Fluid Handling International September-October 2016 by Woodcote Media Ltd

HELPING TO KEEP YOUR BUSINESS FLOWING

SEPTEMBER/OCTOBER 2016

Issue 5 Volume 4

A matter of frequency

Benefits and importance of 80GHz radar level measurement

A newbie with a history

Worldâ&#x20AC;&#x2122;s first wastewater pumping system with integrated intelligence solves clogging issues

2016

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Intelligence is the future

INTERVIEW

Heathrow Airport’s equipment procurement strategy aims to minimise the number of links in the chain while maximising the degree of automation and intelligence

Ian Jolly, systems specialist for water at Heathrow Airport

Heathrow Airport in London, UK, is among the busiest airports in the world. In 2015, nearly 75 million passengers passed through its gates, with more projected for 2016. But what these masses do not see is the miles upon miles of pipework and hundreds of pumps that transfer clean water in and wastewater out from the airport. Ilari Kauppila of Fluid Handling International reached out to the man responsible for keeping the water systems out of the passengers’ sight and minds. Could you please introduce yourself to our readers? My name is Ian Jolly, and I am the systems specialist for water at Heathrow Airport. I work directly for the company Heathrow Airport Ltd. at the Water 8

Services department. We maintain all the external water infrastructure for Heathrow, which includes both the

at Heathrow. It brings together various technical documents, such as sewage reduction plans, and it also includes

incoming potable supplies and the outgoing surface water and foul water drainage. We also ensure the supply of water for the firefighting systems at the airport and the various grey water systems as well. I work on the maintenance side, but also have some influence over the types of equipment we look to purchase, together with our asset engineer, who holds the technical standards.

Heathrow’s own particular requirements and general specifications of what we need. We can then use this information to determine which equipment meets the Heathrow standards. We are also now in the process with the asset engineer of incorporating the Water Industry Mechanical and Electrical Specification (WIMES) documents into the standard. With the addition of WIMES we hope to bring ourselves even further in line with the outside water industry. The technical standard also gives examples of manufacturers that produce equipment that has been proven to work well in our applications and that we understand how to run and maintain.

What kind of equipment exactly do you have at Heathrow? We have in excess of 250 foul water pumping systems across the airport, and more than 400 submersible solid handling pumps. We have a variety of potable water booster stations and underground storage tanks. We maintain large run-off lagoons, together with a vast amount of drainage systems for the airfield run-off surface water. We also provide around 75 miles of water pipe for the various firefighting systems across the airport. How do you determine what equipment to purchase? The Heathrow technical standard, which is held and maintained by the mentioned asset engineer, is the thing that details the type of equipment we acquire. The technical standard was re-written about three years ago by a public health engineer who was contracted to the airport. At the moment it is a standalone document based on our experiences and knowledge of systems that we have built up over the years, in fact since long before I came to work

Could you give some examples of manufacturers mentioned in the document? On the wastewater pump side of things, we have three manufacturers whose equipment is recommended for use at Heathrow. One is Xylem, with the Flygt pumps. We also have Grundfos with the S-tube impeller and Sulzer with the ABS XFP pumps. These are examples of products we know will immediately meet our standards if offered. With Xylem, 95% of all wastewater pumps on the airport are Flygt models. We have a long-standing relationship going back many, many years. They have always provided equipment that has met or exceeded our technical standards. Three or four years ago, however, we felt other manufacturers were starting to step up their game as

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

INTERVIEW well, and now the S-tube and ABS XFP are listed as acceptable products. But just because these three are named as recommended manufacturers does not mean it is a closed shop situation. They are just examples of equipment providers we know to comply with our technical standards and we have a history of working with. Suppliers can of course offer any manufacturer’s pumps they want and we will be happy to consider them. The only difference is that unlisted products have to pass a testing process to prove they meet our requirements. What other considerations are there when procuring equipment? What we are looking for is a combination of several elements, one of which is naturally high reliability. We put considerable thought on the whole life cycle costs, especially now when we are being scrutinised on everything. Sustainability has become a big part of the life cycle costs situation, not just with the equipment itself but also with how we operate it. We are very much focused on trying to do the maximum for the minimum. We are asking ourselves how we can run our machinery to get the best possible results with the minimum power input, and how to reduce our power intake and any further environmental impacts that we may have. Energy efficiency has therefore also become a big consideration on the side and as part of the total life cycle costs. Another important aspect on any piece of equipment is maintenance. Anything that can provide us with a good, costeffective maintenance strategy is going to end up high on the list of possibilities when new acquisitions are considered.

‘We want smaller and more efficient systems while maximising the intelligence in them.’ Ian Jolly

we have visited other users and seen what they are using. We have made notes of what their maintenance requirements are, what the cost and efficiency of these machines is, and also their compliance with environmental standards as well. It is not just a case of looking through a catalogue and picking something. There is quite a bit of research that goes into making sure that we get the right thing. How do you minimise the possibility of ending up with a less than suitable product? We used to have facilities built in the past by our Capital Projects department and there was a bit of a disconnection between them and the maintenance people. The Capital Projects would build something they thought was right and deliver it, which then left us to pick the thing up and try to carry on with it. However, there has been much better communication now between the two worlds. In fact, maintenance is actually now being involved from the beginning on any new projects being planned. We provide guidelines on how to build projects for easier maintenance and

which equipment is most compatible with our existing spare part stocks. What do you see as the big trends that will develop in the future? We have been involved with Xylem’s Flygt Concerter project, just as an example (see page 40). This project rolls back to energy efficiency and maintenance costs. A big part of maintaining our foul water systems is the cleaning that has to be done. Anything that can reduce the need to tanker waste away separately or bring in third party contractors is sure to interest us. We have been using the Flygt Smartrun system for almost three and half years. The system is still nearly as good as when it was installed, but the Concerter is taking that to a new level by putting the intelligence of the system into the pump itself. This is next stage, this is what we are aiming at. Intelligent systems directly translate to a reduced amount of equipment we need to run. When we have less links in the chain, so to speak, there is less that can go wrong. From the maintenance point of view, this makes our systems simpler and easier to maintain. We have a finite footprint available at the airport where we can try to fit things in. We want to reduce the footprint above ground so that we have no need for large panels and kiosks. If we also do not need to visit these locations as often due to them being self-maintaining with maximum SCADA feedback, this is certainly a direction we want to be going. We want smaller and more efficient systems while maximising the intelligence in them. Mr. Jolly, thank you for your time. z

What would you say are the biggest challenges when you are hunting for new equipment and how do you solve them? Our technical standards make it, in a way, almost difficult to deviate from the norm. On the other hand this is a good thing because we know what we are getting, but issues do arise when new things come along that may be a bit out there in the left field. We are always trying to look for any anecdotal evidence that equipment has been used elsewhere successfully to compensate for this. Just as an example, we are currently in the market for replacements for some of our water quality monitoring equipment. Rather than just go looking around blindly, FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 9

MARKET STUDY

A three-in-one solution The multiple advantages of multiphase flowmeters and a look at market developments

A view of the harbour of Bergen, Norway

Multiphase flowmeters play an important role in today’s oil and gas exploration and production activity. They are called “multiphase” flowmeters because they measure three or more phases of fluids that come out of a well. These three phases are typically oil, gas, and water. Before the advent of multiphase meters, these three fluids had to be physically separated using a test separator or a production separator before they could be measured. The meters can measure the amount and relative proportion of the three fluids as they come out of the well and before they are separated into their components. The idea for multiphase meters was born out of a concern to find a way to diagnose the conditions of the wells in the North Sea, near the UK. The first oil field was discovered in the North Sea in 1969. In 1970, the finding of the Forties Field near Scotland confirmed the exploration potential for oil in this region. In 1975, oil was being produced from North Sea fields, but at very low levels. By 1985, oil production had increased to 2.5 million barrels per day. Multiphase flow measurement began when the prospective decline in production of the North Sea oil fields made it necessary to find a way to analyse the increasing amounts of gas and water that pumped from the wells. Several research projects were undertaken

at that time to develop multiphase technology that could provide this analysis on fluids as they came out of the wells. As a result of this interest in the North Sea oil fields, Norway became a centre of production and development for multiphase flowmeters, with Christian Michelsen Research (CMR), located in Bergen, taking the lead. The Christian Michelsen Institute did the research from 1982 to 1985 to create the Fluenta flare gas meter, and in 1985 founded Fluenta, now an ultrasonic flowmeter supplier. CMR also researched multiphase meters during this time. Today a number of multiphase companies call Norway home, including Roxar (Stavanger), FMC/Multi Phase Meter (MPM) (Stavanger), One Subsea (Bergen), and Abbon (Rud). The UK, also on the North Sea, is another important area for multiphase development. TUV SUD National Engineering Laboratories (NEL) in Glasgow, Scotland, is responsible for flow measurement within the UK’s National Measurement System and a worldclass provider of technical consulting, research, testing, flow measurement, and programme management services. Recent research has provided major support for multiphase and wet gas metering as well as for traditional measurement techniques like orifice plates. How multiphase flowmeters work The majority of multiphase flowmeters make a combination of measurements, including temperature, pressure, and differential pressure. They also typically use a nuclear source, usually gamma rays, to help determine the properties of the fluid. Some multiphase flowmeters use a high-energy gamma ray source, while others use a low-energy source. Some companies use both high- and low-energy gamma sources in their multiphase meters. Most multiphase meters have a Venturi tube incorporated into the device. Bernoulli’s theorem is then used to compute the flow rate, as with other differential pressure (DP) flow devices. Density is determined with a combination of temperature, pressure, and DP measurements. The gamma ray technology is used to determine the percentages of gas,

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

MARKET STUDY Total Shipments of Multiphase Flowmeters Worldwide (Millions of Dollars)

Total shipments of multiphase flowmeters worldwide (millions of dollars)

600.0 500.0 400.0 300.0 200.0 100.0 0.0

2015

2016

2017

2018

2019

2020

Source: The World Market for Multiphase Flowmeters, 2nd Edition, published by Flow Research

water, and oil that make up the fluid at the point of measurement. By combining these percentages with the DP flowrates, the amount of flow of each fluid type can be determined. Advantages of multiphase flowmeters

Multiphase flowmeters make it unnecessary to separately test the performance of each individual well in a group of wells, since the required data can be provided from a multiphase meter. This is especially important for subsea applications where the well testing flowlines can be quite long. The use of multiphase meters can reduce or eliminate the need for separate well-testing lines. The use of multiphase meters reduces or eliminates the need for dedicated test separators by measuring flow at the wellhead. This saves on oil platform space and makes it possible to drill with less equipment. As a result, there is less need to install hardware near the wellhead on topside (land-based), offshore, and subsea applications. Multiphase meters also provide important data about the condition of the well itself. Changes in the gas/oil ratio can be detected more quickly on an ongoing basis. By contrast, test separators provide fewer data points with a slower response time. They are also useful for allocation metering, where the produced fluids from different wells must be mixed together and sent to a processing facility. Without multiphase meters, a test separator has to be used on each well before the fluid can be sent on its way. However, these complex instruments combine multiple technologies and therefore demand that the operator be well-versed in the physics of the instrument in addition to its construction,

installation, and use. The reduced number of trained engineers familiar with flow and flow technologies is a serious concern to multiphase flowmeter suppliers. The field performance of these devices is dependent on the operators’ adaptability and their ability to configure the instrument within a dynamic application. Growth factors One important growth factor for multiphase meters is the increasing acceptance of the technology by end-users. This is true in part because multiphase provides the only solution for some applications, but also because of an improving product track record and due to proven performance. Manufacturers are doing the research to provide better multiphase metering solutions. This includes not only higher accuracy but also improved measurement reliability, repeatability, size, and price/ performance ratio. Multiphase meters today provide measurable space and weight advantages. They tend to be more accurate than two or three-phase well testers, and offer well optimisation, shorter test times, and portable units. Manufacturers report repeat orders and are vying to gain market leadership with their particular version of multiphase metering. Greater industry acceptance of Coriolis flowmeters, which are used in some multiphase flowmeters, is also contributing to overall comfort with the solution. As more oil fields are owned by joint ventures, the demand for higher multiphase accuracy for allocation metering and other fiscal measurement is likely to increase. Manufacturers are also producing multiphase solutions that do not require the use of nuclear materials. Many experts

insist that there are no risks or hazards associated with the use of nuclear components in multiphase flowmeters, and manufacturers of nuclear solutions naturally maintain that nuclear provides the best and most robust measurement. However, some manufacturers say that that the industry wants to move away from any perceived problems with nuclear components, with some companies producing alternative solutions, including a source based on an X-ray generator. There is also great potential growth for multiphase meters. Less than 1% of the world’s one million wells are equipped with multiphase technology today. This leaves room for multiphase market growth as well as for marketing and improving the technology. As prices come down, it will be possible to put multiphase meters on more land-based wells, even if they are not high producing wells. High oil prices and substantial oil development have driven multiphase sales. Manufacturers report that some end-users are evaluating multiphase meters and others are purchasing them as an oil field monitoring requirement. The drop in oil prices beginning in August 2014 has cut heavily into subsea projects and in turn has hurt sales of multiphase flowmeters. Even though 2015 was a tough year for subsea markets due to low oil prices, subsea drilling will come back with higher oil prices, at least by 2017. The worldwide demand for oil increases by over one million barrels per day each year, and this demand is likely to continue with population growth and increased industrialisation. There are many multiphase flowmeter suppliers, including Emerson Roxar, Schlumberger/OneSubsea, Agar, Krohne, Weatherford, and others. These suppliers are competing to produce higher quality and lower cost multiphase meters. They have combined to make multiphase meters one of the fastest growing niches in flow measurement. Watch for continued development of this beneficial new technology as end-users become more aware of its many advantages. z

For more information:

This article was written by Jesse Yoder, Ph.D., president of Flow Research and a leading expert on flowmeters. Visit: www. flowresearch.com and www.flowPD.com Flow Research has recently published a new study called “The World Market for Multiphase Flowmeters, 2nd Edition”. For more information, go to www.flowmultiphase.com

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 11

It PACs a punch WASTEWATER TREATMENT

A carbon dosing system solved the issues a UK wastewater facility was having with pesticides in its water

system for mixing and injecting a slurry of powdered activated carbon (PAC) into the municipal water stream. The mobile unit requires only connections to an electric power supply, the municipal water stream, and an external water supply. Environmental impact and site preparation are minimised, as well as the need for maintenance and planning permission. The system is safe TransPAC mobile powder handling and carbon dosing system houses multiple pieces of equipment

to operate, and simple to control. The water treatment works was restored to compliance as the dosed carbon successfully removed pesticide traces from the main water stream. Dosing with the system is accurate and steady without over-dosing or wastage. From the BFF-C-X Bulk-Out split-frame bulk bag discharger, PAC is automatically transferred from a half-tonne bulk bag through a flexible screw conveyor to a surge hopper, from which a second flexible screw conveyor meters the powder into the Transvac ejector. Solution in a box A forklift loads the 1.8m high bag-loading frame and 500kg bulk bag onto the 0.9m high stationary discharger frame inside the shipping container. Once the bag spout is untied, the powder flows into a 5m long, 80mm diameter flexible screw conveyor leading to the 930l capacity surge hopper. A second 3.5m long, 67mm diameter flexible screw conveyor moves the carbon powder from the hopper outlet to the intake of the ejector that accurately doses the

When a water treatment works in northern England faced a spike in pesticide concentration exceeding the allowable concentration limit for the incoming water, the site was forced to shut down. The company then had to divert water from a regional water treatment works in order to provide clean drinking water to its customers until the problem could be solved. The solution to the issue arrived in the form of a mobile, lorry-mounted carbon dosing system, housed in a 6m long steel shipping container that was delivered and activated within one day, without costly and time-consuming site preparation, construction or complex components. Supplied by Transvac Systems, the TransPAC mobile powder handling and carbon dosing system includes a bulk bag discharger and two flexible screw conveyors from Flexicon Europe and Transvacâ&#x20AC;&#x2122;s ejector 12

The 5m long flexible screw conveyor (left) from the bulk bag discharger moves the carbon powder to the surge hopper

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

WASTEWATER TREATMENT

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Bulk bag and lifting frame of the split-frame bulk bag discharger are forklifted onto the stationary discharger frame inside the container

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PAC into the municipal water stream. The conveyors are curved to fit the tight space within the shipping container. From the control panel, the operator sets the speeds of the conveyor drives to automatically dose the proper amount of PAC according to the site water flow. Low and high level sensors in the surge hopper signal the controller to start or stop flow through the first flexible screw conveyor when the hopper contents reach low or high level. The carbon dosing portion of the TransPAC system includes a header tank for incoming water, a booster pump, and the ejector. The velocity of the water flowing through a venturi creates a low pressure zone in the ejector that entrains the carbon powder into the treated water stream at a rate set at the control panel. The unit operates with no moving parts. PAC poses handling problems PAC adsorbs the pesticide on its surface, and the carbon and adsorbed material are subsequently removed as sludge in the flocculation process. However, the extremely fine powder, with an average particle size of only 20 microns and a bulk density of 230kg/m3, is prone to dusting. Both the bulk bag discharger and flexible screw conveyors prevent dusting. The bag outlet spout is connected to the feeder by a Spout-Lock clamp ring, which creates a secure, dust-tight connection between the clean side of the bag spout and clean side of the bag spout interface. Each flexible screw conveyor consists of a stainless steel screw rotating inside a durable polymer tube that contains the fine powder as it is conveyed. The conveyor discharge is likewise dust-free, as powder exits through a transition adapter located forward of the drive at the discharge end, thereby preventing powder from contacting bearings or seals. Transvac has deployed its mobile TransPAC dosing systems in a number of UK water treatment works for similar emergencies for pesticide, or taste or odour problems and as an alternative to traditional PAC batch dosing systems, which are large, complex and costly, and require long lead times by comparison. z

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For more information:

This article was written by Craig Favill, sales manager at Transvac Systems and David Boger, VP of global business development at Flexicon. Visit: www.transvac.co.uk

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 13

LEVEL MEASUREMENT

A matter of frequency Understanding the benefits of 80GHz radar and its importance for all liquid level measurement applications

Small antenna (and housing) sizes of 80GHz radars add to versatility of application in small batch vessels and adaptability to existing nozzles

With the recent launch of radar instruments in the 80GHz frequency range for liquid level measurement, it is now a good time to examine what is behind this new direction in radar technology. Where does it come into its own and what are the benefits of using these new sensors in automated processes for control and inventory? This development signals a brave new world in level measurement, one where radar level measurement can go where it has never gone before. With high-frequency radar level devices on the rise, this is truly an exciting era in automation. The readiness to use radar level sensors is a function of cost and innovation. Decreased expense has led to increased use of the technology across multiple industries. Microwave radar is a popular format for level measurement, being solid state with no mechanical parts to drift or wear and – more importantly – its immunity to pressure, vapours, temperature, viscosity, and density change. Just as computer hardware prices dipped low enough to put a “PC in every home” and a “smartphone in every hand”, it is now possible to put the latest 80GHz radar in virtually any vessel and every plant. Latest innovations have resulted in a technology that can be both affordable and relevant to even more general process applications. This latest generation of modern radar instruments is engineered out of decades of experience, culminating in the best ever optimised antenna designs, with larger dynamic ranges and software algorithms to filter out interference to perform even better. Now that 80GHz radar is available and highly applicable to almost any liquid level measurement, users should get to know and accustomed to the advantages these new contactless sensors provide. The main benefits are produced through better focusing, versatile sizes, enhanced resolution, the

consequently easier setup, and – most importantly – high performance reliability. So what, in detail, are the main areas of development for 80GHz radar level sensors? Focusing Focusing is the primary advantage of 80GHz radar – the one that makes virtually all the other benefits possible. In every contactless liquid measurement application, signal focus is crucial to accurate level measurement, and these new instruments emit the most highly focused signals on the market. Plant operators have struggled with less focused radar – and ultrasonic – sensors for decades. The wider beam angle of 26GHz sensors (and still wider 6 to 10GHz sensors before them) made it difficult for the emitted signals to miss agitators, baffles, ladders, heating coils, and other vessel internal structures. The reflections from these installations distort and confuse the echo picture to the sensor, forcing users to make (often many) adjustments to follow the true liquid level. These new high-transmission models have narrower beams that completely miss vessel installations, as if they are not even there. That is welcome news in pharmaceutical, chemical, and food production, where obtrusive internals are often the norm and space is at a premium. Mounting nearer to vessel sides and taller nozzles, without accuracy loss, is another area of advantage – enabling use of more existing connections, especially in taller vessels. They can also be easily installed to look through process isolation valves, an application area highly desirable in the oil and gas processing and storage industries, for example. In summary, the superior focus makes for accurate measurement, minimal adjustment, simpler installation, and maximum signal return from the product surface. Size Because their focus is improved, 80GHz sensors have smaller antennas. They feature the world’s smallest level radar antenna – smaller than the size of a £1 or €1 coin – so they do not require a large

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

LEVEL MEASUREMENT the food, pharmaceutical, and chemical industries toward batch production. Batching allows operators to produce profitable, special, or seasonal versions and low-volume products, with lower financial investment. Small batches are produced in small vessels, but conventional wisdom says using contactless radar is not possible due to the small process connections, busy vessel internals, and their reduced accuracy over short measuring ranges. However, contactless volume measurement is still highly desirable, especially if unaffected by temperature, pressure, viscosity, density, and conductivity changes that can be seen in different product formulations. Now, thanks to the compact design and performance of 80GHz radar level sensors, operators no longer have to sacrifice accurate measurement in the name of space.

80GHz high resolution means better accuracy and process detail

The greater resolution is also particularly important for shipbuilders, for example, who count on precise level in large cargo and ballast tanks, tens of metres high. It results in better measurement accuracy of every drop of liquid in tanks of all sizes, which is especially important with hydrocarbons in large storage vessels. Process capable

Resolution

The radar beam width of 26GHz in grey and the narrower 80GHz in yellow

horn to focus the beam at the product surface. A compact instrument design and small size also makes a huge impact when it comes to retrofitting. Plants can now integrate the most advanced radar devices into their process without shelling out thousands for vessel modifications. Smaller size and range instruments are not just good for old vessels, they can also help manufacturers stay nimble and market-responsive. There are more trends in

When looking at the picture on a standard definition television next to that of HDTV, the higher resolution delivers a higher quality image – clearer, sharper, and more detailed. Users will see a similar difference switching from lower frequency to highfrequency radar sensors. For example, when the level of a hydrocarbon liquid in a vessel is just starting to fill or empties down, lower frequency process radars do not have the resolution to distinguish the different reflections from the product level and the tank bottom, and so they just see one “echo”. This tells the user the vessel is empty when it is not, presenting a natural handicap to process efficiency. The new 80 GHz devices can measure liquid down to the last millimetre, providing accurate data operators can use to optimise their processes. This is not just about small range applications, either.

Getting close to the product in smaller vessels also means increasing the possibility of sensor build-up through splashing, sublimation, and condensation on the antenna face. This can result in reduced antenna/signal efficiency, causing reduced measurement reliability. The latest sensors with optimal antenna design, dynamic range, sensitivity, and filtering algorithms can handle these challenges with ease. This capability is essential for delivering higher operational reliability, even when the product gets where it should not. There are also units available with certified hygienic fittings for food and pharma industries to ensure thorough cleaning of any sensor process connection. In summary High-frequency contactless radar sensors look set to be the next big thing in level measurement across many industries, processes, and vessel types. They are the proverbial “giant leap”, a marker in time after which the process industry will never be the same. Their excellent focusing makes them well-suited for vessels crowded with internals and difficult mounting nozzles, their small size makes them ideal for retrofitting and batch production, and their unrivalled resolution also allows users to get every last drop of capacity from the largest of tanks. The future of level measurement is here. z For more information:

This article was written by Doug Anderson, marketing manager at Vega Controls. Visit: www.vega.com

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 15

LEVEL MEASUREMENT

Emergency measurements Using visual level indicators will allow processing plant operators to keep a track of tank fill levels even in the case of an emergency power outage

System failure strikes at a fuel processing plant! The process control system is temporarily out of order. Emergency power generators now have to ensure that there are no system outages and that no situations beyond the operator’s control arise. Fill levels of diesel tanks have to be checked periodically and product transferred to another tank, if necessary. Suddenly, monitoring the fill level becomes one of the most important issues in the plant and requires full attention of the staff. Energy-free operation is one of their main features of visual level indicators (VLI), such as magnetic level indicators based on the float principle. Even in the case of a full-scale power failure, the display works reliably, which is imperative for fluid handling operations. Similarly, temporary power failures or power fluctuations do not affect the display either. The most important controls, such as shut-off valves, can also be controlled manually despite comprehensive automation. However, under such circumstances, the necessary information has to be available in order to be able to make use of such facilities. Easy and intuitive readability is also an important factor. Fill level is directly and clearly visible on the VLI installed on the side of a storage tank. How big would a digital display have to be so it can be read from a distance of 50m, even under difficult conditions? Multicolour indicator rails that display different values for different media and location VLI meters can make it possible for plant staff operate even to read them even when the during a power plant has multiple tanks. failure 16

The speed and simplicity of the measurement principle is another advantage. There are no runtime calculations, no conversions, and no sensitive electronics. VLI systems facilitate simple installation, maintenance-free operation under normal conditions, and they can be checked by anyone. Their ruggedness is an advantage in rough environments, which makes them Readability is an important aspect of suitable for use in level meters submarines, ships, offshore platforms, and refineries. Due to a variety of available materials, from plastics to pure titanium, vacuums from >600 bar and fluid densities from 0.27g/cm³ can be displayed. A temperature range from -196°C to +400°C covers media such as LNG as well as steam applications. Operating principle The VLI operating principle is based on the use of a permanent bar magnet system, which ensures the safe and reliable activation of visual indication elements (flags), switches, and transmitters, even when used on thick-wall high-pressure indicator pipe. The magnetic guide tape is integrated within the indication rail to ensure the float bar magnet is always aligned like a compass needle to the polarised flags and switches. This ensures continuous reliability of the indicating, switching and transmitter control functions. Every flag of the indication rail is equipped with its own permanent magnet. Thus the indication flags magnetically interlock with each other and so are kept in a stable position. The guide tape further enhances performance through the magnetic damping effect that produces safe and reliable indication of liquid level, even under difficult applications with rapidly changing liquid levels or vibrations. The low weight of the bar magnet permits the use of lightweight hermetically

sealed floats. These compact floats ensure the highest possible diameter difference between float OD and tube ID – an important advantage when dirty or highly viscous liquids need to be measured. A short float design also often enables a larger indication range compared to competitive products. Why no SIL? All these features should allow VLI meters to reach a high safety integrity level (SIL) rating. However, these ratings only apply to electrical, electronic, and programmable electronic systems. Although VLIs include selective (magnet switch) or continuous electronic data logging (transducer), this is not sufficient for VLIs to receive an SIL rating. The electronic components in the indicators would be fit for certification and meet the requirements, but their function is, however, only established in combination with the float, which is a mechanical component. As the electronic and mechanical components can be separated, an SIL certification for the entire system would give operators an impression of false safety. Yet, a purely mechanical level indicator is probably one of the safest systems available. The measurement principle is highly reliable and minimises system safety and environmental risks. Experience as a basis In addition to high quality standards, experience is an important factor in current and future product design. Weka, a Swiss sensor and valve manufacturer, is certified according to the marketdemanded standards and guidelines. All of the company’s products meet the relevant requirements regarding pressure vessels, explosive environments, and other norms, such as those for shipbuilding or military applications. The company’s 75-year long history and the resulting experience is a valuable asset, too. VLIs, which have been excelling in their tasks with the highest degree of reliability on a daily basis for 50 years, are a reference point for Weka’s product development. For more information:

This article was written by Stefan Otto, product manager for level instruments at Weka. Visit: www.weka-ag.ch

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

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LEVEL MEASUREMENT

Level sensors based on the time domain reflectometry technology have several advantages when working with more opaque liquids, such as olive oil

Measuring the olive level When it comes to process control, level measurement is an important task and is used in many different areas. This means that the requirements can vary greatly – they depend on the location, the medium to be measured, and also the measuring environment. Precise, reliable, and optimally efficient. These same three principles apply to level measurement as it does to other sub-processes in the production run. By selecting the right technology at the earliest possible time, inefficient processes or resource wastage can be minimised – even when different media are used. When measuring bulk materials, the mechanical strain and the kinesic behaviour of the medium impose particular requirements on the sensor. Sensors based on time-of-flight technology are the ideal choice here. They are used both to measure changing materials and for continuous level measurement. The only problem is that this technology has its limitations when it comes to clear and sticky liquids and foams.

Above: Olive oil in a stainless steel tank Right: The pumping system bottling olive oil with the level sensor attached

The ‘guided microwave’ When measuring a liquid, the differing conductivity, density, and viscosity of the medium have an impact on the result. It is also important to keep an eye on deposits, chemical resistance, and any potentially disruptive moving parts in the tanks, such as the mixer or stirrer. LFP Cubic and LFP Inox level sensors from Sick work according to the “guided microwave” measurement principle (time domain reflectometry, TDR). The electronics in the sensor create an electromagnetic pulse (reference pulse). This pulse is guided along the probe – usually a metal rod or a steel cable – via the tank entry (transmitter signal) to the surface of the medium. Part of the pulse is reflected here and runs back along the probe to the electronics. The level is calculated based on the time difference between the transmitted and received signal, taking the individual dielectric 18

constant of the medium into account. Depending on process requirements, the sensor can display the level calculated as an analogue value (“continuous measurement”) or with several switch signals (“point level measurement”). In the past, TDR technology was often seen as an expensive process but it can now be attractive in terms of price for some less complex applications. The LFP Cubic, for example, is well suited for use in metal containers and tanks within the water industry, in mechanical engineering, in machine tools, in plant

construction, and in building technology. The LFP Cubic is flexible thanks to its modular probe concept, and the fact that it is available as a compact version without probe and as variants with a rod probe, coaxial tube, or cable probe. Another advantage of this technology is that factors such as pressure, temperature, vacuum, dust, and particularly foam do not have an appreciable impact on the measurement result. Like the LFP Cubic, the LFP Inox delivers continuous measurement or point level

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

LEVEL MEASUREMENT The LFP Inox is used in the system to monitor the level of olive oil in the stainless steel tank. If the level drops below a certain predefined point, the sensor signals the pump to move more product in from the IBC tank. The pipe pressure is also monitored by the Sick PBS pressure sensor, which allows potential faults to be detected swiftly.

The LFP Inox TDR level sensor checks the level of olive oil

Advantages of separate electronics However, there are more advantages to having separate electronics, in the style of LFP Inox and LFP Cubic. It provides a great deal more flexibility and saves space during installation, particularly in tricky locations. There are also huge advantages when the product is used in high tanks. Since the electronics can be installed separately from the probe (at eye level, for example), both status and measurement result are legible at all times.

Pipe pressure during olive oil production is monitored by pressure sensors, such as the PBS pressure switch

Changes can also be made to sensor settings and parameters with ease. What is more, the electronics are better protected against process heat and the probe can also be used at high temperatures. From EHEDG to the WHG

measurement according to requirements in a single system. The LFP Inox is designed for use in hygienic processes. The sensor is EHEDG certified and the materials used are FDA compliant. The sensor can also be used without restrictions in CIP and SIP processes in the food and drinks industry due to its temperature and pressure resistance. Oil it up Speaking of the food and drinks industry, olive oil is a liquid like any other and must be properly measured and monitored during production. One of the applications the LFP sensors have been used in is a pumping and bottling system developed by Foodtech. Foodtech recently completed installing an automated solution for bottling and packaging olive oil for a retailer specialising in dried tomatoes, olives, and olive oil.

Foodtech CEO Wim Reede describes the project: “For this customer, we developed and constructed a pumping system which fills containers with olive oil automatically. Previously, they filled an average of 250 containers per day by hand, but now our customer can produce thousands of 250ml containers every day.” The olive oil is supplied in large, white IBC tanks, from which it is then pumped into a larger stainless steel tank. Next, the oil is conveyed through pipes from this tank into the two buffer tanks of the bottling system. Finally, the bottling system fills the individual containers with exactly the right amount of olive oil. During this process it is vitally important that the pressure in the pump and the pipes is always kept at the correct level. “As soon as the pressure drops due to air bubbles, there is a risk that olive oil could accumulate on the inner surfaces. It then becomes rubberlike in consistency, make cleaning extremely difficult,” Reede explains.

As the functionality of the sensors from the LFP range does not usually depend on the properties of the medium being measured, the sensors do not have to be calibrated. A key factor is the reliability of the measurement result, taking sector-specific requirements into account. In the food industry, such as in olive oil production, structural regulations regarding cleaning and sterilising the components used often have to be observed. These regulations may be developed by the European Hygienic Engineering Design Group (EHEDG) or the American 3-A Standard. For certain applications, a legal approval is also required, which can only be granted after the level sensors have been checked and certified accordingly. Legal requirements such as the German Federal Water Act (WHG) or corresponding EU directives regulate how water pollutants are handled. Those who operate facilities storing, filling, or emptying these substances must be able to prove that they have protection against overfilling in place.

For more information:

This article was written by Xaver Meier, head of marketing and sales for industrial instrumentation and 3D compact systems, Sick AG. Visit www.sick.com.

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 19

Don’t judge a tank by its bubbles MIXERS

What appears to be an aeriation problem at wastewater treatment works might in reality simply be a need for a good mixer Looks can be deceiving. At first glance there can often appear what seems to be plenty of aeration activity in an effluent tank, but in reality there is sometimes very little happening that is of much benefit to the process. Outdated equipment, such as old surface aerators, can create “a dancing tank”, which produces a great deal of noise and bubbles, but this type of equipment is only capable of aerating the top part of the tank – often accounting for as little as 20% of the total volume. Despite all the bubbling commotion, solids can and do settle in the water, resulting in unpleasant septic solids at the bottom of the tank. When a discharge permit violation or an odour problem has been identified, the dancing effluent tank scenario seems to become even more frenetic. The tendency is to throw more aeration power at it, which of course increases the utility

Landia floating air jet system in place in a tank

bills. This practice is nothing but an unnecessary An air jet mixer in action waste of energy – and still results in a poor settling sludge. Mix it up A supposed aeration problem is often nothing of the sort. What is often needed is simply a decent, appropriate mixer. When aeration equipment first began to be installed in wastewater tanks many years ago, the original design may have achieved the required balance. However, manufacturing requirements, new process technology, and legislation have inevitably seen conditions change. Thus, companies like Landia are often

called in to address wastewater problems caused by changes to production lines that have increased the biological load. There can also be issues brought about by increases in temperature, seasonal loads, in-factory waste minimisation, or improvements and additions to upstream processes. Because aeration and mixing are vital to a healthy treatment process, it is best to routinely review the wastewater element as part of the whole manufacturing process so that a fully mixed and properly aerated tank is consistently operational. Just as big a problem as over-aeration is under-aeration. Low dissolved oxygen (DO) in the tank and reduced biological activity will bring about bulking sludge, unpleasant odours and ultimately, failure to meet discharge permits. Under-aeration can also be brought about by changes to conditions such as COD/ammonia loading and increases in the tank’s temperature. Working with Roquette America, a leading producer of starch products, syrups, and polyols (sugar alcohols), Landia saw how the use of a diffused air system (fed by large blowers) resulted in constant cleaning and replacement of diffuser membranes. This included the substantial outlay of having to hire divers to enter the tanks to carry out maintenance so as not to interrupt the 24/7 operation. Installing a self-aspirating aeration system that incorporates heavy-duty

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

MIXERS chopper pumps has resulted in a completely clog-free operation and a homogenous mixture for higher airto-water transfer. Energy bills alone at Roquette have been reduced by 30% and constant laborious maintenance has now become a simple, economic annual requirement. Increasing treatment rates As with Roquette, the overall aim in the industry should be optimum configuration of aerators and mixers for maximum water treatment at minimum power use and minimum maintenance. Hydraulic mixing of the basin will depend on several factors, not just the tank’s geometry, dimensions, and layout. One needs to look at the actual hydraulic mixing power provided by aerators, as well as issues such as floor-sweeping velocities greater than 0.8ft/sec, which are required to prevent the settling of solids that lead to anoxic or anaerobic pockets. Some facilities can experience serious discharge permit violations or odour problems, but have no monitoring in place

An empty tank with an aerator visible

to tell them what is happening in the aeration basin. But those whose answer is to just divert more power to what they perceive purely as an “aeration problem” should consider the fact that low-speed, energy-efficient propeller mixers can

solve their problem at a fraction of the energy cost. Those with an aeration/ mixing requirement should not be deterred by potential downtime, because a mixer installation can very often be carried out even when the tank is full. Without proper mixing, areas of aeration tanks could be suffering from anaerobic conditions. But unless there is a noticeable odour problem, most operators can be totally unaware that this important part of their treatment process is not working as it should be. This could result in indefinitely forking out money to pay for unnecessarily high bills or failing to meet discharge standards. Without good mixing, aerobic conditions will not be achieved throughout the process vessel, resulting in poor treatment. This is particularly true for any site that has a high-strength effluent to contend with. It is recommended for any facility to try to achieve as high a degree of treatment as possible on-site with aeration and mixing to reduce total operation costs. z For more information:

This article was written by Soren Rasmussen, director at Landia. Visit: www.landia.co.uk

When failure is not an option: Egger SINCE 1947

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FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 21

VALVES

Non-negotiable! The importance of reliability in valve actuation

IMI ICO4-PST solenoid valve

Smart solenoid 1oo1 manifold

For the optimal control of many processes, it is crucial that a valve reaches a certain position. The process of moving from one position to another is governed by the valve’s actuator, a type of drive that is responsible for moving or controlling it. For safety critical applications, the actuation of the valve (the ability of the system to move the valve to a safe condition in response to demand), is of fundamental importance. Pneumatic or hydraulic actuators are a well-proven method of controlling such valves, and these fluid power actuators are, in turn, predominantly operated using an electromagnetic solenoid valve. Many solenoids operate within systems that can stay in one position for many years, with an overall lifetime of decades. They are often used in systems that ensure safety, for example to shut off, release, or distribute fluids. As such, their reliability is of paramount importance. In these circumstances, any failure in actuation can have catastrophic results, so reliability is non-negotiable. Solenoid valves have many advantages. They are flexible, being made in many designs with various ports and fluid paths. When chosen and used appropriately, they can provide safe switching, reliability, durability, and resistance to extreme conditions, extensive lifespan, and compact design. However, historically they have often been seen as the weak link in the final element assembly as they are often chosen based on cost and not design. Solenoid valves must be suitable for the environment in which the valve operates. The valve must be able to resist corrosion, dust, water, and other environmental aggression for many years and must have suitable hazardous area and safety certification. But what qualities and conditions

are required to achieve optimal operation? The answer lies in a combination of unit design and the management of operating forces. Ideal conditions The reliability of a solenoid valve is largely dictated by the forces acting within it. Chief among these are the forces of magnetic flux, retentivity, friction, and spring force. For a solenoid valve to be reliable, the optimum factors when it is closing, and those that are ideal during opening, are quite different. The ideal parameters for closure are a high force friction ratio (FFR), i.e. low internal friction and a high return spring force, and a low dangerous failure rate. On opening, the ideal conditions are: • Low internal friction • High magnetic flux to spring force ratio • A low safe failure rate Understandably, these parameters are not always achieved without effort and careful design. Dangerous failures A dangerous failure is one that prevents the solenoid valve from performing its safety function when required, on demand. This type of failure often occurs because friction and stiction have increased over time. The load holding the valve in the open position increases to the point where the spring force is no longer sufficient to close the valve. A dangerous failure occurs when spring force < friction + retentivity. In order to improve performance against dangerous failures, it is necessary to improve the force friction ratio (FFR). This is the ratio of the spring force to the friction and retentivity within the valve. The following steps can improve the FFR:

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

oves saturation point, thus maximum flux Φ ces hysteresis, thus improves retentivity ΦR Flux density

Saturation

Rententivity

Coercivity

Magnetising force

Magnetising force in opposite direction

Saturation in opposite direction

Flux density in opposite direction

Diagram of soft magnetic material improving magnetic flux

• Reduce the friction in the valve by minimising the number of dynamic seals. Dynamic seals add friction to the design, and therefore using a poppet-type valve rather than a spool valve reduces the inherent friction. • Increase the spring force. This requires improved magnetic flux, so the magnetic efficiency must be improved as the power available is typically limited by the PLC output card.

which may be termed a pull-in failure. Over a period of time, cable damage or termination corrosion can cause an increase in resistance, which subsequently causes a reduced voltage at the solenoid valve coil. Under such circumstances, the voltage may fall below the required pull-in voltage of the solenoid. During a PST, the solenoid coil is de-energised and then reenergised at the end of the test. However, whilst the coil voltage was sufficient to hold the valve in the open position,

Safe failures In safety related systems, it is important to periodically test all of the final elements to prove that the safety function is working to the required performance. This means that it is essential to test the solenoid valve in addition to the actuator and process valve. Safe failures are the biggest concern when solenoid valves are tested. There are two types of safe failure: the spurious trip (which occurs during normal operation) and the failure to operate on demand, which causes a spurious trip during partial stroke testing (PST). One example of a spurious trip could be where the solenoid coil burns out, there is a loss of magnetic flux, and thus the process valve closes. The safe failure rate will be improved if burnout can be prevented, in which case the following may apply: • Reduce the coil running temperature • Ensure efficient thermal dissipation Core tubes reduce cooling efficiency, so an integrated core, armature and coil construction may also help. The second type of safe failure is when valves fail to open on demand,

Optimising solenoid valve design, and in particular ensuring reliable actuation, is absolutely crucial to ensure good outcomes both in PST and in daily applications it is insufficient to pull-in (re-open) the valve from its closed position. As a result, the process valve completely closes, causing an unintended trip. This can be avoided by checking the coil voltage prior to initiating a partial stroke test. One way to improve safe failure rates is to improve magnetic flux, as this allows higher margin of flux over spring force. Fortunately, there are several ways of promoting optimal magnetic flux. Most solenoid valves use

VALVES

a wet armature arrangement where the internal magnetic components are exposed to the instrument media. Therefore, a corrosion-resistant material must be used. Unfortunately, such hard magnetic materials reduce the maximum magnetic flux and increase retentivity. In contrast, a dry armature, where the magnetic components are isolated from the instrument media, allows for soft magnetic materials to be used, which exhibit increased maximum magnetic flux and reduced retentivity. When looking to improve magnetic flux, the core design, and in particular the magnetic path integrity, should also be considered. A core tube design leaks magnetic flux as there are air gaps between the coil and the tube, whereas an integrated design maximises flux strength. Applications To summarise, optimising solenoid valve design, and in particular ensuring reliable actuation, is absolutely crucial to ensure good outcomes both in PST (where it maximises the diagnostic coverage and minimises spurious trips) and in daily applications. In fact, it is in day-to-day use that reliable actuation becomes most important, ensuring safety, efficiency, product quality and productivity. IMI Precision Engineering rebranded from Norgren in 2015, and continues to engineer solutions for fluid and motion control, including solenoid valves and actuators, through its portfolio of flagship product brands: IMI Norgren, IMI Buschjost, IMI FAS, IMI Herion, and IMI Maxseal. z

For more information:

This article was written by Richard Harvey, business development manager at IMI Precision Engineering. Visit: www.imi-precision.com

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 23

PAGE HEADER

Tremie Equipment for Concrete & Piling operaaons Available from 2” and in the main sizes 6”, 8”, 10” & 12” In the Tremie Concrete pouring method, concrete is placed below water or below ground level though a pipe, the lower end of which is kept immersed in fresh concrete so that the rising concrete from the booom displaces the water or Bentonite without washing out the cement content. Tremie can also be used as a noun to refer to the hopper and pipe string used to place the concrete into the cavity.

12” Tremie Rack with Liiing Points

A Heavy Duty 12” Tremie ‘working plaaorm’ and ‘suspension jig’ or ‘catcher’- that enable the assembly and disassembly of the tremie pipe string below the hopper, lowering it in stages into to the cavity that is to be concreted.

• Tremie Hopper & Pipes • Tremie Racks & SSllage • Suspension Jig & Working Plaaorm • Liiing Cap & Pump Bend • Spares and Adaptors • Concrete Flexibles & Pipeline

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8“ Tremie Pipes in a Tremie Rack FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

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Hose and ﬁﬁngs STOCKED to 24” bore - Assembled & tested to your length requirements.

Hammer Lug Unions STOCKED • Carbon Steel • Stainless Steel • H.A. Alloy • HDPE

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FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 25

SPONSORED ARTICLE

Empowered performance in automation An Italian valve manufacturer provides both valves and actuators in one package

From chemical industry to water treatment, from petrochemical to process applications, from oil and gas to the paint industry, Omal has been recognised as a reputable brand and a solution provider by its clients, not afraid to meet any challenge arising from the most demanding end users. Omal has embraced a quality-oriented philosophy since it started its activities in 1981, determined to develop addedvalue products, showing tangible advantages. The company is aware that the market will always reward producers delivering high quality products that ensure improved performance during all the different phases of plant life cycle. The first product developed and constantly improved by Omal, its pneumatic actuator, is recognised as a high quality product for process automation. Its design and construction – through a system called scotch yoke – show features and advantages from different points of view. Omal’s actuators are light-weight, have low air and energy consumption, and provide higher torque output, reducing the size of the equipment required to automate the valve and the process. To reach these results, Omal is constantly engaged in research and development, in controlling the industrialisation process, and in creating

Omal production facility

new solutions leading to measurable targets of real added value. The company calls such a mission “empowered performance”. Omal’s products, including automatic angle seat valves, coaxial valves, butterfly valves, and ball valves, offer high efficiency due to features such as the internal lapped cylinder or self-lubricated strips, which allow lower impacts in terms of energy consumption. Another significant aspect is their verified durability, a result of design research and continuous improvement of the production processes. This point leads to protecting the environment, as a product that lasts longer means a reduction in energy needed for additional production, both for the valve producer and valve user. The accuracy in product research has positive impacts also on personnel safety. Omal’s VIP automatic valves for example, feature a one-piece body containing both the actuation system and the valve and thus avoid external movements. The company’s internal spring system for actuators, with an antiblowout mechanism, avoids risks to the operator during maintenance activities. Pathways to performance R&D at OMAL – started more than 30 years ago – is still key and, after the development of the Magnum and Thor flanged ball valves, new products have been developed in order to expand the range of applications. These products are high pressure (Hercules) and trunnion mounted (Supreme) ball valves and the Heavy Duty actuators.

The main industrial sectors targeted by such products are oil and gas, petrochemical, and chemical. These products are in line with the company mission. Indeed, in addition to the required product certifications needed to act in the market (API6D, TA-Luft, for example), the R&D office conceived them to protect the environment, which is why Omal can rely on additional environmentallydriven certifications proving that its vision, ensuring a better world for our children, is truly implemented. Omal is one of the few players in the market that offers both actuator and valve production, providing customers with a 360° solution and not just a single product. Moreover, Omal is one of the few producers that performs its whole production process in its own country. Indeed, Omal keeps its entire production in Italy, from the foundry to the final assembly, thus maintaining full control on the whole production process. This is all evident in the plants in Villa Carcina and Rodengo Saiano, Italy, where the Omal team implements the company philosophy working passionately and seriously. Innovative and reliable valves and actuators are not “simple” components of a plant, they are key products ensuring empowered preformances in terms of efficiency and sustainability within the entire plant. With this in mind, Omal provides solutions to give businesses a truly empowered experience. Floating ball valves – Thor series The Thor series is designed and engineered to ensure maximum performance in terms of resistance to severe applications and especially to endure high cycle frequencies. The Thor series adopts design and technical features exceeding the toughest tests required by market applications.

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

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SPONSORED ARTICLE yoke systems for its pneumatic actuators in aluminium, has developed a series of Heavy Duty actuators in carbon steel for its pneumatically operated valves (mainly trunnion), aimed at applications where aluminium cannot be used. The Heavy Duty actuators are available as double acting and single acting versions up to 32,000Nm, and they are designed for installation in aggressive environments. They are therefore delivered with a surface coating Thor series floating designed to adequately ball valve protect the the actuator. The Supreme series The available sizes range from trunnion valves with both aluminium and DN15 (1/2”) to DN200 (8”) with flange carbon steel Heavy Duty pneumatic available for EN 1092-1 for ASME B16.5. actuators make Omal one of the few The valves are available in materials companies capable of providing the ranging from mild steel to carbon A105, LF2, stainless steel AISI 304, 316, and special steels as defined in exotic and pressure classes from PN 16 / ANSI 150 to PN400 / ANSI 2500. Trunnion valves – Supreme series To meet the increasingly frequent requests received from the petrochemical and oil and gas industries, Omal has developed the Supreme series trunnion mounted ball valves, which complete the range of floating ball valves. The Supreme series meets the needs of applications requiring ball valves with DN, durability, reliability, and pressure classes not achievable with floating valves. The Supreme Series valves are entirely produced, assembled, and tested in Omal’s own factories, with pressure classes up to ANSI 2500. They are available in sizes up to 24” and in several materials. In addition to the standard carbon steel and stainless steel, the trunnion valves are often made according to customer specifications, running service within the process for which they are intended. In such cases so-called exotic alloys such as Hastelloy, Inkonel, super Duplex, and many others are used. Pneumatic heavy duty actuators Omal, with more than 30 years of experience in the production of scotch 28

Supreme series trunnion valve

entire valve/trunnion package from a single manufacturer in a single location. All Omal products can be viewed at its factory factory in Rodengo Saiano. Products of certified quality Omal does its best to comply with the most advanced certifications and standards, well aware that this is an ongoing process towards an improved and trustworthy brand reputation. Omal products are designed and manufactured to provide the best performance in terms of reliability and durability. The quality and reliability of Omal valves and actuators are widely confirmed by the product certifications the company holds, among which the most important are: • API6D (ball valves series) • SIL3 (actuators and ball valves series) • Fugitive emissions (ball valves) • TA-LUFT (ball valves) • Fire safe API607/ISO10497 (ball valves) • RINA (butterfly valves) • DVGW (butterfly valves) Omal’s ball valves are 100% in-house manufactured with Quality System ISO 9001 and in accordance with the requirements of the ISO14001 environmental certification. Raw materials are certified and registered to maintain full traceability to the end of the assembly and testing process. Omal is also AD2000 certified. z For more information:

This article was written by Lucia Dal Negro, social innovation manager at Omal S.p.A. Visit: www.omal.it

Actuators • Actuators (scotch yoke system): In aluminium, up to 4,000Nm single acting and 8,000Nm double acting • Actuators (scotch yoke system): In stainless steel up to 1,920Nm double acting and 960Nm single acting for special services or environments where use of the stainless steel is required • Pneumatic Heavy Duty actuators: In carbon steel with torques up to 32,000Nm • Electric actuators (on-off and modulating Type) Valves • Floating flanged ball valves (from solid bar) for high cycles applications: Magnum (wafer/split wafer) and Thor (split body) • Floating ball valves, manually operated with cast body: Stark (wafer) and Spartan (split body) • Trunnion mounted ball valves: Supreme, available up to 24” • High pressure ball valves: Hercules • Pneumatic valves coaxial: VIP • Angle seat valves: Ares, Athena, and Zeus • Butterfly valves: Wafer type and Lug type • Ball valves in various materials (brass, stainless steel) and configurations (one-piece, three-piece, threaded, soldered)

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

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Host

StrategieS For the New eNergy LaNdScape Keynote speaker

Keynote & Opening ceremony speaker

rex W. Tillerson Chairman & Chief Executive Officer Exxon Mobil Corporation

WOrld’s largEsT TEchnical Oil & gas cOnFErEncE

dr sultan ahmed al Jaber Group Chief Executive ADNOC

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Bob Dudley CEO BP

CEO TOTAL

Alexander Medvedev

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Dr Daniel Yergin

Sir Richard Shirreff

Deputy Chairman, Management Committee GAZPROM

President and CEO OCCIDENTAL PETROLEUM CORPORATION

Pulitzer Prize-Winning Author

Deputy Supreme Allied Commander NATO Europe 2011-2014

Jeff Miller

Toshiaki Kitamura

Paal Kibsgaard

Lars Christian Bacher

President HALLIBURTON

President and CEO INPEX/JODCO

Chairman and CEO SCHLUMBERGER

Executive Vice President Development and Production International STATOIL

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to regiSter aS a deLegate 1. Online: www.adipec.com/confreg 2. Email: adipec.delegate@dmgeventsme.com 3. Tel: +971 2 6970 517 4. Fax: +971 2 4444 383 1

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FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 29

A heavy-duty solution PUMPS

Grinder pumps allow plant operators to perform three process steps with only a single piece of equipment Solids and particles suspended in liquids can be a huge challenge, especially when one of the process requirements is to disintegrate them while forwarding a homogenised product. The equipment in such processes, like pumps, wears out fast and can fill up with sediment. Before creating a bottleneck by using a pumping solution that is not entirely dedicated for such tasks, it is worth looking for alternatives that are able to do all three jobs â&#x20AC;&#x201C; grinding, pumping, and mixing. So called grinding pumps are a combination of a pump and a grinder. Thanks to this combination of two process steps that are usually performed separately by two individual systems, they can perform as a heavy-duty solution in demanding processes with high solids contents. Grinding pumps grind, chop, macerate, mix, and pump multiphase media all at the same time. Another advantage of this pump type is its ability to create turbulent conditions leading to a better mixing of the liquid and the solid phase. In many areas, this effect can save the costs of a static or dynamic mixer. Grinding pumps can be used in various industries and processes

such as in the chemical, oil and gas, food, pulp and paper, power, wastewater, or paint industry. They are designed for a wide range of fluids, such as adhesives, bitumen, carbide sludge, granulated plastics, pigments, and sewage sludge. Here are two examples of how and why grinder pumps are suitable for highly solids-laden applications. In both examples, the installed pump could help increase operational reliability and safety. The two examples In a chemical plant producing PVC, the grinder pump solution is installed to chop suspended fibres into controllable particle sizes. The production of PVC generates a lot of fibre, and to protect the downstream process equipment installed in the plant from clogging, the fibre needs to be chopped and the standard deviation of the particle size has to be narrow at all times. The end user selected the CP ZMP grinding pump to execute this process since all of its stringent requirements were met. The wear of the mechanical parts from the solution in place needed

Grinding pumps like CPâ&#x20AC;&#x2122;s ZMP are the heavy-duty solution when it comes to applications laden with solids that need to be mixed, disintegrated, and then forwarded

to be reduced and the particles had to meet the previously defined size exactly. Therefore, the grinder pump needed to be customised to these very specific customer needs. Furthermore, it had to be corrosion resistant. As the ZMP pump is available in many different alloys, the pump could be adapted easily to meet this demand. The second application reference is within an industrial water treatment process located in an oil and gas facility. Waste generated in the plant consists of tar and organics. To accelerate the decomposition and clean the water from waste, the particles need to be significantly reduced in size and then projected to the surface of the liquid phase in a homogeneously mixed state. The ZMP grinder pump was selected here again to execute all three functions: pumping, grinding, and mixing. Similar to the previous example, the customer was looking for a corrosion resistant solution to minimise wear and tear of equipment. A matter of design The ZMP is capable of being more resistant than other grinder pumps due to its unique design. The core of the pump is a blade rotor mounted at an oblique angle on the shaft. When the pump is running, the oblique rotating blade creates a tumbling motion that accelerates the medium in both an axial and radial direction, carefully mixing the material being pumped. The rotor rotation simultaneously generates a centrifugal force that accelerates the medium radially through the casing liner and finally discharges it through the discharge nozzle at a higher pressure. Teeth on the rotor blade and on the casing liner grind the solid particles in the medium to a controlled defined maximum particle size. Slots and holes allow both coarse suspensions to be pumped and soft particles to be broken up. The casing liners can be customised to a specified particle size. So far, market demand has been

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

PUMPS

Grinding pumps are designed to meet most stringent quality standards and ensure reliability and utmost safety in production operations

it can pay off to look for a combined solution. With a grinder pump, three relevant process operations can be performed by only one solution, namely grinding, pumping, and mixing. The advantages are obvious. Only one piece of equipment needs less maintenance and monitoring, thus reducing maintenance effort and costs. The apparently higher investment is compensated by lower piping and fittings costs and therefore significantly reduced space requirements. Users select this solution for its compactness, its simplicity, and its durability. z

such that the economics have not been attractive enough to motivate the development of a grinder pump with a magnetic coupling. However, the double mechanical seals in grinding pumps still perform outstandingly concerning safety and reliability. In addition, they offer better conditions for demanding substances that need to be pumped as well as ground and bring significant advantages in hygienic applications. The production of parts in many

This article was written by Jessica ZĂśhner, head of marketing and communications, and Jean-Luc Quenot, head of sales at CP Pumpen. Visit: www.cp-pumps.com

different alloys is not very common in the market. But there are suppliers like CP Pumpen in Switzerland that do offer a wide choice of alloys, hence adding more value for the customer who can choose the suitable pump solution tailored to his needs. Conclusion Whenever particle size and solids in high concentration are an issue in a process,

For more information:

www.cp-pumps.com

Reliable operations even with challenging media? CP pumps keep your production running. As one of the leading manufacturers of energy efficient magnetic drive pumps for pharmaceutical and chemical industries, we offer products that are exactly tailored to your needs. No matter how critical your medium is, our experts will find a solution. The result: your pump, which keeps on running and running â&#x20AC;&#x201C; reliable, safe and low on maintenance.

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 31

A smooth operator

PUMPS

Flow conditioners can be essential to optimising pump performance and reducing downtime and maintenance costs Industrial pumps consume up to 20% of the world’s energy production and can be responsible for 25 to 50% of a process plant’s energy bill, according to Europump, the Hydraulic Institute, and other sources. Nothing moves without them in a process plant, and they are expensive to purchase, maintain, and even more to repair or replace. Reducing pump lifecycle costs (purchase, operation, and maintenance) is critical in a process plant optimising efficiency and product output. The process and the surrounding equipment configuration can be responsible for unnecessary high pump lifecycle costs. Plants that are concerned about pump efficiency and costs can find some of the fastest returns-on-investment (ROI) by optimising pump process control loops and protecting pumps against common hazards. Smooth running pumps at full efficiency always provide a payback. There are some simple pump optimisation strategies that work well, starting with an analysis of process media flow rates.

through-put objectives and demand in many industries, such as refineries, specialty chemicals, food/beverage and more. Irregular material flow is one of the most common impediments to efficient pump operation. The result of irregular material flows can include distorted and asymmetric velocity profiles, turbulent flow, low flows, or even dry running conditions. Controlling material flow ensures that pumps operate efficiently, moving stock or products with the least possible expenditure of energy while reducing maintenance requirements and extending service life. When material flow is irregular, the result can be expensive in terms of equipment maintenance and service life due to cavitation, uneven loads on bearings, and seal failure. Cavitation is a destructive and all too common problem, reducing process flow capacity, and can cause process quality issues. The loss of bearings or seals can lead to pump shutdown, and possibly even a full process line shutdown. These are unfavourable conditions, especially in combustible or toxic material processes.

Optimising plant processes Start with flow analysis With today’s focus on turning plants into 24/7 lean operations, the pumps in most plants are running nearly at full capacity most of the time to keep up with material

A tab type flow conditioner

Pump efficiency begins with analysing the flow. Is the media flowing regularly and at the pressure required by the pump with a

minimum head loss? Irregular and distorted flow regimes can be especially challenging to diagnose and correct. Eliminating their causes is often difficult, expensive, impractical, or impossible, so operators have to work around them instead. For example, in low flow or dry running conditions pump damage can occur when liquid flow dramatically reduces or completely stops. With no liquid flowing to provide cooling, the heat can destroy a pump’s bearings or seals. In addition to pump replacement or repair being expensive, these types of pump failures often ruin the material being processed and reduce process line capacity. Creating regular flow profiles Pumps require a stable upstream flow profile in the pipeline before liquid enters the pump for efficient operation. When unstable flows or swirl are present, they often result in cavitation, noise, or uneven bearing wear. One commonly cited industry pump installation best practice guideline suggests at least 10 diameters of unobstructed pipe be placed between the point of pump suction and the closest upstream flow disturbance. In modern process plants, many real estate restrictions result in the placement of elbows, valves, or other equipment too close to pumps. Such flow disturbances can generate media swirl and velocity profile distortions, which can then result in excess noise and cavitation, causing wear that shortens pump bearing and/or seal life. Installing flow conditioners upstream from pumps helps ensure an optimal flow profile for efficient operation. Eliminating the effects of velocity profile distortions, turbulence, swirl, and other flow anomalies will result in a repeatable, symmetric, and swirl-free velocity profile with minimal pressure loss. Pump life generally increases in a less stressful operating environment. Conditioning the flow stream ensures it meets the impeller with a uniform and equally distributed flow pattern, which

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

PUMPS optimises pump efficiency while extending bearing life and decreasing cavitation. Tab type flow conditioners, such as the Vortab flow conditioner, have proved successful in resolving irregular flow conditions. Other flow conditioning technology choices, including tube bundles, honeycombs and perforated plates, can also be considered depending upon the specifics of the process application. Tab type, which includes elbow flow conditioners, are designed with vortex generating conditioning tabs to produce rapid cross-stream mixing, forcing higher velocity regions to mix with lower velocity regions. The shape of the resultant velocity profile is “flat” and repeatable regardless of the closecoupled upstream flow disturbances. Incorporating anti-swirl mechanisms into the design of the tab type flow conditioners eliminate the swirl condition typically seen exiting 90° elbows. The result is a flow stream that enters the pump in such a way that it maximises the efficiency of its operation and reduces stress. In addition, the tapered design of the antiswirl and profile conditioning tabs make them immune to fouling or clogging. Assuring pump flow To eliminate the potential damage from a low flow or a dry running condition, a point flow switch can be installed in the process loop. Combination point flow switches will detect not only a low flow situation, but also detect a dry running condition. This capability allows the control system or operator to take corrective measures before the bearings of the pumps are overheated and fail. There are many types of point flow switches available. For example, the FCI FlexSwitch FLT93 Series, with its no moving parts design, offers a highly robust solution for pump protection with its dual alarm capability. When alarm 1 initiates, the switch will have detected a low flow situation Flow/level/temperature FlexSwitch

anywhere between 0.003 to 0.9m/s. This low flow alarm can be regarded as a pre-warning signal for the control system or operator, who can then decide to keep the pump running or to shut it down. Should an alarm 2 occur when the feed line to the pump is running dry, this condition would be an emergency signal to shut down the pump immediately because the bearings now see gas instead of a liquid as a heat transfer media. In such situations, the temperature of the bearings may rise quickly to the point where they are damaged. Using a flow switch prevents permanent damage to the pump’s bearings. The FLT flow switch is a dual-function instrument that indicates both flow and temperature, and/or level sensing in a single device. It can be specified in either insertion or in-line styles for pipe or tube installation. This single switch monitors direct variable interest, flow, and temperature simultaneously with high accuracy and reliability. The dual 6A relay outputs are standard and are assignable to flow, level, or temperature. Choosing a flow switch When considering a flow switch for pump protection or any other application, the first step is choosing the appropriate flow technology. There are multiple flow switch sensing technologies available, and the major ones now include: • Paddle • Piston • Thermal mass • Pressure • Magnetic reed All of the flow switch technologies have their advantages and disadvantages, depending on the media and application requirements. In some media or processes there might be only one choice. Operators should be sure to review their plants’ layout, environmental conditions, maintenance schedules,

energy cost and ROI, which will help them quickly narrow the field best choices. Conclusions Pump requirements should be considered a top priority when designing new plants, adding plant capacity, or when retrofitting older facilities. Optimising processes with pumps in mind offers a wide range of benefits, including higher capacity, improved quality, lower energy costs, reduced maintenance, and longer equipment life. It is also good to keep in mind that a distorted velocity profile is one of the most common pump problems that frequently results when the minimum pipe straight run required between the point of pump suction and elbows, valves, or other equipment is either ignored or pushed to/beyond the limits. The installation of a flow conditioner frequently eliminates cavitation, vibration, and noise issues. Pumps needs protecting from accidental low flow or dry running conditions, which can lead to bearing or seal loss requiring expense repairs. Installing a dual alarm flow switch in a process loop not only protects the pump from damage, but will alert operators to a potential problem and let them make adjustments before a shutdown is necessary. z

For more information:

This article was written by Don Lundberg, senior member of technical staff at Fluid Components International. Visit: www.fluidcomponents.com

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 33

PUMPS

Optimising energy consumption in pumping systems Major cost savings can be realised by carrying out energy audits to optimise energy consumption in pump systems

Pumping systems account for nearly 20% of the world’s electrical energy demand and between 25% -50% of the electrical energy usage in certain applications. Pumps are the single largest user of electricity within industry across the EU, consuming over 300TWhpa of electricity, which in turn accounts for over 65Mt of CO2 a year. It is also well documented that rotodynamic pumps, which account for 80% of the installed base, are between 2030% oversized. There is therefore a major potential to save energy if rotodynamic pumps are properly sized and operated. To be able to begin making cost and energy savings, operators must first have a thorough understanding of their pumping system. To identify if a pumping system is sized correctly, the following checks should be made: • Is liquid flow being wasted? • Is the system creating additional pressure? • What is the control philosophy? • Is there excessive noise in the system? • Proactive equipment replacement to current EU legislation Choosing the right equipment is also a challenge in itself, and it requires understanding drive technology.

Operators can use the latest EU regulations to achieve best possible drive efficiency in the following areas: • Variable speed drive • Integrated control and monitoring • Permanent magnet technology Choosing the supplier While choosing the supplier is ultimately up to the judgment of the operator, it is recommendable to choose a supplier that is a member of a recognised trade association, such as the British Pump Manufacturers Association (BPMA). Companies that are part of the BPMA are able to use the BPMA logo in their marketing efforts. By ensuring a pump supplier is a member of BPMA, it will be guaranteed to operate within the agreed standards and Code of Practice. The great majority of pump systems are not designed with energy conservation as a major consideration. If pump systems are initially designed on an energy efficiency basis and pumps are correctly applied and sized, the energy savings will often be in excess of 50%. To design an energy efficient pump system, all of the following criteria should be taken into account: • Basic plant layout

Graph of pump performance efficiency

• Pipe work configuration and restrictions • Liquid velocity in pipe work • System characteristics and pump selection • Pump/system control Low energy costs are a direct result of selecting the correct pump and matching it to the system. When selecting a pump, it is important to determine the required flow and pressure to be generated by the pump. The flow may be determined by a process requirement, by the heating or cooling required in the system, or by the peak water demand for utilities. The pressure required may be to elevate the liquid within the system or to overcome the pressure losses in the system created as liquid passes through it. It is important to know as much about the pump system as possible and to create a pressure/flow profile for the system. The energy required to drive the pump is directly related to the flow and pressure required. To generate high pressures generally leads to designs that may be inefficient, and therefore it is important that neither the flow nor the pressure is overspecified. Variable speed drives can save energy

Costs of saving 1kg of CO2 emissions

It is estimated that significant energy savings have already been made by using variable speed drive and high efficiency FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

PUMPS motors. Generally, variable speed drives energy and are used to continually adjust the speed maintenance It is estimated that significant energy savings have already been made by using variable speed drive of the pump to the demand. The savings savings can be and high efficiency motors. Generally, variable speed drives are used to continually adjust the speed can be determined by the affinity laws: achieved.

of the pump to the demand. The savings can be determined by the affinity laws:

Has ease of maintenance been allowed for? When designing or replacing pumps, ease of future maintenance requirements Q = flow, H = head, P = power, and n = rotational speed Q = flow, H = head, P = power, and n = rotational should be Life cycle cost percentages of pump ownership speed considered. When building a new pumping system, most pumps are selected with a "safety factor" for potential future uprates or to allow for wear in the pump or fouling of the system. Often there are many When building a new pumping system, Variable speed drive considerations different parties involved in specifying and building a system and the safety factor can grow exponentially. This results in the pump delivering much higher flows than required. There may also most pumps are selected with a “safety When fitting VSD to a pumping be the need to vary the flow due to process conditions or varying heating and cooling needs within factor” for potential future uprates or system, output and input filters buildings. to allow for wear in the pump or fouling should be considered, along with of the system. Often there are many insulated motor bearings. Traditionally, throttling is used to regulate flow in a pumping system. While throttling reduces the different parties involved in specifying flow, the motor is still running at full speed and works even harder as it has to work against a restriction. By reducing the speed of the motor, the variable speed drive ensures no more energy and building a system and the safety than necessary is used to achieve the required flow. A centrifugal pump running at half speed factor can grow exponentially. This consumes only one-eighth of the energy compared to one running at full speed. Utilising an electrical results in the pump delivering much variable speed drive is the simplest and most economical way of controlling the pump and matching higher flows than required. There may it to the pump system. also be the need to vary the flow due Q&A <ALISON: The below are not subheads, just highlighted until ‘energy audit’> to process conditions or varying heating Questions for engineers, project managers and buyers to ask when optimising energy consumption in and cooling needs within buildings. pumping systems: Traditionally, throttling is used to regulate flow in a pumping system. While Has an alternative configuration been considered? throttling reduces the flow, the motor In some cases moving from an existing pump layout to an alternative can offer energy saving possibilities. is still running at full speed and works even harder as it has to work against Is the pump performance monitored? a restriction. By reducing the speed of Maintenance By looking for early signs of pump wear, which can include increased noise, vibration, or power the motor, the variable speed drive When maintaining pumping consumption, major energy and maintenance savings can be achieved. systems it is recommended to ensures no more energy than necessary Has ease of maintenance been allowed for? is used to achieve the required flow. use original manufacturers’ When designing or replacing pumps, ease of future maintenance requirements should be considered. A centrifugal pump running at half recommendations and parts. speed consumes only one-eighth of the Variable speed drive considerations energy compared to one running at full Reliability/security When fitting VSD to a pumping system, output and input filters should be considered, along with speed. Utilising an electrical variable Efficient, well maintained pumps insulated motor bearings.

It is recommendable to choose a pump supplier that is a member of a recognised trade association

speed drive is the simplest and most economical way of controlling the pump and matching it to the pump system.

are more likely to be reliable and unlikely to fail prematurely and cause loss of production or services.

Questions and answers

Valves Valves are considered to waste energy within a pumping system. However, if installed, they should be checked for correct operation.

Questions for engineers, project managers and buyers to ask when optimising energy consumption in pumping systems include: Has an alternative configuration been considered? In some cases moving from an existing pump layout to an alternative can offer energy saving possibilities. Is the pump performance monitored? By looking for early signs of pump wear, which can include increased noise, vibration, or power consumption, major

Pumps not in use Stand-by pump units or pumps with no demand should be switched off to save energy. Is the pump working most of the time close to its best efficiency point? Rotodynamic pumps operating away from BEP not only waste energy, but also reduce the life expectancy of the pump.

System alterations When upgrading, changing, or expanding a pumping system, the demand may have changed and existing pumps may not be the most efficient solution. Purchasing the correct pump set When purchasing a pump set, price should not be the deciding factor. If a pump is sized correctly the return on investment is shorter. Likewise, if a pump is oversized and is wasting energy, going forward operators will have this additional cost for the anticipated life of the pump set. Has energy check been done on existing system? Under UK ESOS regulation, all non-SME organisations are mandated to carry out energy audits. Pumping systems can offer substantial energy savings. Running an energy audit When specifying a new pump, operators should ask for a high efficiency motor to be fitted. If replacing or rewinding a motor, then the cost of fitting a high efficiency motor should be evaluated, remembering to factor in the running savings that will pay back any increase in cost. Investing in carrying out an energy audit is also recommended, as is reviewing utility bills and understanding the energy consumed in the process. An audit should be carried out if: • Energy bills are high • The plant has continuously operating pumps • There are many pumps in the system • There are processes with varying flows • Throttled pumps are being used • Pumps are on bypass • There are noisy valves or pipework • Critical systems have been subject to breakdowns

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 35

PUMPS The purpose of an energy audit is to reduce operating costs by reducing energy consumption, and the UK government has estimated that most companies can reduce their energy consumption by 10% to 20%. Energy audits carried out by BPMA members have shown that savings from 30 to 50% are not unusual. When deciding whether or not to carry out an energy audit, a good starting point is to assume that at least 10% of current energy consumption will be saved. By reviewing utility bills, operators can get an indication of the savings to be made and investment that should be prepared to be put into the auditing process. In most industrial sites, about two-thirds of the energy is consumed by electric motors. In its lifetime, the cost of energy consumed by an electric motor may be 100 times its purchase cost. Therefore, the reduction of losses in the motor itself is very important and modern electric motor design can reduce the energy loss in the motor by up to 30%. Many pumps and motors are operated at full

It is important to know as much about the pump system as possible and to create a pressure/ flow profile for the system power constantly, irrespective of process needs, and in some sites this offers the potential of large cost reductions. BPMA involvement Given the amount of energy consumed by pumps through their normal operation, and the potential for energy efficiency gains within pump systems, the BPMA has developed a Certified Pump System Auditor Scheme (CPSA). Through the CPSA, pump engineers are being trained to correctly assess the efficiency of pump systems, and to provide appropriate recommendations in order to improve

the efficiency of those systems. The CPSA accreditation is achieved by successfully completing a four-day residential course, followed by the satisfactory completion of a pump system audit. Only then can “Certified Pump System Auditor” status be achieved. Within the full ESOS Guidance document, the ISO/14414-Pump System Energy Assessment standard is referenced as an auditing methodology that can be accepted by “Lead Assessors” approved by the Environment Agency. Accordingly, it is hoped that CPSA accredited persons (who are trained according to the IS0 14414 standard) will be recommended by Lead Assessors to undertake the pumping system elements of company-wide energy audits. z

For more information:

This article was written by Steve Schofield, director and CEO of the British Pump Manufacturers Assocation. Visit: www.bpma.org.uk

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FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

Electricity trumps air

PUMPS

An electric double diaphragm pump can provide operators with process security and greatly reduced energy bills Centrifugal pumps often have unwanted effects on sensitive materials. When material is fed into the pump, operators cannot always be sure of what is going to come out from the other end due to the high rotational speed of a centrifugal pump, which can change the structure of the material. Especially in food and cosmetics applications, where product ingredients need to be transferred without any change to the consistency and structure of the ingredients, low shear, low pulsation pumps are required. Operators of progressive cavity pumps also know that a close eye has to be kept on them in case they run dry. Otherwise, the whole production process is in trouble. In fact, if a progressive cavity pump runs dry, operators might soon find themselves calling their procurement manager to arrange for the delivery of a new pump. And that is not to mention the difficulties with pumping particle-laden products. The electricity factor The Graco SaniForce 1040e pump is the first electric double diaphragm transfer pump with all the features of an air-operated pump. The electric drive provides energy efficiency, quiet operation, batching, and dosing capabilities. While it consists of the same fluid parts as a conventional

Cutaway of the SaniForce 1040e

SaniForce 1040e as a standalone and cart-mounted version

air-operated diaphragm pump, this pump can self-prime, stall under pressure, pump particles, and run dry. The SaniForce pump features an airfilled centre section. With every rotation, the electric drive pulls the diaphragms, which are not mechanically connected with each other. The air in the centre section pushes the opposite diaphragm out, allowing the pump to operate. This design not only reduces pulsation but also allows the pump to stall under pressure. The centre section can be aluminium or stainless steel, while the fluid section can be aluminium, polypropylene, or stainless steel. Maximum fluid working pressure is 4.8 bar, while the air pressure operating range is 1.4 to 5.5 bar. The pump can also be mounted on a cart and is available in brushless DC, AC and, AC ATEX options. The pump comes in two motor versions, both AC and DC. With the controls on the DC version, the pump can deliver product and then stop pumping with 1% precision. The brushless 2HP DC motor offers increased control, maintenance and alarm notification, batch operation, and meets API 675

and ANSI 7.1-7.5 standards. The electric 2HP AC motor increases efficiency, ATEX options, and runs on 110V, 220V, or 480V. The SaniForce 1040e can stall under pressure without installing pressure sensors and without damaging the pump or the production line. This means operators do not need to worry about blocked or clogged lines or closed valves. Stalling increases diaphragm lifetime, and reduces the threat of contamination as there is no hydraulic backing. Its energy efficient electric drive reduces energy consumption by up to five times compared to traditional air operated diaphragm pumps. In applications where saving energy is the key driving force, the SaniForce 1040e is an interesting replacement for AODDs running in continuous duty applications. A comparison can be drawn between the SaniForce 1040e 1” EODD with a conventional 1” AODD. Let us say that both are operating for 24 hours at a flow rate of 95l/min and a fluid pressure of 3.5 bar. The air required for the 1040e is 0.6l/day, while the air required for a conventional 1” AODD is measured at 700l/min. This corresponds to an annual operating cost for the SaniForce 1040e of €460, compared to €2,300 for the conventional 1050 AODD, marking a five-fold cost saving. z For more information:

This article was written by Walter Leeten, product marketing specialist process at Graco. Visit: www.graco.com

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 37

PUMPS

A fresh approach

A new type of impeller solves issues with clogging pumps in wastewater applications When it comes to selecting the most appropriate type of impeller, there is no shortage of choices for pumping wastewater and effluent. The most important factor in impeller selection is the operating reliability and this can only be obtained by choosing the right size for the free passage. This should take into account the gas content, the fibrous matter content, the size of solids, the dry substance content, and the sand/ grit content of the pumped medium. In order for a pump to reach its optimum operating point, it is essential to select the correct impeller and size it correctly for the application. Whilst free-flow or “open” impellers enable suspended solids in wastewater to pass more easily through the pump than closed single channel or multichannel impellers, they do not compare favourably when it comes to performance. Thus, the goal in improving performance has been to develop

an open impeller that can achieve and even exceed the efficiency levels associated with single-channel impellers. To open or not to open Open impellers offer the benefit of allowing debris that might foul the impeller to be dragged along and in the process rubbing against the front and rear stationary wear plates. This grinds down solids to a size where they can pass through the impeller. This works well with soft materials, but does not achieve the desired results if the solids are hard, as they will damage both the impeller and the wear plates. The impeller vanes also have to be fairly thick. The Vortex impeller, however, addresses these issues as the semi-open design can withstand harsh conditions due to the hydraulic vortex technique, which is based on a whirlpool. The vortex is created by the rotating recessed cup-shaped impeller extending into the suction line, drawing liquid/ solids into the pump and then rapidly through the discharge, minimising fluid/ solids contact with the impeller and volute. This simple design allows solids to pass though the pump without choking the impeller, so reducing wear and potential blockages. It is these reasons that convinced pump manufacturer KSB to work on a new design of vortex impeller for its Amarex KRT pump that would meet the growing demands for submersible motor pumps that resist clogging, deliver reliability, and contribute to improving energy efficiency. Impeller development

The F-max impeller

Cutaway of the Amarex KRT F-max pump

According to KSB, the first stage in finding a solution to clogging was to differentiate between rigid and non-rigid solids. Michael Lebkuecher, who headed the product management solid burden pumps, comments: “Rigid solids need

to have sufficient space in the pump chamber for them to pass through the pump. When it comes to non-rigid solids we have to ensure that the presence of wet tissues and similar fibrous materials do not form a mass. These problems were resolved, but then the next challenge was to address overall efficiency.” Fibrous materials, such as hygienic wipes, have become a major problem in wastewater transport, as their use has markedly increased in the last few years. As a result of the trend towards conserving drinking water and separating stormwater and wastewater, the wastewater to be handled has become “thicker”. This is why operators now demand non-clogging impellers that offer reliable operation without sacrificing high efficiencies, even for small wastewater pumps. Based on decades of experience in free-flow impeller design, computational fluid dynamics (CFD) provided detailed knowledge about the complex flow

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

PUMPS processes inside the pump via computeraided simulations. Using this information led to the design of the six-vane F-Max impeller. The six vanes on the surface of the vortex impeller are spaced at irregular intervals that creates gaps which allow rigid solids to pass through the impeller, even when the impeller is close to the suction cover. Machining grooves into the surface of the reverse side of the impeller spread out from the centre balances the axial thrust. Making a groove rather than a vane means that the impeller can be moved closer to the suction cover, thereby minimising the gap. Swirly motion Having resolved the issue with rigid solids, KSB’s designers turned their attention to that of soft tissues and similar fibrous materials. Blockages involving soft materials start at the hub or “eye” of the impeller. There is a physical reason for this. The revolving motion of the impeller introduces velocity, and the greater the distance from the centre of the impeller, the greater the velocity. If there is material at the centre of the

impeller, the speed will be insufficient to eject the material, which means that a swirl has to be created to remove it. The three-dimensional swirl comes from the radius and shape inside the impeller vanes and it is this which moves the materials through the system. The F-Max achieves a highly effective swirl motion through a slight convex profile at the hub of the impeller, achieving efficiencies that have previously only been reached by single-channel impellers. When rotating, the impeller creates a strong swirl that keeps solids in suspension, significantly reducing the risk of clogging. Since the radial forces and vibrations created by the new impeller are usually lower than those of single-channel impellers, the service life of shaft seals and rolling element bearings is increased. Pumps with F-Max impellers therefore require only minimal maintenance and replacing the impeller itself is also straightforward. The Amarex KRT F-Max impeller can handle wastewater, riverwater, stormwater, municipal wastewater, sludges, industrial wastewater, seawater, and brackish water, delivering flow rates of up to

An Amarex KRT F-max pump

130m³/h and heads up to 60m. In order to accommodate these applications, impellers are available in cast iron, stainless, and acid-resistant duplex steel. z

For more information:

This article was written by Bryan Orchard, a freelance journalist, for KSB. Visit: www.ksb.com

How do you get an accurate and reliable signal from your manual linear valves to your DCS? VPI is the most reliable position indicator available. Sensors are protected inside the body and its sophisticated mechanism generates an accurate signal. VPI fits any type of multi turn or gearbox operated valve with universal mounting materials. Do you want to see for yourself? Visit our stand B33 at Tank Storage Asia, 27 & 28 September in Singapore.

Interested how VPI can improve your process performance? Contact us now! Find your local agent on www.netherlocks.com

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 39

PUMPS The Flygt Concertor pump

The newbie with a history World’s first wastewater pumping system with integrated intelligence solves clogging issues at Heathrow Airport Across the wastewater sector there is a demand for ever more efficient and intelligent technologies that solve the complex challenges facing those working in the sector on a daily basis. Customers are increasingly considering the total lifetime cost of technology and systems, rather than just the initial investment cost. Frost & Sullivan’s report European Smart Pumps Market for the Water and Wastewater Industry (2014) notes that a sustained focus on energy efficiency and a reduction in the total cost of ownership of pumps are likely to lead to an increased demand for intelligent pumping solutions. Similarly, a recent report by water solutions company Xylem, called Powering the Wastewater Renaissance, found that high-efficiency technologies could reduce electricity-related greenhouse gas (GHG) emissions from the global wastewater sector by up to 50%. Adopting these technologies would also have a significant impact on the GHG emissions responsible for fuelling climate change – equivalent to removing 11.4 million cars from the road, according to American Forests, a non-profit organisation based in the US. The analysis also suggests that much of this reduction in electricity-related emissions can be achieved at a negative or neutral cost.

senses the operating conditions of its environment, adapts its performance in real time, and provides feedback to pumping station operators. It offers high pumping efficiency and reliability as well as a lower overall cost of ownership. The system simplifies the entire pumping process from selection, installation, commissioning, and monitoring with the added bonus of a smaller footprint. Fields tests conducted around the world have validated improvements with Flygt Concertor, including: • Energy savings of up to 70% compared to a conventional pumping system • Reduced inventory by up to 80% due to flexible performance • Clog-free pumping operation

and clean wet wells saving up to 80% in vacuum cleaning costs • Compact design, reducing cabinet size by up to 50% One of these pilot tests took place at Heathrow Airport in London – one of Europe’s busiest airports catering for more than 200,000 passengers each day with an average of 1,200 flights arriving and departing daily. Heathrow Airport Water Services Department has an extensive network of 120 pumping stations to manage and has been a Xylem customer for 25 years. They agreed to install and trial Xylem’s new wastewater pumping system in an effort to solve chronic clogging issues at one of the airport’s wastewater pumping stations. In

First in the world Xylem recently launched Flygt Concertor, the world’s first wastewater pumping system with integrated intelligence. The smart, interconnected wastewater pumping system from Xylem’s Flygt brand 40

Ian Jolly, systems specialist for water at Heathrow Airport

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

PUMPS

One of Heathrow’s aircraft wastewater vehicles

addition to delivering consistently clogfree pumping, Flygt Concertor reduced energy consumption by 53% at the station. The airport challenge The Central Area Sanitation unit, adjacent to Terminal 1, is a receiving station for all aircraft toilet waste, and was experiencing a very tough clogging challenge. The station manages wastewater directly from aircrafts, which contains a high level of non-biological solids including various plastic materials, wipes, nappies, and clothing. This stringy material can be difficult to pump since it can easily get caught on the impeller and partially block the pump. This can lead to increased energy consumption and in some cases a full blockage of the pump, resulting in regular clogging and the sump requiring significant maintenance in an effort to keep it clean. “We would usually have to deal with two or three clogging issues during a three month period,” says Ian Jolly, systems specialist for water at Heathrow Airport Water Services Department. “We also used to see a shelf of fat and material deposits build up on the walls of the sump as well as floating debris. This presented a very tough challenge to our existing wastewater pumps, which we frequently had to de-clog.” A loyal Xylem customer, the Heathrow team trusted in the company’s expertise in solving these particularly challenging problems. “We have used a number of Flygt technologies over the years and have found the Flygt team to be very willing to listen to our needs, always eager to find a solution to our particular challenge,” said Ian. As a world’s first, Flygt’s new wastewater pumping system combines built-in sump

and pipe cleaning functionalities in a single integrated solution, capable of tackling sump floating debris as well as pipe sedimentation. Furthermore, the pump cleaning function, together with adaptive N-hydraulics, effectively detects and solves clogging from large debris. Since the installation of Flygt Concertor at the Heathrow Central Area Sanitation Unit in November 2015, Concertor has provided 100% clog-free operation and improved the wet well environment. “Since installing Concertor we have had absolutely no clogging and the sump remains clean with no fat build-up,” says Jolly. “As well as peace of mind – which really is priceless – the cost savings are significant at approximately 87.5% of the annual costs in cleaning and servicing.” Wait, there’s more Clog-free operations and a clean wastewater pumping station are, however, not the only ways in which the Flygt Concertor can improve wastewater operations. The system aims to deliver proven reliability at the lowest total cost of ownership and to achieve this it also reduces energy consumption. In the case of the once-troublesome Central Area Sanitation Unit pumping station, energy savings are up to 53%, which is a result of both sophisticated software and modern components. The patented energy minimiser function automatically ensures that all the pumps run at their most efficient duty points, together with Concertor’s IE4 high-efficiency motor and selfcleaning adaptive N-hydraulics. The system’s constant power functionality means that the pump operates at varying rotational speeds to achieve a constant motor power, avoiding

overloading pump curves and substantially increasing off-design pump performance. Additionally, since there is no need for ventilation, cooling, or heating of cabinets, operators benefit from energy savings over the system’s total lifecycle. “Concertor’s compact design allowed it to fit into the existing position within the pump station, without any extra investment required to enlarge the cabinet. From an aesthetic and practical consideration, the reduced panel requirement size will be of great benefit,” Jolly says. “It was simple to install and very user friendly. Actually, the trial pump was installed by one of the airport’s water services mechanical technicians, who was not experienced in the commissioning of wastewater pumping systems and quickly gained confidence with the ease of installation and operation.” Flygt Concertor is suitable for use with wastewater pumps in the range of 2.2 to 7.3kW and has a system design that combines IE4 motor efficiency, N-hydraulics, integrated power electronics, and intelligent controls. All these features are designed to work in harmony with each other, which results in optimal pumping performance at a low cost of ownership. Backed by history Concertor shares a rich heritage with other Flygt innovations. One notable example from mid-1950s is when the team introduced the world’s first submersible wastewater pump, reducing the space required for modern pumping stations. In 1997, Flygt engineers invented a self-cleaning hydraulic design that enables sustained pumping efficiency, and in 2011 they integrated their wastewater process knowledge into an intelligent wastewater control, which included patented functions such as the Flygt energy minimiser. Xylem is determined to push the limits of technology to create high quality, reliable, and sustainable wastewater pumping systems. The company is convinced that the answer to the challenges facing the modern wastewater industry is not more components and complexity, but rather sophisticated, user-friendly pumping systems. z

For more information:

This article was written by Mark Willson, field sales engineer for infrastructure at Xylem, South East UK region. Visit: www.xylem.com

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EVENT PREVIEW

The German spectacle The Hamburg Messe in Germany will once again be a meeting place for the top experts of tank storage industries, who gather on 16-17 November to discuss the latest developments and showcase the hottest innovations at the Tank Storage Germany trade show. In this preview we give you just a small taste of all the things to see

Tank Storage Germany 2016, the leading event for the German bulk liquid storage industry, returns to the Hamburg Messe in Hamburg on 16-17 November. The show brings together a dedicated audience of decision-makers and buyers, all looking to attend the highly anticipated conference programme and source the latest in tank storage products and solutions. Nick Powell, StocExpo & Tank Storage portfolio event director comments: â&#x20AC;&#x153;We are delighted with the growth we are experiencing in 2016, once again proving the need for an event dedicated to the German market. The show is already firmly established as the leading event of its kind in Germany and we have accentuated this in 2016 with an expanded showfloor, a bigger conference programme, and more innovation on show than ever before. The show brings together leaders from the German bulk liquid storage industry, providing the perfect opportunity for manufacturers and suppliers to showcase their innovative products and services to a captive audience of buyers. Packed exhibition hall Over 65 leading industry suppliers have already signed up to exhibit, including Climbex, Loadtec Engineered Systems, Emerson Process Management, BĂśrger, Ivens, Siemens, Mueller-Behaelterbau, and M+F Technologies. Many of them will use the show to launch new products

and services to the tank storage market. For instance, Scully Systems has revealed that it will be presenting its new Intellitrol 2 overfill prevention and earthing control system, designed for loading gantries, in addition to the ST-15WX storage tank liquid level detection and spill prevention system. H. Timm Elektronik will be presenting its recently launched marine grounding system, SEK-3, which offers high 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. In terms of measurement, FMC Technologies Measurement Solutions will have its full range of measuring products on show. Visitors will be able to see its ultrasonic flowmeter Smith Meter, Sening tank truck products, as well as FUEL-FACS+ terminal automation system (TAS) for multiple terminals locally or centrally. Buchen will be using the event to showcase its automatic jet washer systems. The complete automatic tank cleaning system has a modular design and is installed in sea containers. It can be transported to the deployment site quickly, plus is suitable for both floating and fixed roof tanks. Its main components are mobile suction, pressure modules and jet washers, which largely eliminate the use of chemicals. SZE Hagenuk will be exhibiting its

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

EVENT PREVIEW

professional leak detection location – the LeaCom System. Based on a real-time working digital time domain reflectometry (DTDR) technology, this system is designed for fast and reliable detection and location of liquid leaks. It uses special sensor cables or gas sensors, which signal at the earliest possible moment when a leaking liquid is detected. Powell comments: “We are pleased to have so many leading exhibitors signed up for the 2016 show and so much innovation already on the agenda. We can really feel the momentum starting to build, although we are still three months out, as companies are getting ready to launch their new products into the German market.” Educational content The Tank Storage Germany 2016 exhibition runs alongside a two-day conference programme, which features more than 16 global authorities from the bulk liquid storage sector. Experts, including Alexander Fokker, commercial manager at Vopak Terminal Hamburg and Thomas Schröder, COO of TanQuid, will explore the latest global and local industry issues, developments, and trends affecting the German bulk liquid storage sector. “The seminar content we have on offer is more relevant than ever, with leading experts from OilTanking, JP Morgan, Arcadis, Vopak, Channoil, and Deloitte taking to the stage to discuss all things storage. We have worked tirelessly to provide our visitors with the biggest names in the industry, ensuring that there is something for everyone,” Powell says.

Wilhelmshaven is the single largest independent tank storage facility for petroleum products including LPG in Germany and the only deepwater port in the country. With expansion at the site planned, Sven Partzsch, managing director of HES Wilhelmshaven, will kick off the conference with a detailed look at the terminal and port. Industry forecasts will be provided by four experts including Henning Müller, principle at McKinsey & Company, who will consider the European refining industry. Michael Dei-Michei, analyst at JBC, will deliver the outlook for refining, product demand and trade flows. Duane Dickson, global chemicals sector leader at Deloitte will assess the chemical market, whilst Peter Hills, senior consultant at Channoil Consulting, will outline the changes to the shale industry and the sector’s impact on trade flows. Tighter rules and regulations within the German storage market, in particular

concerning environmental and climate issues, are placing greater pressure on storage operators to ensure correct operations are in place whilst maintaining cost effective business. Regional regulations are set to be a key theme within the 2016 conference programme. Oliver Stanelle from Oiltanking will provide an update on German regulations, whilst Sven Eric Utsch, managing partner at Utsch & Partners, will explore the wider regulatory environment within which companies have to operate. Storage has been seen as a stable and attractive investment opportunity. However, not all terminal investment opportunities are the same. So what are the criteria that investors look out for when choosing whether or not to invest in a terminal or a region? Robert Hardy, executive director at JP Morgan, will provide a financial investor’s perspective. Staying with the investment theme, Frank Schreurs, managing partner at In-Energy, will explain how terminals can benefit from developments in investor markets. Energy efficiency is another hot topic. Stefan Goestl, oil and midstream lead at Arcadis will show how to optimise the energy footprint to reduce costs, while also being technically and environmentally compliant. The two-day Tank Storage Germany conference also has practical sessions for tank terminal operators. For instance, Olatoyosi Joseph Akanni, terminal manager at Vision Middle East, in a talk focused on aboveground storage tank management and best practice, will look at how to remove the cost barrier and extract more value from operations, considering how developments such as wireless technology and automation have reduced costs or improved operations. Michel Houtermans, managing partner at Risknowlogy will share his experience with SIL and overfill prevention systems, while Thomas Geier, CEO at FSP-Tech and HSE manager at Nynas Hamburg, will share insight into how tank showers deliver both safety and cost saving methods. Powell concludes: “This is our best show to date, so it would be a shame for anyone involved in the bulk liquid storage sector to miss out. We have so much on offer that we have something for everyone. With registration very much open, there is no excuse for missing out!” z For more information on visiting the exhibition, booking as a delegate for the conference or becoming a media partner, call +44 (0)20 8843 8800 or visit the event website

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 43

MAINTENANCE

Right tool for the right job An innovative handheld motor testing instrument revealed lacking pump performance at a US nuclear plant

A nuclear power generating facility, located in the northeastern US, relies on four vertical service water pumps to feed water to a heat exchanger, which cools the sealed ultrapure water/steam that drives the turbine generators. Of the four identical service water pumps, all of which had 30ft long shafts, two of the pumps began to exhibit some performance issues. This motivated the maintenance team to conduct a performance study on the pumps, which were quite old. They had been installed when the nuclear plant had been built in the early 1970s. The nuclear power generating facilityâ&#x20AC;&#x2122;s maintenance team planned to analyse a number of measurements, including vibration, pressure, and flow. They also wanted to perform electrical signature analysis (ESA) as part of the The All-Test Pro Online II testing instrument

A US nuclear plant was suffering from pump performance issues

pump performance assessment, so they contacted Bob Dunn at I & E Central, a company known for providing on-site predictive maintenance services as well as distributing industrial test equipment for predictive maintenance (PdM), electrical and reliability professionals. In January 2016, Dunn went to the nuclear power plant to perform the electrical signature analysis on two of the 350hp, 480V motors. Performing the ESA ESA is performed by connecting current sensors and voltage leads to the motor, and then capturing high resolution current and voltage waveforms, which can then be analysed as FFTâ&#x20AC;&#x2122;s as well as raw waveform data. The resulting data gives insight into the entire motor system, both mechanically and electrically, from the incoming power through the driven load. This technology actually uses the motor as a transducer for the mechanical analysis. Any mechanical phenomena will be modulated onto the current waveform where they can be detected and analysed. Dunn used the All-Test Pro Online (ATPOL) II energised motor testing instrument to perform the electrical signature analysis. He connected the ATPOL II to the system, which was set to a flow rate of 5600gpm for the test. The motor terminal box was kept opened for the test, and the data collector was placed near the motor. The tester collected and transmitted

the data via Bluetooth, while Dunn and the maintenance team were positioned a safe distance away from the high voltage equipment. The electrical signature data was collected in two segments, a high resolution low fmax (100Hz) current acquisition of 50 seconds that primarily shows issues at running speed (misalignment, unbalance), and below the synchronous speed (rotor bar or load related issues). A high frequency capture and FFT of both voltage and current shows: 1. Electrical issues including power harmonics, power factor issues, voltage and current versus nameplate and balance 2. High frequency mechanical faults (stator mechanical and electrical issues, air gap, and even bearing issues) Results revealed Based on the results of the test, Dunn and the maintenance team determined that the motor was electrically perfect, with balanced current and voltage and 90+ power factor. The motor and pump were mechanically excellent with no indications of misalignment or unbalance, bearing issues, rotor, or stator issues. However, the tests showed a significant fluctuation in the current draw, pulsing at about 10Hz. Dunn and the team collectively determined that this was caused by nonlaminar flow, or turbulence in the system. The indication of turbulence on the

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

MAINTENANCE two under-performing vertical service water pumps was a revelation. What was more surprising to the maintenance team was that the turbulence had not been detected with any of the other tests. It was only the ESA that had revealed the underlying cause of poor pump performance. One of the key benefits of ESA is that it can show mechanical issues in the driven load â&#x20AC;&#x201C; even in the case of this vertical pump with the impeller 30ft below. This is in addition to detailed information on the entire system, both electrical and mechanical. Once the maintenance team understood the root cause of the performance issues, they were able to take the necessary steps to remedy the situation and get the pumps operating to the nuclear power plantâ&#x20AC;&#x2122;s performance requirements. Lessons learned Predictive maintenance is important. Monitoring industrial equipment and evaluating performance issues before catastrophic failure occurs can save operations from costly downtime and unwanted expenses. Reactive maintenance (run it until it fails) is considered to be the most costly type of maintenance process, because when a failure does occur, it often damages other components of the machine as well. Repairing or replacing these other components can mean long lead times for new parts or a higher cost due to the urgency of getting the system repaired (labour overtime). Moreover, a sudden shutdown can also impact the quality of the production process, which may require scrapping an entire production run. Finally, in the case of equipment for controlling plant pollution emissions, a sudden equipment failure can lead to a release of a controlled pollutant into the air or water. Resulting fines and other costs associated with a pollution event can easily exceed the cost in lost production. As this case shows, performing ESA along with vibration analysis can provide a more in-depth look at what is really going on with plant equipment. Making sure that operators have the proper tools to perform these kinds of analyses is critical to any condition-based maintenance or predictive maintenance programme. Devices such as the ATPOL II make performing these predictive tasks easier and less time consuming. ESA and motor current signature analysis (MCSA) has been available for many years. What is different with the development of ATPOL II is the focus on offering a portable, battery-operated, handheld data collector. Field testing often requires accessing the motor in a confined space, climbing a stairway, or in an outside space. Traditional testing instruments are large, heavy, and difficult to use in this type of testing environment. Energised testing using the ATPOL II instrument offers increased safety as it is designed with wireless Bluetooth technology, allowing operators to stay a safe distance away from energised equipment. All-Safe Pro connection boxes can also be installed to further increase operator safety during the data collection process. The ATPOL II is not industry specific and is used to monitor rotating equipment in many different types of industries, including industrial, municipality (potable and wastewater), mining, manufacturing, and food. In each of these applications, investing in the right tools is needed to keep people safe. z For more information:

This article was written by Bob Dunn, reliability equipment provider at I&E Central, and Simon Young, regional manager at All-Test Pro. Visit: www.alltestpro.com

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I know safety

MAINTENANCE

Training plant personnel through virtual reality helps plants conform to regulations and save lives The largest challenge for any plant, facility, or rig is keeping its workforce safe. According to US Department of Labor’s Occupational Safety and Health Administration (OSHA), nearly three million workers, including machine operators and labourers, regularly service or maintain equipment that could expose them to a hazardous energy injury. “Lockout/tagout (LOTO) procedures are an integral part of plant worker safety,” says David Hirsch, CEO of Systran, a technical and training services company. “Precautions are not always followed even though everyone in the industry has heard of the devastating consequences of not having or not following lockout/tagout procedures.” Overlooking written procedures can result in life-altering accidents and even death, so one has to wonder if the hazards of improper or ignored lockout/ tagout procedures are clearly understood.

A virtual plant operator adjusting a valve

Why comply? Protecting employees, preserving equipment, and avoiding fines are the top three reasons for companies to comply with regulations. Research clearly shows LOTO procedures help prevent serious consequences. Last year alone 50,000 injuries and 120 deaths were prevented when operators followed energy control procedures. Creating and implementing a LOTO safety programme are just the first steps to mitigate the fifth most cited OSHA violation. Companies need to go further and establish an overall safety culture through consistent training to avoid adding to future statistics. In the recently published Top Ten OSHA Violations for 2015, 3,223 total LOTO violations and over $10 million (€9m) collected in LOTO penalties were recorded. Until LOTO procedures are consistently followed, incidents and violations will rise. OSHA cited the following as the most common LOTO violations: 46

Simulated hands-on experience sticks to employees’ mind better than simple lectures

• Failure to develop, document and utilise hazardous energy control procedures • Failure to establish a LOTO programme that includes energy control procedures, employee training, and periodic inspections • Failure to provide adequate employee training. Problems with traditional training Many employees do not have a mindset that prioritises LOTO, and inadequate training is at the centre of this issue.

The root of the concern is not that operators are complacent or forgetful. The unease results from employees not having sufficient, realistic training on the consequences of improper action. Simply put, operators do not recognise the benefits that outweigh saving time. It is this mentality, perpetuated by outdated training methods, that is responsible for the high volume of accidents. Providing employees with only classroom training can be unsuccessful if the trainees are not completely focused on the presentation or lecture.

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MAINTENANCE Furthermore, reviewing process flow diagrams and going over procedures without the equipment present to reference can be confusing and makes it difficult for trainees to interpret and understand the procedure and the implications of making mistakes. While some facilities utilise purpose-built physical trainers to practice LOTO, they are expensive to build and only a few students can use the trainer at any given time. Going out into the field and using the plant to perform LOTO scenarios can be effective, but requires dedicated trainers working in small groups to be successful. These approaches are resource intensive and do not factor in the noise, heat, and other factors that impact learning. “Many times, classroom training doesn’t include the hands-on experience crucial for practicing and comprehending lockout/tagout procedures,” explains Hirsch. “Until an employee completes the actions directly and sees how everything he or she does impacts everyone working in the plant, they will not understand the importance of following LOTO procedures every time.” Another training concern is the lack of demonstrations for trainees to visualise how to use the appropriate locks and tags. There have been countless OSHA-recorded incidents involving workers only locking out portions of the equipment they are servicing instead of the whole equipment system. Including hands-on experiences in training programmes reinforces learned information and provides trainees with much needed guided practice.

In late 2015, Systran released LOTO EXP, its virtual experience training platform that brings the plant into the classroom and allows users to practice LOTO procedures in a virtual environment. The training tool is strategically designed to increase engagement and improve knowledge retention and build experience prior to going into the plant. The VR trainer was designed to support all types of LOTO training. In a classroom environment, the instructor can use the simulator to control the operator and demonstrate how each step is executed. The tool also allows trainees to step into the virtual operator’s shoes and follow written procedures in the virtual environment. “The scenario graphics, background, and moving character are all welldesigned, which makes it interesting to work through the different tasks,”

accurately they perform the procedures. To reinforce the importance of following the proper protocol, trainees must adhere to the written procedures. VR training programs have proven to be superior tools that engage a workforce, which is slowly but surely changing. Adapting training strategies to target the newer and younger generations, while also keeping the focus of the experienced operators, is a necessary balance. Programs such as Systran’s LOTO EXP help build confidence that the workforce is competent to perform LOTO properly whenever needed. End-user perspective By tapping the power of VR, training tools can be customised to match any plant layout or environment. Trainees receive

Train with virtual reality

Computer simulation improves operator training programmes

Providing training that is engaging makes learners more inclined to focus on the benefits of LOTO and perform the appropriate procedures every time. Virtual reality, primarily used for video games, has been repurposed as a training tool designed to capture the attention of learners. By using virtual reality, or VR, trainers can provide realistic training scenarios that are innovative and interesting to the learner. When the workforce is enthusiastic, they are more motivated to learn and retain significantly more of what they are taught. VR training is appropriate for all types of users because trainees visualise what they are learning and can practice components of their job in a safe and controlled environment.

explains Brett Newton, learning development manager at a major petrochemical facility. “The simulator is a very effective tool, especially for new hire operations personnel.” The most effective VR training offers practice and feedback. To practice, learners can operate at their own pace while opening and closing valves, turning equipment on and off and connecting and disconnecting hoses. Since it is a virtual plant, students can interact with their environment, make mistakes and receive feedback to continue to learn how to correctly execute LOTO procedures. During the evaluation mode, the trainees’ knowledge and comprehension are assessed to see how

immediate feedback on how accurately they can LOTO valves, pumps, hoses, and other equipment found in the plant they work in every day. The VR trainer also works to prevent mistakes, as it increases engagement around this critical topic. Tools like LOTO EXP can be used to supplement current safety programmes. Cost-effective and easy to implement, VR training programs can introduce typical LOTO scenarios, act as a practice field for using procedures effectively, and evaluate the employee’s ability to demonstrate competency. z

For more information:

This article was written by Rebekah Maurin, a consultant for Systran. Visit: www.systraninc.com

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 47

EVENTS

Fluid Handling International will be distributed at the following events 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

11-12 October 2016

European Waste Water Management (EWWM) Manchester, UK

18-20 October 2016

Oil & Gas Vietnam (OGAV) Exhibition 2016

Vung Tau City, Vietnam

2-3 November 2016

WWEM 2016

Telford, UK

16-17 November 2016

Tank Storage Germany

Hamburg, Germany

29 November - 1 December 2016

Valve World Expo

Dusseldorf, Germany

Donâ&#x20AC;&#x2122;t miss your chance to appear in the November/December 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: Chemicals/petrochemicals Fluid focus: Seals, piping Regular features: Pumps, valves, meters

Advertising deadline: 27 October, 2016 48

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016

PAGE HEADER

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FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016 49

PAGE HEADER

A radar beam focused like a laser! The future is 80 GHz: a new generation of radar level sensors

The latest cutting-edge technology from the world leader: the unsurpassed focusing of VEGAPULS 64. This enables the radar beam to be targeted at the liquid surface with pinpoint accuracy, avoiding internal obstructions like heating coils and agitators. This new generation of level sensors is also completely unaffected by condensation or buildup and has the smallest antenna of its kind. Simply world-class! www.vega.com/radar

FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2016