxic process media.

This safeguards plant personnel, plant assets, and the surrounding communities and environment from damage Valve solutions

The need for safety There are many aspects to plant safety.

Installations need to be robust and well-maintained not only to maximise uptime and process efficiency, but to also ensure safe and reliable operations.

While numerous safety devices are required for both land-based and offshore liquefaction, one of the most critical areas is valve design and application.

FLNG vessels are drawing increased attention over land-based facilities

26

Pilot operated pressure relief devices Mandatory by international code for the protection of pressure vessels and pipelines, pressure relief valves (PRVs) are the last line of defence when it comes to plant safety. Selection of the correct PRV type ensures that the valve can operate under extreme operating temperatures to provide optimum safety in the LNG process. It also minimises environmental impact from seat leakage. As the final device designed to prevent failure during overpressure conditions, PRVs must offer complete reliability that they will open at a predetermined set pressure, allow a specific capacity flow within the allowable overpressure limit, and close once normal conditions have been restored. The design of these valves must withstand corrosive process media, enable critical protection against overpressure, and avoid the risk of explosion.

PRV manufacturing has evolved over the years to adapt to changing requirements of LNG applications.

Considerations such as flow capacity, footprint, durability, and opening and closing performance must be taken into account, all the while being able to tolerate increasing operational and output demands. Pilot operated PRVs on LNG carriers and land-based LNG

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

VALVES systems, the complete lifecycle should be considered from front end engineering design (FEED) through to maintenance, commissioning, and service. Additional optimisation can be achieved through a simplified control scheme, which reduces the need for human dependency. It can be utilised to extend proof test intervals and, when combined with effective diagnostics, PST allows customers to move from reactive to predictive maintenance. Such optimisation strategies are essential for developing a system that not only meets the requirements of high integrity safety systems, but which also allows for the responsible management of CAPEX and OPEX.

Safety is integral for LNG facilities

storage tanks are vital to process safety due to their compliance with high seat tightness standards (zero leakage as per API RP 527). This improves further as the operating pressure reaches its set pressure point. PRVs’ full opening capability and the large surface area of the pilot diaphragm ensure instantaneous and accurate pressure relief. Further advantages such as high flow capacity, optimised flow/size ratio, and minimised maintenance requirements deliver additional key benefits to engineers.

Safety instrumented systems Designed to protect personnel, equipment, and the environment by mitigating the likelihood and severity of potential risks, safety instrumented systems (SIS) also constitute a critical factor in LNG applications. Comprising sensors, a logic solver, and emergency shutdown valves (ESDVs), the SIS serves to take the process to a safe state when predetermined safety configurations are violated.

Emergency shutdown (ESD) systems and high integrity pressure protection systems (HIPPS) are two subsystems of SIS, with the former providing safe and reliable shutdown of a process and HIPPS designed to prevent over-pressurisation.

Each consists of an automated ESDV package, known as the final control element due to its role as the “last line of defence” in the event of an emergency situation. This component is required to fall close or open in response to potentially hazardous process conditions and is in direct contact with the process media, so it is considered the weakest link in the

system. It also contributes more than 50% of the calculated risk reduction factor (RRF). Selection and design of the ESDV, therefore, require special attention to ensure that it is suited to the operational requirements of the ESD system.

A critical factor to take into consideration is compliance with safety standards. Each component of the SIS must meet the safety integrity level (SIL) required to satisfy plant safety requirement specifications. Operating companies can substantially increase their SIL loop rating if they adopt a rigorous testing and maintenance programme on their safety valves. By combining partial stroke testing (PST) of valves with more frequent inspection, companies can achieve a higher SIL rating without incurring the costs associated with additional hardware.

As an important step to ensure that an ESDV will perform as intended when needed, PST has long been used to deliver numerous advantages in addition to an improved SIL rating. These include access to predictive maintenance data, reduced need for valve bypasses, extension of full stroke testing intervals, and availability of valves to respond to process demands during test periods.

The latest developments enable PST to be carried out with limited human intervention in a semi-automatic way through the use of smart microprocessorbased devices. This advanced monitoring and control technology for ESDVs has made PST more effective and easier to implement, helping to achieve improved integrity and safety of processes.

When designing HIPPS and ESD

Triple offset technology Triple offset valves (TOVs) also play a key role in LNG applications and are integral to the safe operation of critical functions. Effective design and superior performance characteristics enable the valve to handle the demands of the liquefaction process. For example, the valves’ non-rubbing metal-to-metal seating design provides zero leakage shut-off performance and complete fire safety. This enhances reliability and can reduce overall equipment footprint and cost of ownership.

Different types of TOVs offer additional benefits. Top entry TOVs, for example, are designed to allow inline maintenance, enabling users to access individual valve parts in total safety.

Certification considerations FLNG comprises additional risks, requiring further consideration with regard to safety and standards. Understanding the risks and how best to mitigate them will help prevent the potential for disasters and provide guidance on how to ensure optimum safety on a vessel.

Certification bodies play a key role here, validating that critical equipment meets the required safety standards. With a focus on technical assessment advisory and risk management, Det Norske Veritas (DNV), is an example of an international classification and certification association that may impose overarching requirements for certain valves in FLNG. Manufacturers must submit their valves for a formal design review, which comprises a design verification report, survey during manufacture, and a data book review. Following this they have two options: type approval or a product

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 27

VALVES accountability, and robust, high quality products with proven performance in LNG applications. Whether a single TOV, a range of PRVs, or a fully integrated SIS package, Pentair’s portfolio of LNG solutions provides a high level of product integrity in compliance with rigorous safety standards.

Summary An industry where safety is a must, LNG operations – whether land-based or offshore – cannot be considered lightly. While plant operators demand efficiency, durability, and minimised cost and maintenance from their process equipment, a key focus is placed on protecting people and assets, and the avoidance of operational downtime.

Manufacturers of critical components must therefore keep safety in mind as they craft solutions for this challenging Pentair ESDV package

certification, the latter of which is hull, project, or application specific. Valve types covered can include PRV, ESDV, cryogenic, and hull- and boiler-related valves. This rigorous process is performed to ensure that the components fulfil their specific requirements, helping to guide the development of the design phase and ensure maximum safety.

Partnering with an OEM Ensuring that plants are safe and equipment complies with SIL requirements

and other standards is imperative.

Specification and installation of valves, actuators, and controls can be made more efficient by working with one manufacturer who provides safety elements and solutions designed to withstand the demanding conditions of the liquefaction process. Pentair Valves & Controls acts as one single point of contact from assembly through to aftermarket support to help operators mitigate risks and optimise their value chain. As an OEM, the company offers a complete package warranty, sole source

environment. Optimised valve technology created in line with industry evolution and tailored to specific applications of the LNG process can meet the needs of plant designers and operators. z

For more information:

This article was written by Shawn Statham, APM actuated safety systems, Pentair Valves & Controls. Visit: www.pentair.com

References:

1) BP Statistical Review, Energy Insights’ Global Gas Model & Global Energy Perspective Model, Jun 15

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FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

Long live the globe VALVES

Extending the service life of globe valves through innovative coating application Globe valves, which are used for regulating flow in pipelines, consist of a movable disk-type element and a stationary ring seat in a generally spherical body. They are named for their body shape with the two halves of the body separated by an internal baffle.

As cast components, globe valves can be produced in virtually any shape required. In addition, inlets and outlets are designed with a constant cross-sectional area that allows the flow of material to remain uniform. In effect, this means that inlets can be round to match the pipes delivering the flow of material, but then changed to an elliptical shape of the same cross sectional area to maintain the compact dimensions of the valves in order to optimise flow within the valve.

Globe valves are linear motion valves and are commonly used as on/off valves and as throttling systems for both liquid and gas systems. The gradual change in spacing between the disk and seat ring gives the globe valve good throttling ability, as long as the pressure and temperature limits are not exceeded and the process does not require special materials to combat corrosion.

However, it is generally acknowledged that globe valves contain inherent cavities that can easily promote contamination and allow slurry material to become entrapped in the body of the valve, disabling its operation. This often prevents globe valves being specified for high purity or slurry systems.

Solving the challenge As globe valves are castings and can therefore be made to any shape the customer wants, designers generally try to keep the inlets and outlets at a constant cross-sectional area. As mentioned earlier, this means valve inlets are circular to match incoming pipework, and then change to an elliptical section of the same

cross-sectional area, which keeps the valve around a fixed component, accurately dimensions compact. When a globe valve positioning it to apply the overlay to is cast, the internal shapes are generally large and/or complex components created naturally. However, service using MIG, TIG, Hot Wire, Twin Wire and repair can cause future problems, TIG, and Twin-Head, enabling four as applying anti-corrosion coatings wires to be clad simultaneously. for long term protection can be very Having worked with the specialist difficult due to the complicated shapes machines for five years, Arc Energy has created by a valve’s internal geometry. gained valuable experience of their Whilst it can be a challenge to strengths, one of which is versatility. apply anti-corrosion coatings to the This has enabled Arc Energy’s welding internal surfaces of castings, the weld engineering team to develop a technique overlay cladding specialist Arc Energy that enables the company to improve Resources has successfully applied its access to the internal surfaces and the specialised coatings to globe valves coverage and consistency of the coatings for companies such as Masilinia Dresser that can be applied to difficult internal and Severn Glocon. The company also and external surfaces. Significantly, this has, more recently, developed special technique has proven valuable in the techniques with the cooperation of application of coatings for globe valves. globe valve manufacturers to apply “To achieve the improvements, we the coatings more cost-effectively. now work with valve manufacturers to These techniques are also dramatically develop certain aspects at the design improving the protection performance stage, which enable us to apply coatings and the efficiency of the valves. more efficiently and cost-effectively. The Commenting for Arc Energy, managing developers then analyse our suggestions director Alan Robinson says: “We have been applying corrosion resistant coatings to equipment in the oil and gas industry throughout the world and have been aware of the difficulties with globe valves for some time.

However, following an investment in two specialist welding machines, which we bought specifically to handle the difficulties mentioned, we have already coated globe valves from 12 to 24 inches. Since installation, these machines have played an important part in the initial planning for globe valve contracts and have applied anticorrosive coatings to the first batch of globe valves in an important current contract.“ The automated machines manipulate Welding a globe valve the welding torch

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 29

VALVES

A 24” globe valve prepared for Severn Glocon

to confirm the functionality of the globe valves is still intact,” Robinson says.

The Middle East story In terms of the design changes needed to enable the coating operation to succeed, Arc Energy briefed one customer’s engineering teams on the specific design changes involved, and followed that with further discussions and demonstrations at its Eastington, UK, facilities covering every aspect of the project. Whilst also showing that the changes would not reduce the flow of the globe valves, the engineers who design, produce, and sell the actual products were impressed that lasting material flow rates could be accurately maintained.

Having shown the customer the potential of the new approach, they still had to be convinced that the flow would achieve the performance requirements they expected. The client is based in the Middle East and its senior engineer – the man in charge of the whole project – needed convincing that the cladding could be completed successfully before he gave the go-ahead. So, he flew over to the UK for just one day, had a four-hour meeting, and flew back fully convinced.

Prior to his visit, Arc Energy had already carried out its own design check, so the company was able to show the senior engineer details of the changes planned for the valves and what was required.

Following the meeting, Arc Energy prepared CAD drawings and sent them on for approval. The client ran computer-based tests to successfully confirm the flow figures 30

based on the engineering team’s drawings.

The globe valves are intended for an island that is dedicated to an extraction system for oil drawn from a particular area of the Mediterranean.

All the oil coming off this island will be delivered through these valves.

“The business approach was actually quite intriguing. The client spoke to a major Kuwait-based cladding company, who recommended us. We received emails saying they had a number of globe valves they were having real trouble with, and asking if we could help them. This was quite interesting because it confirmed that there are companies having problems with globe valves and that it is recognised that we are one of few companies in the world capable of solving the problem,” Robinson says.

For operations in the Middle East, some customers may cast valves in Inconel 625, but for globe valves, the percentage cast in steel compared to Inconel 625 depends on factors such as the type of oil they will be pumping, where the globe valves are in the delivery chain, where the globe valve fits into the process flow, and where it is located in the delivery chain. Customers also need to assess the corrosive nature of the oil itself to determine whether, for example, it may need to be chemically adjusted to make it less corrosive.

The globe valves that Arc Energy is coating for the current Middle East contract are located “at source” on the island where the oil is extracted and where it is at its most corrosive, which means chemical pre-treatment is not practical. The location is a potentially huge development planned over the next few years, and Robinson hopes there will be long-term opportunities for the company’s globe valve coating operations.

“We think there may be up to 20 projects planned – one each year – so we are hopeful that the success of the first twelve globe valves will convince the client to consider us for future projects. With the exception of smaller 8” and 12” globe valves, all those for this particular project are steel cast and internally clad.”

Getting to every nook and cranny Previous experience also helped Arc Energy to convince the current customer to accept the welding proposal, including the cladding of highly specialised globe valves for Severn Glocon. Severn Glocon is a manufacturer of control and choke valves for specialist markets, such as oil and gas, liquefied natural gas, and power.

Its control valves were destined for the subsea Manifa field development in Saudi Arabia, which has the potential to produce 900,000 barrels of heavy crude oil a day.

Weld overlay cladding has enabled Severn Glocon to overcome the prohibitive cost associated with the casting of corrosion resistant alloy valves, which is the conventional method of protecting them from sour, corrosive gases such as hydrogen sulphide. The Arc Energy contract involved cladding all internal wetted areas of 24 globe valves ranging from 6” to 24” diameters with a 4mm thick metallically bonded layer of a corrosion resistant nickel-based alloy. The largest of the valves, four 24” units weighing 12 tonnes each, were also among the first to be clad using the two specialist welding machines.

Commenting on the contract, Robinson says the vast weight and size of the 24” valves would have presented a serious handling challenge for conventional welding workstations, where the overlay cladding is deposited by moving components around a fixed welding torch. Explaining the significance of the automated specialist machines, he says they are designed to manipulate the welding head around the fixed globe valve, positioning the head to apply the overlay accurately to the complex cast geometries. He adds that Arc Energy worked with Severn Glocon engineers to develop a geometry that was suitable for cladding, and the new machines certainly justified the investment by effectively applying the essential protective coating in areas that would usually be considered difficult to clad.

Arc Energy’s project management of this contract involved the production of bespoke tooling to handle the various sizes of valves and to meet the varied and difficult access requirements. All 24 valves were produced to a strict delivery schedule, with Arc Energy effectively using its resources to meet cladding deadlines.

The company also undertook heat treatment after the cladding process, as well as pre- and post-weld NDT testing.

Summing up, Severn Glocon sales director Ron Baker comments: “The close working relationship with Arc Energy helped ensure that our high-integrity valves met even the most demanding needs of our customers, whilst still being cost-effective.” z

For more information:

This article was written by Dennis Cantillion for Arc Energy Resources.

Visit: www.arcenergy.co.uk

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

It’s the little differences

Using alternative peristaltic pump designs can bring operators significant cost savings when pumping slurries and corrosive substances

PUMPS Mining companies and many other industries are learning that pumping high solid content slurries provide enormous savings. Often when moving high solid content slurries, the pump of choice may be a centrifugal pump. They can pump at 30-35% solids quite comfortably, but when solids content increases to 50-60%, centrifugal wear part consumption typically becomes significantly more expensive and leads to much greater pump downtime.

However, if slurry can be pumped at 50-80% solids content or greater, a peristaltic pump can be a more suitable choice of equipment. There are excellent peristaltic pumps that can pump this thickened slurry with great savings to the user. These savings are often not realised by the customer. Some examples of the savings are: • Less make-up water is required to pump 80% solid slurries • Less costly to clean process water after slurry is pumped • Chemical consumption for water treatment is reduced • If the user consumes only 20% make-up water with a peristaltic versus 65% in the case of centrifugal pump, then all downstream equipment can be much smaller and less costly • Lower energy consumption due to less overall tonnage pumped • Global pressure to be greener and cleaner- if the user consumes less water, power, and chemicals, has smaller infrastructure and less residual water treatment, then they are greener and cleaner Why peristaltic?

Figure 1: Typical thickener underflow arrangement utilising peristaltic pump

When dealing with high solids content slurries or extremely corrosive chemicals, the peristaltic pump is often a great choice since the rubber hose is the only component in contact with the slurry or chemical. Peristaltic pumps have rubber hoses that are ideal for extremely abrasive chemicals, and they can also utilise hose materials such as EPDM for corrosive chemicals or nitrile hoses that are ideal for animal fats or oils. With peristaltic pumps, the hose is typically the only wear part and can be changed quickly and in place, meaning the pump does not need to be removed to a workshop. Changing the hose in a 50mm diameter pump and smaller may only take 30 minutes, and even in 65mm diameter pumps and larger the maintenance time is still typically less than two hours.

A particular advantage that peristaltic pump have in corrosive chemical applications is that the hose is the only component that needs to be chemically resistant, rather than the entire pump housing like in many pump designs. For this reason the peristaltic pump may be both much more economical and more reliable when working with corrosive chemicals.

An alternative design

Figure 2: Flowrox 80mm rolling peristaltic pump utilised in silver mining operation in thickener underflow

A new design for peristaltic pumps emerged approximately 12 years ago incorporating a rolling design. Since the 1930s, most peristaltic pumps had previously operated by utilising two metal shoes to compress the rubber hose, based on a fixed rotation point in the centre of the pump head. Figure 3 illustrates the operational principle of a shoe design peristaltic pump.

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 31

PUMPS

Figure 3: Shoe design peristaltic pump

The disadvantages of this older design include: • Shoes rub against the hose, generating heat and wearing down the rubber hose • Due to heat, large amounts of glycerine are required inside the pump housing to dissipate the heat build-up • Pumps cannot run at high RPM because of the high heat generation and hose degradation • Pumps need to be one or two sizes larger than rolling design peristaltic pumps to produce the same flow • Higher energy consumption than with rolling designs • Glycerine consumption is expensive – if the hose needs to be changed four times a year for a 65mm pump, approximately 20 gallons of glycerine at a cost greater than $2,465 (€2,133) annually • Hose life in shoe design pumps is often only a fraction of single roller design peristaltic pumps Single roller peristaltic pumps use a cam shaft and a large metal roller that rolls over the rubber hose. The efficiency of this design is much greater than that in shoe or multiple roller peristaltic pumps. To offer a simple analogy, one could ask how long your tyres will last if the emergency brake is on. If they are allowed to roll freely down the road, then the tyre life will be far better than if they are skidding on the road. The effect of a shoe design pump on the rubber hose is a skidding action. In fact, if the RPMs are too high on shoe design pumps, they need to run for two hours and cool for two hours so they do not destroy the hoses and damage the pump bearings.

The advantages of the single roller design include: 32

• Hose life typically exceeds shoe design pumps by three to five times • Energy consumption is often 1/3 less • One hose compression per revolution results in greatest flow per compression of any peristaltic pump • Fraction of glycerine utilised compared to shoe designs • No heat generation even when operating at top RPM • Smaller diameter pump at much higher flow rate • Patented hose change compression setting • In-line piping configuration • Patented hose connection – hose cannot leak into pump housing

• Heavy duty construction (not thin plate welded steel as found in many designs) • Hinged door • Access window for hose compression system and visual inspection.

The Ohio case Understanding the advantages and financial implications of this new peristaltic pumping technology is critical for why operators might consider a single roller design over shoe designs. In order to best describe the financial implications, it is best to rely on a real user’s experience with both designs. A power plant in Hamilton, Ohio, US, had 100mm shoe

LPP-T Economics Update

Basic parameters in example process Reguired flow, gpm Use hour/a Utilisation rate, % Use hours@ min ut.rate,h Hose life, revolutions Speed, rpm Revolutions/hour Power consumption, kW/h Total down time/ hose Glycerine need/hose, gallons Maintenance time/hose brake Revolutions/a Number of spare hoses/a Maintenance time/a Utilisation rate Operating costs Lubricant Hoses Electricity Maintenance Total Difference to LPP, $

Difference to LPP-T %

30 8,322 99% 8239 LPP-T2.5" 2,721,600 21

lubricant, gallon Electricity, kWh Hose, psc work hour

29/07/2008 Unit price, conventional 4" $96.00 $0.06 $2,300.00 $43.75 Competitor 4" 518,400 6

1,260 7.4 15

360 12 30

0.75 2

15.8 4

10,485,720 4.0 60 99.3 %

2,995,920 6.0 180 97.8 %

$348.00 $4,800.00 $3,571.80 $350.00

$9,100.80 $13,800.00 $5,792.11 $525.00

$9,069.80 $0.00

$29,217.91 $20,148.11

0%

69%

Unit price, LPP-T2.5"

$1,200.00

The LPP-T2.5” has 69% less operating cost and the savings is enough to buy FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 another LPP-T2.5 pump in one year

Figure 4: Flowrox rolling design pumps compared to shoe design pumps at Hamilton, Ohio power plant pumping lime slurry

PUMPS of Hamilton was so pleased with the early result that they purchased their second Flowrox pump in June of 2008.

Conclusion

Figure 5: Flowrox 65 mm rolling design pumping lime slurry at Hamilton, Ohio, US

peristaltic pumps installed and was experiencing frequent hose changes and high maintenance costs. The power plant contacted Flowrox in late 2007 to discuss whether Flowrox peristaltic pumps could help improve the situation.

In February 2008, Flowrox delivered the first 65mm rolling design peristaltic pump to this customer. Because Flowrox pumps do not generate heat, the pumps can run faster and produce more flow out of a smaller diameter pump. This is why the Flowrox pumps were 65mm, whereas the shoe design pumps were 100mm. The Flowrox pumps operated

at a nearly four times higher RPM than the shoe designs and provided more than five times longer hose life than the shoe pumps. Also, the Flowrox pumps’ glycerine consumption is only a fraction of that of the shoe pumps, which also adds to the savings they achieved.

As depicted in Figure 4, the operational savings per year of the Flowrox pumps compared to the shoe pumps is roughly $20,148. This amount of savings is nearly enough that a customer utilising shoe design pumps could purchase a Flowrox rolling design pump every year with the savings they would achieve. The City

With many pump technologies, there are alternative designs that have modest technical differences, which still produce modest advantages or disadvantages for the user. In most cases, the cost of selecting the wrong design does not have significant financial implications.

Flowrox completely redesigned peristaltic pumps to produce significant savings over competing peristaltic pump designs.

The customer illustrated above purchased 100mm pumps for approximately $40,000 each. They operated those pumps at only 6rpm and were spending $29,000 annually on spare parts. The customer then installed Flowrox 65mm pumps at a cost of less than $30,000 each and then operated those pumps at nearly four times the speed compared to the 100mm pumps, producing results which netted them $20,000 in maintenance savings per years. Those users unhappy with current peristaltic pump designs or centrifugal designs might consider a single rolling design to improve process performance and reduce operating costs. z

For more information:

This article was written by Terhi Tella, marketing manager at Flowrox. Visit: www.flowrox.com

OPTIMIZE SLURRY TRANSFER

WITH HEAVY DUTY HOSE PUMPS • One compression per revolution for better performance

• Less energy used

• 2-5 times longer hose life

• Lower operating costs

• 75% less glycerin consumption compared to a conventional model

• Smaller pump size

www.flowrox.com FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 33

Centrifugal pumps in a nutshell PUMPS

Nutshell filters are used to separate oil from water, but without a properly engineered pump the process will not be optimal One of the challenges faced by the offshore oil and gas industry is cleaning water contaminated with oil produced by the drilling operations so that it can be disposed of in accordance with environmental regulations. This is achieved on a platform or a floating production, storage, and offloading (FPSO) vessel using a separation package. The final cleaning phase in these packages, just before the water is returned to the sea or re-injected into the well, can use nutshell filters to capture any last remaining oil.

For nutshell filters to work efficiently, it is crucial that the mixing of oil and water must be minimised, preventing restructuring and emulsification during the transfer of the fluid through the separation system. Amarinth, a UK-based pump manufacturer, has worked closely with a number of separator package providers, including Larsen & Toubro, Axsia Serk Baker, and most recently AI Energy Solutions, designing centrifugal pumps that exhibit low shear properties to minimise emulsification of the produced water being presented to the nutshell filters.

Oil is trapped by the nutshells During the extraction of oil and gas, quantities of water are also produced during the process. This water is contaminated with oil, which must be removed before the water is returned to the sea. A water treatment plant on the platform removes the oil from the water and the final stage of this process uses nutshell filters, which are very effective at removing the suspended oil from the water.

Oily water is introduced into the vessel and distributed to ensure even flow throughout the vessel. As the water flows through the vessel, the nutshell media, which usually consists of walnut or pecan shells, absorbs the oil allowing cleaned 34

water to exit the vessel. Nutshell filters typically clean oil to less than 5mg/l, easily exceeding, for example, the European OSPAR regulations of 30mg/l oil concentration for produced water that is to be returned to the sea. Over time, the oil accumulates on the media and so, to regenerate the filter media, a backflow of produced water is established and the nutshell media is agitated, releasing the filtered oil, which is pumped safely away.

The effects of shear Generally speaking, centrifugal pumps shear liquids and the higher the speed of the pump, the more shearing will occur.

When pumping produced water into nutshell filters, the emulsification of the oil and water produced by this shearing would render the nutshell filters ineffective.

Shearing occurs along a boundary layer when the velocity of the fluid is changed, creating a velocity gradient across the fluid. This causes shear stress between the slower and faster moving flows in the liquid. In a centrifugal pump, the shearing effect is highest at the impeller and it is the resulting turbulence in a fluid of oil suspended in water, which causes the oil and water to emulsify.

Traditionally, low speed progressive cavity (PC) pumps have been used in low shear applications as they emulsify the

Modelling shear energy

oil and water much less than centrifugal pumps. However, as operators pump more oil, the amount of produced water increases too. To handle larger volumes of fluids, PC pumps have to increase in length to perhaps 3 or 4m, and so there is a finite limit to their workable capacity, which is comparatively small.

On an offshore platform or FPSO there is simply not enough space available for the size of PC pumps that would be required to handle the larger volumes of produced water that need processing.

Visualising the flow The oil and gas industry has therefore been at the forefront of the need for compact, highly-efficient pumps for separation systems that will not shear the produced water. Unfortunately, there is no international standard or definition defining “low shear�. The end-user specification for a pump will usually only include, for example, the flow rate and an estimation of the parts per million of oil in the water, and it is down to the manufacturer to design a pump that exhibits the necessary characteristics to perform the required duty.

The challenge of using centrifugal pumps for nutshell filters is that to minimise the shearing of the fluid and prevent the emulsification of the oil and water, it is generally accepted that the pump must be run at less than 1800rpm. Additionally, limiting the pressure the pump generates during selection and ensuring the pump efficiency is greater than 75%, all contribute to the fluid flow becoming less disrupted as it passes through the pump and through the impeller vanes.

However, running the pump too slowly can increase internal recirculation and result in cavitation, thereby not only causing the unwanted emulsification of the oil and water as the fluid exits but also

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

PUMPS the preferred operating range – often pumps in the allowable operating range will work equally well • Minimal shear at the impeller surface can be achieved through an enhanced surface finish of the impeller Using this knowledge, combined with computer-aided engineering tools and vane creation software, the engineers were then able to design new impellers and vanes and optimise the geometry of the water passages through the impeller to minimise shear. Stress analysis was also carried out on the new impeller and vanes to ensure that the design was still capable of handling the dynamic loads and mechanical stresses.

High volume, low shear centrifugal pump Amarinth has now supplied its API 610 high volume, low shear centrifugal pumps to separation package providers

Amarinth’s custom-designed centrifugal pump impellers

reducing the pump’s life in the long term.

In response to this, Amarinth approached the use of centrifugal pumps in low shear applications afresh.

Using the latest in computational fluid dynamic (CFD) modelling, Amarinth’s hydraulic design engineers investigated how to reduce the shearing action of impellers in centrifugal pumps at higher flow rates. Using CFD, they were able to visualise the fluid flow through the pump volute and impeller to produce a design that could maintain efficiency and reduce shearing. Experimentation determined that the key ratios to reduce the shearing action on the fluid are the inlet and outlet areas and matching the outlet area to the volute throat area.

Using these techniques, Amarinth’s

engineers deduced that: • Turbulence is significantly reduced through controlled changes in fluid velocity and smooth changes in direction • Optimising the vane tip radius at the impeller inlet can create fluid stagnation at the blade tip, which promotes streamline non-turbulent flow into the impeller channels • Turbulence and shear can be further reduced by matching the impeller vane profile to the casing volute and cutwater design minimises recirculation and exit wake from the vane trailing edge • Minimal disruption (eliminating cavitation) of the pumped liquid can be achieved by selecting pumps in

for use on platforms and FPSOs around the world. Manufactured in a variety of materials, usually super-duplex, the low shear pumps can be provided with shrouded or open impellers. The open impeller design, used when the pumped fluid contains high concentrations of solids, creates further demands on the design engineers than a shrouded impeller as shearing can happen more readily on the open impeller vanes.

To minimise the footprint and fit within the confines of the platform or FPSO, Amarinth has also designed the pumps knowing that there will be a need to provide bespoke solutions, including close coupled pumps with horizontal and vertical mounting options and seal support systems, all of which the company can now deliver on the short lead-times often demanded by the industry. Stateof-the-art software continues to assist the Amarinth hydraulic design team in modelling fluid behaviour in fine detail and predict with increasingly high degrees of accuracy how mixed fluids such as oil and water will flow through impellers and pumps. This knowledge enables engineers to design more cost-effective solutions to meet the demands of the oil and gas industry, including the use of centrifugal pumps in new applications. z

For more information:

This article was written by Andrew Foreman, head of technical engineering at Amarinth. Visit: www.amarinth.com

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 35

PUMPS

Conveying wave technology

Bridging the gap between peristaltic and diaphragm pumps Peristaltic pumps are used for a broad range of fluid handling applications. They are simple, low-cost, and flexible. As soon as requirements are more challenging, such as when media compatibility or runtime become important, diaphragm pumps are often the system designer´s primary choice. With this type of pump, the parts in contact with media in the streamed area are available in a broader range of materials.

Furthermore, the moving part – the diaphragm – is stressed less and in an optimised way compared to a tube in a peristaltic pump. The conveying wave technology (CWT) combines the advantages of peristaltic and diaphragm pumps in a smart way and eliminates at the same time the disadvantages.

pump´s pump chamber by pushing the diaphragm down.

The design of the cross-section allows the usage of a broad range of materials in the diaphragm. This includes relatively stiff materials like peek-foil or even spring steel. But, of course, many other common diaphragm materials are also an option.

It is important to remember that elastomers are not required.

It meters, too The medium in a CWT pump is not only transported but is also precisely metered. Due to the properties of relatively stiff diaphragm material, the precision of the diaphragm´s movement is very high and stable over the lifetime of the pump chamber. Dosing accuracies below 1% even at volume flows as low as a couple of millilitres per hour are possible.

Due to a very laminar flow, the CWT pumps are very smooth and therefore highly interesting for applications in which the medium needs gentle treatment. Disposable usage of the pump chambers at relatively low cost, often required in these kind of applications, is possible as well.

Developer of the technology is Qonqave, based in Stuttgart, Germany. Qonqave develops CWT products to help its customers develop new markets or to defend existing markets with new innovative fluid handling solutions. Therefore, Qonqave does not necessarily plan to produce its own products but rather plans to exclusively license the technology for different market segments.

Actual CWT solutions are for medical devices, lab automation, food and beverage, automotive, white goods, and more. Pump designs are highly customised following the specific requirements for each application. Qonqave pumps are available in the linear, planar, or radial CWT design. Depending on the need, the design provides high scalability. It can be used for a broad range of viscosities. z

Move like a fish Inspired by the swimming or meandering motion of fish, a smooth, wavelike peristaltic movement is used to convey fluids, gases, mixed forms, and pastry fluids. This happens in a cavity between a flexible diaphragm and a stiff lock side.

Connected, these two parts form the CWT pump chamber.

The pump chamber of a CWT pump fulfils the same basic function as the tube of a peristaltic pump, meaning that it is the streamed part. The activation points are comparable with rolls of a peristaltic pump on the functional layer. At these points, a tight fit between the diaphragm and the counter-side is formed.

By moving the activation points into the designated direction a volume flow is achieved. No moving parts in the fluid are required.

Stiff counter side Flexible diaphragm Moving activation points

Figure 1: Longitudinal section of linear pump chamber (functional sketch)

For more information: This article was written by Lars Redschlag, manager of So far, the basic principle seems to be similar to a peristaltic business development, and Alois Krutzenbichler, director of pump. The added value of CWT becomes evident as soon as we innovation at Qonqave. Visit: www.qonqave.com have a look at the patented cross-section. A geometric setup allows a tight fit between the diaphragm and the counter-side at the activation points without elongation or compression of Confidential - Vertraulich the material. In comparison to squeezing a tube until it closes, there is no extra force needed to close the conveying wave Seite

1

counter side (blue), length s Opened pump chamber (cross section)

+ diaphragm (green), same length s

Closed pump chamber (cross section)

= Tight fit between diaphragm and counterside

Figure 2: Cross-section of the pump chamber (functional, simplified sketch)

36

Figure 3: Eccentric concept with bidirectional activation of the diaphragm

Figure 4: Radial pump chamber with rotating balls as activation points

Figure 5: Worm drive concept with multiple pump chambers on one activation

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

PUMPS

A historic partnership A French-German ceramics company enhances its 267year history with the assistance of innovative AODD pumps

In 1748, Francois Boch and his three sons decided to open a pottery company in the small French village of Audun le Tiche, near the country’s northeastern border. To illustrate just how long ago that really was, Boch’s company celebrated its 40th anniversary the year before the French Revolution began in 1789. In other words, the odds of a company that was created 267 years ago still being in business today are astronomically small.

But that little pottery manufacturer beat those odds and still survives and thrives today – though not without some significant changes. For instance, in 1801 the company headquarters were relocated to Mettlach, Germany, where they remain today, and, most significantly,

Since 1748, Villeroy & Boch has been one of the world’s leading manufacturers of bathware

in 1836 Francois Boch’s company merged with Nicolas Villeroy’s competitive outfit and became known as Villeroy & Boch.

Today, the Villeroy & Boch name is known worldwide and its brand of ceramics, housewares, tableware, and bathware is available in 125 countries, with global sales exceeding €766 million in 2014. Helping Villeroy & Boch meet the global demand for its products is a network of 14 production

Gerrit Klaassen, right, of Holland Air Pumps recommends Wilden pumps for various continuous-duty pumping operations to Mario Nieman, left, and Henk Kampijon of Villeroy & Boch

facilities located strategically in Europe, Mexico, and Thailand.

The heart of the system One of Villeroy & Boch’s most critical facilities is the Wellness plant located in Roden, Netherlands. It is there that the company manufactures various bath and wellness products, such as shower floors, whirlpools, and bathtubs for the worldwide consumer market. The plant personnel at the Wellness facility are busy making its various products 24 hours a day, seven days a week. It is a production cycle that cannot be altered, with any delays due to equipment failures or breakdowns resulting in downtime that can mean added costs and lost revenue.

“Everything in this plant needs to be working 24 hours, seven days a week,” says Mario Nieman, project engineer for the Wellness operation. “If something breaks down, the entire factory comes to a standstill with a lot of added costs.

So, we must have reliable systems, and if we don’t we have a lot of problems, a lot of expensive troubles.”

Specifically, the pumps used to transfer the various raw materials needed to manufacture Villeroy & Boch’s products must possess the ability to operate reliably during continuous-duty operations. For 20 years, Villeroy & Boch has been relying on Wilden Advanced Series (bolted) metal

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 37

PUMPS air-operated double diaphragm (AODD) pumps to perform these critical tasks.

Supplying the pumps to Villeroy & Boch is Holland Air Pumps, located in Oirschot, Netherlands, an exclusive distributor of Wilden pumps in Western Europe.

Part of PSG, a Dover company, and manufactured in PSG’s Grand Terrace, California, facility, Wilden invented AODD pump technology in 1955 and has spent the ensuing six decades developing its pump technology ever further.

“We have good cooperation with Holland Air Pumps and Wilden,” says Henk Kampijon, manager of maintenance for the Wellness plant. “If I call Holland Air Pumps today, then tomorrow I have spare parts. The relationship with Holland Air Pumps and Wilden is wonderful – they are helpful, confident, do what they say, and that’s what we need.”

One of the plant’s key activities is pumping base polymer to various production areas where it is needed to produce various styles of bathtubs and shower floors. Every drop of the base polymer that travels through the plant finds its way through a single Wilden Advanced Series metal pump.

“That is the heart of our company,” says Kampijon. “If this pump goes down, then we have a lot of problems and no more production. This pump runs 24/7 and it is reliable, and it is necessary that it is reliable. It’s pumping all of the materials around the company, feeding many different machines.”

The Wilden pump is not only delivering the polymer where it needs to go all day, every day, but it is also doing it safely.

A single AODD pump is required to pump base polymers to 11 different machines around the clock in Villeroy & Boch’s Wellness manufacturing operation

“The safety at this company is very important and that’s another reason we have Wilden ATEX pumps,” continues Kampijon. “It’s necessary to create a safe atmosphere for all of the people working here. We don’t have any problems with the Wilden pumps, no leakage, no spills.”

The new technology While Villeroy & Boch is committed to Wilden pumps, the company is also pragmatic, meaning that when it can find a way to save production or operational costs, it will. Fortunately for them, Wilden relatively recently released a new feature to its pumps, which has helped the Wellness plant in its operation.

Villeroy & Boch has relied on Wilden Advanced Series AODD pumps for 20 years

38

This latest feature was released in June 2013. Known as the Pro-Flo Shift, it is an AODD pump air distribution system (ADS) that effectively eliminates the main hiccup in AODD pump operation, namely the air that is wasted at the end of each stroke. The Pro-Flo Shift accomplishes this by incorporating an air control spool that automatically meters the air to prevent overfilling at the end of the stroke – with no corresponding reduction in product yield. Holland Air Pumps and its commercial director, Gerrit Klaassen, introduced Kampijon and Nieman to the Pro-Flo Shift ADS technology in 2013 and it was virtually love at first sight.

“For the Pro-Flo Shift, Holland Air Pumps showed us what the savings could be in our particular situation,” says Nieman.

“They made a very good case, showing us the actual pump and that we could make an annual €5,000 a year in savings with quite a small investment. The return on investment is three months and that is a very short period for any pump.”

Sold on the financial and operational benefits of the technology, Nieman and Kampijon have had the new ADS installed on all of the existing Wilden pumps in the Wellness plant.

“I think the Pro-Flo Shift also makes the pump’s construction better. It’s not over-expanding the diaphragms,” says Nieman. “At the end of the cycle, the air pressure is always getting lower and not putting that much stress on the membranes at a critical point, so we expect to have less maintenance costs.

The Pro-Flo Shift also makes the pump somewhat quieter because at the end

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

PAGE HEADER of the cycle there’s less strain, less pressure. It sounds better.”

Joining a fleet of 15 Wilden pumps on the plant floor are three Chemicor Series AODD pumps from Almatec. Like Wilden, Almatec is a brand from PSG, Oakbrook Terrace, Illinois, US. Almatec AODD pumps are manufactured in PSG’s Kamp-Lintfort, Germany, facility. Used to pump oils and colour pastes for Villeroy & Boch, the Chemicor pumps feature a solid-block plastic design with soft product chambers that deliver smooth product flow with no dead spaces.

“We have three Almatec pumps that have been in operation for 20 years and they are also very reliable,” says Kampijon. “You can also hear when the pump is running that they are very quiet.”

Protecting your equipment makes sense

Conclusion For a manufacturing company to remain viable for more than two-and-a-half centuries, it must successfully identify and implement the equipment and systems that help it most effectively conduct its operations, with the end goal being the creation of products that the consuming public will continue to purchase. That company must also constantly look for ways to improve the efficiencies within its operations.

Two decades ago, Villeroy & Boch decided that Wilden AODD pumps were the right pump technology for the production operations at its Wellness facility. The partnership with Wilden continues to pay dividends, because Wilden is also a company that does not rest on its laurels and is continuously looking for ways to improve its products. The Pro-Flo Shift is the latest invention that is setting a new standard in AODDpump operation, and Villeroy & Boch is reaping the benefits.

“Wilden is always doing a lot of modifications on its pumps, and now they have the Pro-Flo Shift, which brings a lot of savings to the operation,” says Kampijon. “We’ve been using Wilden pumps here for 20 years and we have had a very good experience with them. We have no problems and they always work very well.” z

Rely on Rotork

For more information:

This article was written by Neil Walters, regional manager – Northern Europe at PSG. Visit: www.wildenpump.com

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

Villeroy & Boch utilises three Almatec Chemicor series AODD pumps to transfer various oils and colour pastes

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 39

PUMPS

Unlocking energy savings potential

There is still great potential to reduce pump operating costs, especially in existing plants

A new mobile application helps plant engineers optimise their pumps’ energy consumption

In many process engineering applications, pump systems form the backbone of production and greatly impact the economic efficiency of the entire system.

Pumps consume a large amount of the electrical energy used in industry.

Depending on the scope of analysis, the potential savings on energy in current industrial systems range between 30 and 40%. In concrete terms, the German Energy Agency (DENA) has calculated that pump system operators in Germany could save as much as 14 billion kWh per year. That would translate into annual savings of €1.12 billion for the operators themselves and a drop of 7.7 million tonnes in CO2 emissions.

There are many reasons why far too much energy is still being wasted in connection with pump operation.

In refineries and process engineering plants maximum priority is attached to 40

productivity and fast restarting following repairs. Frequently, when piping systems have been modified for productionrelated reasons, the installed pump sizes are not subsequently adjusted to match.

More than a necessary amount of energy is sometimes used due to wrong valve choices and using valves that are not dimensioned correctly, installing inadequate pipe radii, or undersized pipe cross-sections. Aggravating the situation is the fact that many pumps are selected with a 10 or 15% “safety margin” – just to be sure. Another widespread problem is that pumps are often left to run far off of their originally envisaged operating point.

Probing the potential It is relatively easy to select a hydraulically optimal pump for new installations. As

long as the requirements to be met by the pump are known, an energy-efficient pump set can be chosen with great accuracy by way of pump selection programmes like those that most manufacturers have on hand for their customers. It is, of course, essential that a large number of closely spaced pump sizes be available to the user, and that the impeller diameters be trimmed to match the required operating point. Safety margins should be avoided. Even efficient pumps cannot run economically if they are used in the wrong operating mode.

The first step in identifying energy saving potential is to ascertain the pump’s present operating point and mode of operation. In the past, this was almost impossible without using additional measuring equipment. German pump manufacturer KSB has developed the

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

PUMPS walkdown by service staff. Identification of potential on the basis of the pump’s age, an inconvenient paper-based process that does not provide meaningful results, is no longer necessary, while checks using the new app can be included in the daily work schedule.

Furthermore, by repeating the analysis of a pump at different times, it is possible to eliminate the risk that the operating conditions prevailing during one particular measurement have falsified results.

The system question

The KSB Sonolyzer mobile app allows users to analyse the efficiency of fixed speed pumps with asynchronous motors

Sonolyzer mobile application to help plant operators. The free smartphone and tablet app can analyse potential savings in a fast measurement process. The app can determine within 20 seconds whether or not a pump is working under part load. It is compatible with all pump makes and it is designed to save time by calculating operating points simply and intuitively.

After downloading the app, the user selects the relevant pump type and enters the name plate data of the pump and connected asynchronous motor. It is also possible to enter a designation for the measurement and save it with a photograph of the pump in the data record.

The measurement is then started and the smart phone is held next to the fan hood of the motor for 20 seconds.

The motor fan’s noise is recorded and the noise spectrum is transferred to the KSB Cloud for analysis via a secure connection. Based on the maximum amplitude of the recorded spectrum, the algorithm now calculates the number of blades of the fan impeller and the blade passing frequency and derives from this information the shaft speed of the machine.

Using the nominal data of the asynchronous motor entered by the user and a slip model, the algorithm then calculates the input power on the basis of the shaft speed. It can estimate the pump flow rate from the input power calculation. By correlating the performance data entered by the user with the hydraulic systems database developed by the manufacturer, the app can conclude whether the pump

is operating at part load. The applied algorithm is patented and has already been in use for a number of years in thousands of practical applications as part of the PumpMeter product.

The analysis result is displayed on the mobile phone or tablet. If it is established that the pump is working under part load, then there is potential for energy efficiency optimisation. Using the Sonolyzer app, it is possible to identify pumps with optimisation potential simply and efficiently during a site survey or plant

Identification of potential, however, is only the first step in analysing pumps for the purpose of optimising energy efficiency and reducing operating costs. It is not only important to assess the individual machine, but to evaluate the system as a whole. In the case of pumps, this means that valves and piping must also be taken into account.

Although an assessment of individual components can identify potential savings of up to 10%, an evaluation of the whole system can achieve savings of up to 60%. While identification of potential savings is important, it is also vital to focus on the cost effectiveness of optimisation measures.

Finding ways to reduce the operating costs of pumps and other rotating equipment can also be simplified with KSB Sonolyzer. For the actual implementation of energy saving measures, KSB offers the FluidFuture energy efficiency concept, a structured system of suitable products, equipment, and services.

The following options are available, depending on the load profile: • Operate based on actual demand (variable speed operation) • Reduce the impeller diameter • Use smaller pump sizes • Install high-efficiency motors • Optimise piping Modern centrifugal pumps have already achieved a level of efficiency that could hardly be further improved. When they appear to be consuming more energy than necessary, it is probably due to the fact that people pay too little attention to pumps that just keep running. No pump can operate more economically than its surrounding system allows. z

For more information:

Screenshot of the KSB Sonolyzer measuring a pump operating under part load

This article was written by Christoph Pauly, technical press representative at KSB Aktiengesellschaft. Visit: www.ksb.com

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 41

EVENT PREVIEW

Momentum continues to grow for Tank Storage Asia The best and brightest of the Asian tank storage scene will crowd to The Marina Bay Sands in Singapore on 27-28 September. Let our preview help you decide who to see and where to go Tank Storage Asia 2016, the leading event for the Asian tank storage industry, returns to The Marina Bay Sands, Singapore, on 27-28 September with an expanded show floor, improved conference programme, and more international suppliers than ever before.

The show brings together the best and brightest from the Asian bulk liquid storage industry, providing a great opportunity for leading manufacturers and suppliers to showcase their innovative products and services to a captive audience of international buyers and decision-makers.

Nick Powell, StocExpo and Tank Storage portfolio event director, comments: “The 2016 show is going to be located in a bigger hall on level 1, which reflects just how fast we have grown. In fact, since 2013 we have increased visitor numbers by 135% and exhibitors by 60%, which is just incredible for a specialist show like this.

It also proves that a well-run event that listens to its audience can capitalise in such a busy and productive marketplace.

“Last year we welcomed industry professionals from all over the globe, covering 52 different countries, and we expect to exceed this in 2016. The 42

educational content we have on offer is more relevant than ever, with a regional and international mix. We are working very hard to make sure the 2016 event offers something for everyone involved with the tank storage industry, so mark the dates in your diaries and stay tuned.”

Packed exhibition hall Over 65 leading organisations are signed up to exhibit at the 2016 show already, including Colfax Fluid Handling, Emco Wheaton, Scully Systems, Siemens, Verwater, Viscoy, Zheijang, Maide Machine, and Brodie International. Many of these will use the show to launch new products and services to the tank storage market.

For instance, Loadtec Engineered Systems will be presenting the Loadtec Service, its new servicing company aimed at providing quality lifetime servicing and support for road, sea, and marine loading and access equipment.

Fort Vale will be using Tank Storage Asia to launch its Safeload loading arm, the latest addition to its range of products for the petroleum transfer industry. Its unique safety and design features include an

integral earth system that ensures electrical continuity without separate wiring, a device to prevent over-rotation, and a three-seal dual needle/dual ball race bearing combination for maximum axial and radial strength and performance.

Its stainless steel and aluminium construction, fitted with specialist highpressure low-friction seals, also ensures high corrosion resistance, rugged durability, and enhanced performance.

BIOex will be launching its new formula, Ecopol F3 HC. It is the first fluorine-free 3% foam concentrate, suitable for use on hydrocarbon fires. It performs better than any AFFFs, is biodegradable, and is exceptionally fast acting.

If it is valves you are after, head to the Zwick stand. The company will be displaying its full product ranges, including its metal-seated triple offset butterfly valves, check valves, Tri-Block series, and its double-block-and-bleed (DBB) design.

The DBB features a unique design of the linkage between the two shafts. This means the user can actuate both shafts with only one actuator and reach zero leakage with the two available sealing surfaces.

Netherlocks Safety Systems will be

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

EVENT PREVIEW

exhibiting its range of valve position indicators, which offer a highly accurate signal about a valve’s status, helping tank storage operators to ensure a correct line-up of manual valves and avoid wrong (off)loading operations, product spills, and product contamination. There will be a particular focus at Tank Storage Asia 2016 on its recently launched aluminium coated A-Series, providing a lightweight, cost effective, yet high end solution for non-corrosive environments.

Timm Elektronik will be unveiling its new Marine Grounding System, SEK-3, which offers the highest safety during the loading and unloading of vessels.

It has a compact design, good visibility of status lamps, both on device and clamp, as well as a multifunctional status display. The Marine Grounding System has EX certification according to ATEX and IECEx standard. The system has been developed in collaboration with The Hamburg University of Applied Science.

Powell comments: “We are thrilled to welcome so many big name exhibitors to the show this year. The floorplan is now 93% full and has already surpassed the size of last year’s exhibition, plus the showfloor is bursting at the seams with innovation, which is all wonderful news.

2016 is going to be the best show yet!”

Educational content The Tank Storage Asia 2016 exhibition runs alongside a two-day conference programme, which features over 20 global authorities from the bulk liquid storage sector. Experts from companies such as Nexant, Tri-Zen, Aurecon, and Peaker Energy will provide visitors with an insight into the sector’s critical issues at both a local level and on a global scale.

Clive Gibson, VP of Asia energy and chemicals at Nexant, will take a regional outlook, focusing on the

key drivers for storage demand in Asia crude oil, and looking at the petrochemical trends in the region.

Maintaining the regional emphasis will be Danial Mah, CEO of Labuan International Business and Financial Centre, who will present Malaysia as Asia’s Trading Hub. He will examine why Malaysia is perfectly suited for oil and gas trading, whilst also looking at the incentives for oil commodities traders in the area.

Continuing with this theme will be Moe Merican, lead consultant at Tri-Zen, who will talk about Asia’s oil and gas storage. He will explore the market’s outlook and its investment prospects.

Matthew Goita, CEO of Peaker Energy will analyse the region’s shale industry and the impact of supply and demand.

China is set to be a key focus at the 2016 conference, with Ms Lili, head of research team at ICIS China, taking to the stage on day one to discuss China: Good or bad timing for the crude oil storage business in the world’s top crude importing country? Ms Lili will examine China’s trading, renting and contango, looking into its crude oil importing and storage prospects, and speaking about China’s State Petroleum Reserve Plan.

With China in mind, Xiabo Liu, general manager at InFull Services will look at China’s storage market, explaining that what you see is not always what you get.

Many of the speakers will be taking a more industry specific focus, for example, Ignatius Hwang, partner at Squire Patton Boggs Singapore, will look at mitigating development risks for storage terminals.

Eric Ho, representative for Southeast Asia and Australia at American Petroleum Institute, will give a policy update, focusing specifically on standards and certifications.

Bob Gill, general manager for Southeast Asia at Arc Advisory Group, will discuss Asset Management, whilst Trinath Sahoo, chief manager at Indian Oil,

will be using the conference to explore the advances in storage tank sealing systems and environmental control.

Many may be wondering about the short-, mid-, and long-term effects of the current oil price environment on investment in storage. Jack van Lint, MD at Nomar Investment, will analyse the impact from both a strategic and investor point of view.

As always, tank integrity continues to play an important role within the bulk liquid sector. Alan Munn, senior engineer at MMI Engineering will outline ten ways that tank integrity is compromised, and explain how to prevent these turning into major incidents. Following the same theme, Jonas Berge, director of applied technology at Emerson Process Management Asia Pacific, will detail how to modernise old tank farms, so that they meet all the new requirements and regulations.

Looking towards the future will be Antonio Della Pelle, MD at Enerdata, who will be taking a look at the next 25 years of primary energy demand. He will forecast the energy demand, perform a deepdown analysis of the key new energy and storage requirements – gas/LNG and renewables – and explore the availability of LNG storage for spot trading purposes.

Powell concludes: “Each year we strive to improve the show, keeping it at the forefront of the latest tank storage trends and movements. With this in mind, we put particular focus into providing educational content, that is relevant on a regional, international and industry level.

We really feel that this year’s conference has something for everybody. If you are involved in the bulk liquid sector, then the Tank Storage Asia conference has something for you. It is without doubt our most comprehensive programme yet.” z For more information:

To register for free, please visit www. tankstorageasia.com or contact event director Nick Powell, on +44 (0)20 8843 8801 or at nick@stocexpo.com

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 43

Magnesium oxide in tertiary oil recovery OIL RECOVERY

Old oil wells will lose pressure over time and innovative methods need to be used to recover the remaining oil The presence of sufficient heat is key in the extraction of crude oil when other natural or applied recovery methods are not available. During the primary recovery stage, reservoir drive – the force that transmits oil to the surface – comes from a number of natural mechanisms.

These include natural water displacing oil downward into the well, expansion of the natural gas at the top of the reservoir, expansion of the gas initially dissolved in the crude oil, and gravity drainage resulting from the movement of oil within the reservoir from the upper to the lower parts where the wells are located. Recovery factor during the primary recovery stage is typically 5-15%.

While the underground pressure resulting from these factors in the oil reservoir is sufficient to force the oil to the surface, all that is needed is to place a complex arrangement of valves (the Christmas tree) on the well head to connect the well to a pipeline network for storage and processing. Sometimes pumps, such as beam pumps and electrical submersible pumps (ESPs), are used to bring the oil to the surface. These are known as artificial lift mechanisms.

Helping an old well However, over the lifetime of the well the pressure will fall, and at some point there will be insufficient underground pressure to force the oil to the surface. After natural reservoir drive diminishes, secondary recovery methods are adopted. These rely on the supply of external energy into the reservoir in the form of injecting fluids to increase reservoir pressure, which replaces or increases the natural reservoir drive with an artificial drive.

Secondary recovery techniques increase the reservoir’s pressure by water injection, natural gas reinjection, or gas lift, which 44

injects air, carbon dioxide, or some other gas into the bottom of an active well, reducing the overall density of fluid in the wellbore. Typical recovery factor from water-flood operations is about 30%, depending on the properties of oil and the characteristics of the reservoir rock. On average, the recovery factor after primary and secondary oil recovery operations is between 35 and 45%. The injection process requires power, but installing gas turbines on offshore platforms means shutting down the extraction process and losing valuable income.

It brings the heat To further support the extraction process, enhanced or tertiary oil recovery methods are applied. The most common are thermally enhanced oil recovery methods (TEOR) which heat the oil, thus reducing its viscosity and making it easier to extract by increasing its permeability, thereby allowing it to be physically pumped to the surface. These are widely used to meet the needs of extracting oil from deeper wells in thermally assisted gravity drainage (TAG-D) applications.

Heating is an area governed by strict international regulation in the form of the ASRM E-1652-14 standard, often supplemented by an individual oil and gas company’s own internal regulations, which may be even more stringent. In most modern heating systems, mineral-insulated cables are fed through pre-drilled holes.

A high voltage of up to 5,000V is then transmitted through the cables, heating the oil and turning it into a permeable form. The process also helps to heat up the surrounding water, while other chemicals are burnt off, with the additional pressure created contributing to the process of forcing the crude oil towards the surface.

The cable must have high electrical

conductivity through the heater element, as well as a consistent electrical connection to ensure the heat is supplied to the very end of the cable. With cable operating temperatures of up to 500°C, material choice is key in the cable and its heating elements, the exterior metal sheath, and the insulation blocks.

For the heating elements, the choice is typically between copper and nickel, depending on whether cost or performance is paramount. A variety of materials are available for the metal sheaths, but one thing they all have in common is strong corrosion resistance, enabling them to protect the heating element and insulator. Steel is typically the most popular choice.

The magnesium oxide solution However, it is arguably in the area of insulation blocks where material performance attributes are most crucial. The key aspect here is that the insulation blocks must offer excellent electrical insulation, given the high voltages involved, but be highly thermally conductive to enable maximum heat transfer to the crude oil. Meanwhile, the increased depth of wells has stimulated demand for materials which can be extruded into longer elements, up to 2km, without compromise in performance or the risk of breaking, with all its associated risks. This has created major opportunities for magnesium oxide (MgO) which is believed to be the most cost-effective way of manufacturing mineral insulated cables whilst achieving the required performance.

MgO offers a variety of performance advantages, the first being exceptional purity, as high as 99.8%. This is key as impurities even slightly exceeding this threshold can significantly impact on

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

OIL RECOVERY

MgO insulators provide high purity and durability

the electrical resistance properties.

Different levels of purity are available depending on the application. The least, still 99%, would be used mainly for cartridge heaters, while the purest, compliant with the ASTM/ E1652 standard, would typically be employed in high temperature thermocouples.

The use of MgO also enables formulations to be tailored to deliver bespoke functionality in attributes such as strength, dielectric performance, and thermal resistivity. This level of purity

A variety of Morgan MgO insulation blocks

can be achieved in other materials but not as consistently, creating potential uncertainty over long-term performance.

MgO products also have a reduced servicing requirement and cost compared with alternative heating solutions. Finally, the availability of MgO in crushable blocks allows longer lengths of cables to be achieved, as they can be grouped inside the outer sheath. Cable length is usually only limited by the customer’s own manufacturing processes.

The availability of MgO is opening

up new possibilities for oil extraction companies who are now able to access a reliable long-term method of extracting oil from deeper wells through the employment of a highly durable and versatile material. z

For more information:

This article was written by Sam Woods, business development manager at Morgan Advanced Materials. Visit: www.morganadvancedmaterials.com

When failure is not an option: Egger SINCE 1947

www.eggerpumps.com

EO/EOS Series Process and slurry pumps Entrained gases up to 25% Vol. System press. up to 100 bar Temperatures up to 300 °C

RPP Series Large flows with solids and /or shear sensitive product

Turo® Series High solids concentrations and shear sensitive products

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 45

A design challenge

HEATING

A multitude of hardships and challenges need to be taken into account when designing steam trace systems

Heat tracing systems, also called satellite systems play an essential role in the correct functioning of industrial installations. Technical solutions that guarantee safe working of the installation should be linked to the economical side of the problem.

Because of the ever-increasing price of energy expenditure, it is necessary to maximise the possibilities of reducing energy costs by imposing optimal temperature control solutions.

Nowadays, temperature regulated heating systems as well as steam distribution and condensate collection systems should be optimised.

Heat tracing systems protect installations against low temperatures in autumn-winter conditions and ensure all year long that the transfer of the products takes place at the lowest A steam tracing scheme resistance of flow, that is the lowest viscosity of the transferred medium. Heat tracing systems can be electric (considered twice the environment, and is characterised by high convective as expensive as a steam heating system), hot water heating heat-transfer coefficient. These characteristics make steam (not so effective), hot oil systems (require very good leakthe main heating medium for trace heating systems. tightness at the system and problematic), or steam systems.

Steam is easily accessible in most industrial plants, and Challenging design in steam tracing systems it serves to replenish heat loss of the transferred product. Steam at the correctly selected Anyone who designs steam tracing systems knows how pressure ensures product temperature at the right level, problematic and complicated it can be. The practical side of i.e. it guarantees that the temperature of the transferred steam tracing construction is based on assembling many steam medium will not drop below the temperature assumed by the tracer sections at the same time and connecting them (in logical process engineer. Steam is incombustible, does not pollute and effective way) with steam distribution and condensate collection points, which must be also connected to the main steam and condensate pipelines. This global issue requires knowledge and experience about recommended lengths of steam tracers, type of insulation, compensation, standards of valves, pumping and regulation system heating, etc.

Another extremely important issue is correctly addressing the whole installation to ensure easy and effective maintenance in the future. Satellite systems of many installations might consist of several hundred heating loops. A detailed marking of each loop is therefore very important. Each heating loop should be marked at the beginning, that means the steam distributor, and then at the end, or the condensate collector. It is important that the markings on steam trace heating pipes are the same during designing, installation, and operation of the particular installation.

During the design of the satellite system, the main decision we have to make is the choice of steam pressure, which determines the saturation temperature. It is true that we often depend on the A steam tracing system installed in Poland 46

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

HEATING

ZFM – Zamkon condensate collection station

RFM – Zamkon steam distribution station

parameters of the steam available on a particular installation.

According to the laws of thermodynamics, the lower the steam pressure, the higher the heat of condensation, leading to lower absolute steam consumption. At the same time, however, higher required product temperature leads to higher heating steam saturation temperature, and therefore higher steam pressure.

steam tracing business is building its own modern RFM (steam distribution) and ZFM (condensate collection) stations. At the heart of these systems is always a manifold made from steel forging modules. It lengthens the systems’ operating life and enables them to save required space by up to 50%. This solution also enhances the aesthetical aspects, which today are also taken into consideration during designing new installations.

It is also important that the built-in on/off valves are replaceable, including valve seats, as it allows for quick replacement without the need of either the station or individual elements being disassembled. Zamkon offers the above mentioned stations as a complete device ready to be installed at the destination point. They contain all necessary equipment, including the manifold with on/off valves, drain valves for startup and later maintenance, steam traps, flanges, column, etc.

This solution is also very attractive during the system assembly, because the stations are prefabricated at Zamkon’s factory and delivered as a packet, tested and certified. Zamkon cooperates with all chemical plants and power and plants in Poland as a supplier or a design company. During the last few years, the company has also engaged in projects abroad and it continue to develop its activities outside Poland. z

For more information:

This article was written by Angieszka Wojciechowska of Zamkon.

Visit: www.zamkon.com.pl

What to do The first step in the design process is calculating the energy balance of all heat losses in the whole heating installation. Based on the required product temperature, heat transfer coefficient, and the thickness of the insulating material, as well as the lowest ambient temperature, we can calculate the heat loss per a metre of pipeline. Through this method, we can calculate one by one the heat consumption of each loop of steam trace heating pipe.

Adding up the heat losses of all the loops, we will get the maximum global heat consumption for the whole heating installation as t/h.

While designing a satellite system, an extremely important issue is the selection of the right type of steam trap. Many mistakes have been made in this area, and as a result, problems with keeping the correct product temperature have occurred. The inverted bucket steam trap is certainly the best recommended type for satellite systems. It can work for many years without steam losses, without any restrictions concerning steam pressure at low, medium, or high pressures. It needs only to be remembered that the steam trap should have an internal check valve.

Thermal bimetallic steam traps can be also used, but mostly at medium and high steam pressures. Steam pressure at or above 3 bar is assumed as the lowest acceptable operating point. At lower pressure ranges (<2.5 bar), the steam trap may experience perturbations, especially when colder condensate is constantly present on the outlet side. The saying “bimetal behaves strangely at lower pressures” is often heard among Polish operators.

INDUSTRIAL VALVES

www.zamkon.pl

VALVES MANUFACTURE

STEAM TRAPS, GLOBE VALVES, GATE VALVES, BUTTERFLY VALVES, SEPARATORS

ENGINEERING COMPANY

STEAM TRACING SYSTEMS, CONDENSATE RECOVERY UNITS, PRESSURE REDUCTION STATION, FLASH VESSELS

Conclusion Zamkon is a Polish manufacturer of industrial fittings, specialising in steam tracing systems. The standard of the company’s FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016 47

EVENTS

Fluid Handling International will be distributed at the following events 20-22 July 2016

Indowater

Indonesia

12-15 September 2016

TPS 2016

Houston, USA

21-22 September 2016

9th Biofuels International Conference 2016

Ghent, Belgium

24-28 September

WEFTEC

New Orleans, Louisiana, US

27-28 September 2016

Tank Storage Asia

Marina Bay Sands, Singapore

4-6 October 2016

Wetex

Dubai, UAE

18-20 October 2016

Oil & Gas Vietnam (OGAV) Exhibition 2016

Vung Tau City, Vietnam

29 November - 1 December 2016

Valve World Expo

Dusseldorf, Germany

Donâ&#x20AC;&#x2122;t miss your chance to appear in the September/October 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: Russell Priestley, russell@fluidhandlingmag.com, +44 (0) 208 648 7092 Next issue features include: Industry spotlight: Water/wastewater Fluid focus: Mixers, level gauging Regular features: Pumps, valves, meters

Advertising deadline: 19 August, 2016 48

FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2016

PAGE HEADER Can the biofuels market be both profitable and sustainable?

9th Biofuels International Conference & Expo Ghent Marriott, Belgium, 20-22 September 2016 2 great networking tours now included in your delegate ticket!

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Now in its 9th year more and more companies recognise that this is the one event not to be missed each year and have made long lasting business relationships seeing their business grow.

For sponsorship enquiries contact: Matthew Clifton tel: +44 (0)203 551 5751 email: matthew@biofuels-news.com To register: www.biofuels-news.com/conference/16_register.php Key Sponsors

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international

international

CREATING THE FUTURE OF WATER WEFTEC is the one event for professionals, industry experts, and the most innovative companies from around the world.

Learn from the very best thought-leaders in water quality.

REGISTRATION IS NOW OPEN

JOIN US IN NEW ORLEANS. New Orleans Morial Convention Center September 24 â&#x20AC;&#x201C; 28, 2016

www.weftec.org