Fluid Handling International January/February 2017

HELPING TO KEEP YOUR BUSINESS FLOWING

JANUARY/FEBRUARY 2017

Issue 1 Volume 5

An early bird saves in costs Proactive maintenance helps bring down expenses

For the better of all The story of social innovation

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COMMENT & CONTENTS

Contents January/February 2017

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Latest news

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Dropping the hammer

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An early bird saves in costs Proactive and preventative maintenance strategies reduce plant operators’ expenses and headaches

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A year of light and shadows Having survived 2016, the Spanish fluid handling equipment industry is looking to the future

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Protect your pumps Polymeric repair materials and coatings can extend pump service life in harsh applications

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An attractive solution A magnetic scaffold anchoring system saves plant owners money and increases safety

ISSUE 1 • VOLUME 5

Woodcote Media Ltd Marshall House 124 Middleton Road, Morden, Surrey SM4 6RW, UK www.fluidhandlingmag.com MANAGING DIRECTOR Peter Patterson Tel: +44(0)20 8648 7082 peter@woodcotemedia.com EDITOR Ilari Kauppila Tel: +44 (0)20 8687 4146 ilari@woodcotemedia.com DEPUTY EDITOR Liz Gyekye Tel: +44 (0)20 8687 4183 liz@woodcotemedia.com

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For the better of all An Italian valve maker has engaged its community in a social responsibility programme – with good results Never alone Why a single flowmeter is not enough for custody transfer Crude oil measurement systems for custody transfer While each application is unique, ultrasonic flowmeters have certain advantages in oil transfer applications

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Many players, one goal Creating compatibility from diversity in LNG operations

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Driving towards actuation success Despite initial costs, upgrading hydraulic actuators can bring significant savings

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Engineering control valves to handle black powder duty How an intelligent OEM retrofit extended control valve life

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The next generation A new TOV design offers evolved features and benefits for expanded applications

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Ball or small?

The pros and cons of leading flowmeter prover technologies

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HELPING TO KEEP YOUR BUSINESS FLOWING

JANUARY/FEBRUARY 2017

Caught in the flow Entrained gas measurement features provide huge operational benefits

40 A fluid situation: Sustainability in compressors 41 Events

Issue 1 Volume 5

An early bird saves in costs Proactive maintenance helps bring down expenses

For the better of all

The story of social innovation

FC_FH_January-February_2017.indd 1

27/01/2017 12:33

Sparrow drinking fresh water from a fountain tube. ©angelsimon. Picture from bigstockphoto.com

ADVERTISING SALES MANAGER Russell Priestley Tel: +44 (0)208 6487 092 russell@fluidhandlingmag.com PRODUCTION Alison Balmer Tel: +44 (0)1673 876143 alisonbalmer@btconnect.com

Comment Dear reader,

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

It’s finally over, the year 2016, that is. And it was quite a year.

While he has dominated the headlines daily for the past couple of months, I don’t think there is a way I can avoid talking about US President Donald Trump. In the lead-up to his surprise election in November, Trump promised he would dismantle many of the environmental safeguards put in place by the Obama administration and “bring back” American business.

And with the approvals of the Keystone XL and Dakota Access pipelines, Trump seems to be doing just that.

Global opinions on Trump are strictly divided, but his policies may open up possibilities for US liquid handling equipment manufacturers and distributors. If Trump manages to breathe new life into the oil and gas business, there could be plentiful new projects in drilling and exploration that would significantly increase demand for new pieces of kit. Add to this the possible new fossil fuel-powered energy projects, and the market landscape for US producers looks cautiously positive.

But even if the US market would end up falling flat, there is always Asia. Rapid industrialisation, urbanisation, and increasing manufacturing, particularly in China and India, are spurring the markets for many fluid handling products. The countries are developing large numbers of projects varying from O&G to wastewater and chemicals, which opens plentiful avenues for manufacturers.

But there are of course also hindrances on the horizon. Wildly swinging oil prices could affect the market in a positive or negative way, marks Fluidex (see page 14), and the lack of investment is barring the way to increased demand. Markets are also not quite sure yet what to make of both Trump and Britain’s exit from the EU. Perhaps what we’re looking for most in 2017 is stability.

Best wishes,

Ilari ISSN 2399-5602 1

VALVE NEWS

Bonomi NA introduces high-pressure ball valves and automated valve packages for hydraulic applications Bonomi North America is introducing a new line of high-pressure carbon steel ball valves for use in hydraulic applications.

The new valves come in two-way and three-way configurations with a choice of NPT or SAE thread end connections.

Both the two-way valves (3200 Series NPT/3300 Series SAE) and the three-way valves (3400 Series NPT/3500 Series SAE) are available in 3/8” through 1” sizes.

Rated working pressures range from 5145 to 7350 PSI and the valves are tested to rated pressure in the open and closed position before shipping.

While a lever handle is standard, an integral ISO 5211 mounting pad simplifies actuation on the new valves and they are also available in factoryassembled automated valve packages with Bonomi’s Valbia brand electric or pneumatic actuators.

Valbia electric actuators have dual 100-240VAC or dual 24 AC/DC reversing motors with torque limiters, thermal protection, auxiliary limit switch, NEMA 4X indoor use enclosure, manual override, and position indicator as standard.

Options include a 4-20mA positioner, battery backup and 180° rotation, with both technopolymer and powdercoated cast aluminium enclosures also available.

Valbia pneumatic rack-and-pinion actuators for the new hydraulic valve packages feature anodised aluminium bodies designed for 80 PSI control air pressure and are operable using air, water, nitrogen, or other compatible hydraulic fluids from 40 to 120 PSI. z

Clarke Industrial Engineering signs distribution agreement with Curtiss-Wright Clarke Industrial Engineering has entered into a licensing agreement with Curtiss-Wright Corp. to exclusively distribute Clarke’s patented and proprietary shutter valve technology for various markets.

The shutter valves will be exclusively available to Curtiss-Wright for the worldwide naval defence market, the US maritime homeland security market, and the commercial nuclear power market.

“We are very excited to partner with one of the world’s finest industrial companies. Curtiss-Wright’s strong market position and Clarke’s industry leading valve technology are a natural combination,” said Kyle Daniels, president and CEO of Clarke.

The shutter valve design is “whisper quiet” even in extreme operating conditions and provides limitless and precise flow control, zero pressure drop, and full port operation, along with reduced turbulence, cavitation, and water hammer.

Greatly reduced costs compared to other valves is generally achieved through its very low torque requirement providing for less expensive actuators, Clarke says.

From an ongoing cost perspective, the valve is easily maintained and its compact design allows for simple installation, repair and removal.

James White, senior general manager of the valve group at Curtiss-Wright’s industrial division, stated: “As a result of this agreement, we will be able to leverage many of our existing technologies toward the implementation of the shutter valve in our target markets. This is an exciting and complementary addition to Curtiss-Wright’s existing product portfolio of valve technologies.” z

Andritz Hydro to supply valves and electromechanical equipment for two hydro projects Andritz Hydro, part of the international technology group Andritz, has received an order from Eidsiva Vannkraft to supply electromechanical equipment for a new Norwegian hydropower plant.

Andritz’s contract comprises design, manufacturing, and delivery of the complete electromechanical equipment for the new Nedre Otta plant.

The supply deal includes two vertical Kaplan turbines with a total output of around 86MW (315GWh), generators, governors, main inlet valves, mechanical auxiliaries, installation, supervision, and commissioning.

Nedre Otta is a greenfield hydropower project located in the community of Oppland, some 270km north of Oslo.

The power plant will be equipped with two Kaplan turbines of identical size and operated as a runof-the-river plant with no intake reservoir.

Andritz has previously been awarded the

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supply of hydropower equipment for the Matre Haugsdal, Lysebotn, and Smibelg-Storåvatn hydropower plants over the past few years.

The company has also signed a deal with the government utility Société Nationale d’Électricité (SNEL) for rehabilitation of the existing Mwadingusha hydropower plant in the Democratic Republic of the Congo.

The scope of supply for Andritz comprises replacement of four turbine units, generators, governors, inlet valves, exciters, voltage regulation, and draft tube stop logs, including dismantling, erection, and commissioning.

The new turbines have almost 10% more output than the previous units.

After completion and reconnecting to the grid, the Mwadingusha hydropower plant will provide electric power to the copper mines in the Katanga region as well as to the public distribution grid of SNEL. z

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

VALVE NEWS

Nordson releases innovative closedloop motorised valve assembly for extrusion coating Nordson Corp., an Ohio, USheadquartered machinery manufacturer, has introduced a new patent-pending motorised back pressure valve assembly for extrusion coating and laminating.

The new EDI PolyStream is Nordson EDI PolyStream is the first hands-free system for the first such system to provide regulating back pressure in extrusion coating closed-loop control, minimising human error and the possibility of injury when making manual adjustments, to the substrate, and a high level according to a company statement. of product quality,” Iuliano said.

“The PolyStream valve assembly is The drive for the valve responds to a the first completely hands-free system controller that receives a continuous flow for regulating back pressure in extrusion of signals from a pressure transducer, coating,” said Sam G. Iuliano, business causing the valve to open at varying development manager for polymer dyes. degrees in accordance with whether back Although extrusion coating operates pressure is trending too high or too low. at higher melt temperatures than other When the valve reaches its limit extrusion processes and requires use of of opening as a result of excessive a back pressure valve to reach these contaminant build-up on the filtration temperatures, excess back pressure screen, an automated warning indicates can lead to polymer degradation. that it is time to change the screen.

Installed between the extruder A human/machine interface and the dye, the valve assembly uses (HMI) enables the operator to closed-loop control to maintain back specify process conditions or to use pressure within a range targeted specifications from a recipe. to ensure optimal processing.

The valve assembly can be run “Back pressure conditions are manually, although Nordson recommends affected by numerous factors and are automated closed-loop operation. in a constant state of flux. By making The PolyStream assembly includes operator intervention unnecessary, a motor, breaker plate screen pack, our new system helps to ensure coat linear valve, melt pipe, control system, weight consistency, adequate adhesion and optional display panel. z

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With years of experience and extensive application knowledge, we provide pump designs that have proven reliability, operational safety and low lifecycle costs.

Please call regarding API confirmity.

Hantemp Controls introduces S4At stainless steel solenoid valve Hantemp Controls, a manufacturer of stainless steel liquid control devices, is now offering the model S4At stainless steel solenoid valve.

While ideal for ammonia, these solenoid valves can also control CO2, fluorinated refrigerants, glycols, pure water, light oils, and other approved liquids.

For ammonia refrigeration systems, they can be used for overfeed/ recirculating liquid lines, suction lines over -12°C, hot gas lines, high-pressure liquid lines, and discharge gas lines.

Functionally and dimensionally, the S4At replaces similar models from traditional steel and iron valve manufacturers. z

NETZSCH Pumpen & Systeme GmbH Business Field Oil & Gas info.nps@netzsch.com www.netzsch.com

Hantemp Controls’ new S4At solenoid valve is suitable for varying refrigeration applications

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

3

VALVE NEWS

Bournemouth Water reduces leak and burst frequencies with IVL Flow Control valves Bournemouth Water in the UK has redesigned much of its network to use intelligent network calming and pressure management valves produced by IVL Flow Control to reduce leakage.

Bournemouth Water provides drinking water to nearly half a million people on the southern coast of England.

Initially, 13 of the company’s district metering areas (DMAs) were set up, with a further 50 DMAs covered by October 2016, significantly reducing leakage.

The project uses IVL Flow Control’s two-way and three-way pressure management valves and HWM Radcom Pegasus controllers.

Bournemouth Water used fully calibrated network models to forecast the benefits and to set targets that have been realised.

Paul Johnstone, network modelling performance manager at South West Water, commented: “Capital investment in this project, using IVL Flow Control valves, has resulted in huge benefits, achieving reductions in leak and burst frequencies and creating a more efficient and intelligent network.”

“Bournemouth Water has been very forward-thinking in its decision to introduce state-of-the-art pressure management,

IVL Flow Control’s smart network model has benefited Bournemouth Water

which sets a very good example for the industry,” Craig Stanners, director of IVL Flow Control, added.

The network supplying more than half of the population served by Bournemouth Water is now covered by the new pressure management regime. z

Emerson valve remote control solution chosen for world’s largest crane vessel

Heerema Marine Contractors has chosen Emerson Automation Solutions to provide a valve remote control (VRC) system for the world’s largest semisubmersible offshore crane vessel.

SSCV Sleipnir, currently under construction at Sembcorp Marine’s shipyard in Singapore, is a 220m long vessel designed for the installation and removal of large offshore structures.

These include oil and gas platforms, subsea production facilities, foundations, moorings, and deep water floating structures.

3D model of SSCV Sleipnir

4

Each of the ship’s two revolving cranes is capable of lifting up to 10,000 tonnes.

The critical task of stabilising Sleipnir during lifting operations will be carried out by the ship’s ballast control system, which transfers water between onboard tanks to counterbalance the weight of shifting loads.

Not only must the ballast control system operate reliably in demanding marine conditions, but it must do so on an extraordinary scale.

To address these unique challenges, Emerson’s experts worked closely with the stakeholders to design a custom,

fully-redundant Damcos VRC solution for the ship’s fluid management and ballast systems that includes a total of 847 valves, actuators, local power units (LPUs), and eight interface cabinets connected by a P-NET communication bus.

Emerson’s Damcos LPUs are rated at IP68, meaning that they are able to operate while submerged at a depth of three bar (30m) for at least 24 hours.

The LPUs are mounted directly on the actuators and connected to the P-NET network, saving the shipyard installation man-hours by eliminating hydraulic tubing and greatly improving reliability with their short circuit-tolerant design.

The configuration allows any LPU to fail entirely without affecting the other units in the loop.

“A groundbreaking project like this called for us to partner with automation experts who could provide a VRC solution that minimised cost, weight, size, and energy use while ensuring years of safe operation in some of the toughest situations imaginable,” said Leo Stobbe, commissioning manager for Sleipnir at Heerema.

“Across the board, we are confident that Emerson has delivered,” he added. z

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

PUMP NEWS

Xylem wins $1.5m contract to retrofit pumps for North Carolina wastewater plant

Busch offers nearly €1bn for Pfeiffer takeover

Water technology company Xylem has upgraded in order to support demand. won a $1.5 million (€1.39m) contract to “A successful pilot of our pumps over provide new pumps for use at a wastewater a two-year period has allowed us to treatment plant in North Carolina, US. demonstrate how Xylem can significantly Busch, German vacuum Xylem’s Flygt NP-3400 submersible pumps improve the reliability of infrastructure at the pump manufacturer, has will be used to replace ageing pumps McAlpine plant. We are working closely with made an offer of €96.2 per at the central influent pump station of Charlotte Water to build a more resilient share, totalling at €949 million, McAlpine Creek wastewater treatment and cost-effective pumping system for this to purchase its compatriot plant in Pineville. important wastewater treatment plant,” Jim Pfeiffer Vacuum.

The retrofit of ten new pumps will provide Prince, sales representative at Xylem, said.

Busch is already holding the plant with a longer operating life and “Charlotte Water oversees more than 27.2% of Pfeiffer’s shares, and help reduce overall maintenance costs at $200 million worth of water improvement it has secured additional the facility. projects each year across its five stock to bring its ownership to Ageing infrastructure has become a wastewater treatment plants. Through this 29.98% before the takeover pressing issue in the US, as historically continued investment, Charlotte Water is offer is published. an emphasis had been placed on the committed to safeguarding the future of Pfeiffer shares were up 6.4% expansion of water and wastewater their water supply by reducing the impact in Frankfurt trade, and the systems, rather than the maintenance and of ageing infrastructure on local water and company stock closed at repair of those already in existence. wastewater systems.” €92.81, up 12% over the past As a result, communities are faced with The McAlpine Creek wastewater year. the massive challenge of replacing critical treatment plant is the largest of Charlotte The firm’s lender LBBW water and wastewater infrastructure and Water’s five treatment plants, serving the has already committed to many systems are nearing the end of their City of Charlotte and the surrounding area financing the deal, which useful life. of Mecklenburg County in North Carolina. is not conditional upon Shifting population growth has also In total, the plants collect wastewater any minimum acceptance placed considerable strain on water and from approximately 246,299 households threshold. wastewater systems which today serve and businesses throughout the county and Pfeiffer produces pumps for more than 238 million Americans, or 76% of treat over 85 million gallons of wastewater semiconductor and analytical the population. per day. device manufacturers, who Significant growth brings with it an The retrofit of the McAlpine plant will be use them in products such as The hose pump is the pump solution for the is a simple Thefutur. hoseItpump is the and pump solution for the futur. It is a simple and increase in the quantity of wastewater, completed phases and the project will in the electron microscopes. z well proven construction in one in sense butwell alsoproven a “newthinker” construction in one sense but also a “newthinker” in the stressing the need for water systems bethe hose beisdelivered late z fact thatto only in contactby with the2017. fluid that is being pumped. fact that only the hose is in contact with the fluid that is being pumped.

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For us at ALBIN PUMP this means lower costs and better pumps soluFor us at ALBIN PUMP this means lower andand better pumps soluThe hose pump is the pump solution for the futur.

It iscosts a simple tions. If you want to know more about well the proven technique, test and results tions. construction If you wantinto know about the technique, one sensemore but also a “newthinker” in the test and results welcome to www.albinpump.com forfact more information. that only the hose is in contact with the fluid that welcome to www.albinpump.com foris being morepumped. information.

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This minimises downtime from maintenance and simplifies pump use.

For us at ALBIN PUMP this means lower costs and better pumps solutions. If you want to know more about the technique, test and results welcome to www.albinpump.com for more information.

The hose pump is the pump solution for the future. It is a simple and well proven construction in one sense but also a “newthinker” in the fact that only the hose is in contact with the fluid that is being pumped. This minimises downtime from maintenance and simplifies pump use. For us at ALBIN PUMP this means lower costs and better pumps solu-tions. If you want to know more about the technique, test and results welcome to www.albinpump.com for more information.

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PUMP NEWS

Ruhrpumpen provides seawater lift pump package for offshore application Ruhrpumpen has successfully commissioned a seawater lift pump package in a floating production, storage and offloading (FPSO) vessel owned and operated by Avant Garde Petroleum Co. Dubai.

The package consists of three main pumps – vertically mounted ZW 20x16x30 model – and one startup seawater lift pump, a vertically mounted ZW 12x8x19 (A) model.

In order to provide water for firing up the steam boilers, the startup seawater lift pump is started.

Once the power generation system is running, high voltage power supply is available to activate the main seawater lift pumps, whose function will be to supply seawater for the topside processes such as water injection and for the accommodation quarters.

The pumps were manufactured, tested, and commissioned

by RP India and designed by RP Specialists in Mexico combining specialised analysis and the latest software technology.

The pumps are designed to meet the very specific needs of the offshore industry and operate according to DNV Marine Class Certification.

The package is located in the sea chest of the FPSO Cyrus, which has a storage capacity of 600,000 barrels and utilises tri-fuel-fired (gas, crude oil, and heavy fuel oil) steam boilers

Total places second order for Amarinth super duplex pumps Pump maker Amarinth has secured a further order of API 610 OH2 pumps to be used aboard Total’s new Egina floating production storage offloading (FPSO) vessel.

Amarinth’s Malaysian operation secured the second order for API 610 OH2 super duplex pumps for a de-sanding and process water treatment package aboard Total’s Egina FPSO following on from its successful delivery of a previous order for the same pumps with Plan 53B seal support systems.

The 200,000b/d capacity vessel, being built

by Samsung Heavy Industries of Korea at a cost of $3.3 billion (€3bn), will arrive in Nigeria around April 2017 and will be working in Total’s $16 billion Egina deepwater field situated 150km off the coast of Nigeria in water depths of up to 1,750m.

“We are delighted to provide these additional pumps to the Egina FPSO project, an order which also underlines our decision to open our office in Malaysia last year enabling us to offer even better support to our rapidly growing customer base in Asia Pacific,” said Oliver Brigginshaw, managing director at Amarinth. z 6

The FPSO Cyrus will use Ruhrpumpen’s sea water lift pumps

and turbo generators to meet captive and export power requirements.

An FPSO is a floating vessel used by the oil and gas industry to produce, process, and store oil from subsea reservoirs.

This kind of units have been serving the offshore oil and gas industry for more than 30 years.

The FPSO market size was over $21 billion in 2015 and is forecasted to grow over 19% from 2016 to 2024. z

MV Products rolls out customisable inlet traps for vacuum pumps MV Products has introduced a full line of vacuum inlet traps and filter media for protecting vacuum pumps employed in research and production atomic layer deposition (ALD) processes.

MV vacuum inlet traps for ALD processes range from 4” to 16” in diameter with port sizes from NW-25 to ISO-160 for protecting vacuum pumps in applications with vacuum flow rates from 25 to 2000cfm.

Featuring interchangeable filter elements, the stainless steel traps can be customised by users to remove all ALD process by-products from precursors such as TMA, TiCl, DeZ, and H2S, including particulates and unreacted precursors.

Suited for the ALD manufacturing of ICs, MEMS, LEDs and OLEDs, optics and displays, batteries, and more, MV vacuum inlet traps include the PosiTrap and Multi-Trap product lines.

Interchangeable filter elements include stainless steel gauze for particle filtration, activated charcoal for unreacted precursor adsorption, Sodasorb for acid neutralisation, and Sulfatreat for H2S neutralisation.

MV Products is a division of Massachusetts, US-based Mass-Vac, which specialises in solving process contamination problems associated MV Products PosiTrap and Multi-Trap vacuum with vacuum systems. z inlet traps are easily customisable FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

PUMP NEWS

Dorian Drake to distribute Dean centrifugal pumps internationally Dean Pump, a centrifugal pump manufacturer and CECO Environmental brand, has entered into a distribution agreement with Dorian Drake International.

Under the terms of the agreement, Dorian Drake will be responsible for sales in specific international markets, including all of Europe, Middle East, Africa, Asia, and South America.

The agreement is the first step in a major initiative for the Dean Pump brand to globalise its business with local sales and support. ”We are very excited about expanding our geographic footprint with the support of Dorian Drake, whose mission of building world-class distribution for leading manufacturers in select industries

is fully aligned with our needs,” said Gennaro A. D’Alterio, president of CECO Environmental’s global fluid handling and filtration business.

“We will provide a new heightened level of local service and support to our existing customers while driving our core focus in various high-temperature applications.” z

Study reveals top five leading pump vendors for oil and gas market Technavio has announced the top five leading vendors in its recent report on the global pumps market for the oil and gas industry until 2020.

Flowserve, ITT, KSB, Sulzer, and Grundofs are expected to have the largest impact on the market during the forecast period.

The oil industry is currently in need of improved and enhanced oil recovery processes, the study states.

The global crude production increased significantly due to the emergence of innovations such as horizontal drilling, hydraulic fracturing, and seismic imaging.

Companies in the oil and gas industry are emphasising on increasing productivity from existing wells, which is creating new demand for pumps and driving market growth.

“Additionally, refining capacity additions, the opening of new avenues for natural gas markets, and expansion of crude oil pipelines are also pushing the global pumps market for the oil and gas industry,” said Anju Ajaykumar, one of the lead analysts at Technavio for unit operations research.

“With the rectified crude oil prices expected to have sufficiently trickled down, the market is expected to witness

significant growth in the second half of the forecast period. The upstream players are expected to bolster up their production volumes, thereby leading to the growth of this market space,” she added.

Competitive vendor landscape The uncertain scenario of the oil and gas industry is expected to lead to a tight price war among the larger players in the market.

The decline in oil prices is leading to consolidation of various activities, and the industry is experiencing a shift to innovative operational procedures.

The advent of the internet of things (IoT) will increase operational efficiency by nearly 45%, which will create an opportunity for vendors to widen application and scope.

Moreover, the market in Asia Pacific is providing vendors with many opportunities to add to their refinery capacities projected during the forecast period.

Pump manufacturers are looking to tap this potential through sustained focus on innovation, by increasing adoption of remote monitoring and proactive maintenance. z

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FLOWMETER NEWS

Endress+Hauser DNV GL awards industryfirst fiscal metering technology releases Proline 300/500 smart flow qualification to Emerson instruments Emerson’s Daniel 3415 and 3416 dual-configuration gas ultrasonic meters have received the industry’s first technology qualification (TQ) from DNV GL for fiscal gas meters.

The TQ is a risk-based assessment that evaluates meter performance in real-life operational environments to ensure the technology meets the highest fiscal measurement standards.

The certification programme verifies the meters’ ability to meet the industry’s fiscal and contractual requirements when operating under field conditions where dust, liquids, build-up, drift, and pulsations are common.

It also authenticates the ability of the meter’s advanced diagnostics to detect and compensate for process disturbances and provide early warning of fouling to ensure greater meter integrity and measurement accuracy.

Furthermore, the TQ confirms the robustness and reliability of the meters in minimising financial risk and provides evidence to support extending calibration intervals to reduce operating costs.

“Current international gas measurement standards for fiscal flowmeters focus only on the design and installation of the meters and don’t cover meter performance under field conditions,” said DNV GL’s oil and gas senior VP, Liv Hovem.

“DNV GL’s TQ puts meter performance claims to the test and provides evidence of the impact of actual operating conditions on meter health and measurement accuracy of gas sales. This evidence helps metering system operators mitigate financial risk and improve the reliability of their metering stations in satisfying fiscal and custody transfer contractual agreements,” she added.

The Daniel 3415 and 3416 meters, which are already certified to the OIML R137 1&2 Accuracy Class 0.5, are the only ultrasonic meters on the market at the moment that have undergone DNV GL’s field testing and demonstrated field robustness, Emerson says.

“Detecting dirt build-up and small amounts of liquid or contamination at the bottom of the meter can be challenging for direct-path meter designs,” said Rob Sedlak, general manager of Daniel ultrasonic meters at Emerson Automation Solutions.

“Having reflective path technology and direct path measurement combined in one ultrasonic flowmeter body, as is the case in the 3415 and 3416 meters, enables natural gas operators to detect process upsets long before measurement is impaired and replace complex, frequent inspection procedures with condition-based maintenance practices.”

The DNV GL assessment process is built upon scientific research and is recognised by regulators, insurers, and major clients throughout the world.

The process is widely accepted and applied Emerson’s Daniel ultrasonic gas meters are the to new fit-for-purpose first in the industry to receive the technology technologies. z

Endress+Hauser has released Proline 300/500, a family of industry-optimised smart Coriolis mass and electromagnetic flow instruments that simplify installation, speed up commissioning, and streamline both operation and maintenance.

The Proline Promass Coriolis mass flowmeters are available in 11 models ranging in sizes from 1/24” to 14” in diameter, for measuring flows up to 100,000 tonnes per day.

Proline Promag flowmeters are available in three models in sizes from 1/12” to 78” for volume flows up to 634 million gallons per day.

Both types are available in models suitable for high temperatures, corrosive fluids, and hygienic and sterile process applications.

Proline instruments connect to control systems via 4-20mA HART, WirelessHART, PROFIBUS PA/DP, FOUNDATION Fieldbus, Modbus, EtherNet/IP, or PROFINET. Both families provide access to users via the device’s display, a web server, a wireless LAN, handheld devices, asset management or process automation solutions, and Fieldbus protocol.

Each provides fast commissioning, in-situ device verification during operation, continuous selfdiagnostics, and automatic on-board data storage.

Both families have robust transmitter housings available in aluminium, hygienic or severe service stainless steel.

Each housing has a two-chamber system with a front-mounted compartment for connecting source power, wiring the analogue and/or digital inputs and outputs, and accessing the Ethernet service access port or device display.

The second chamber permits service technicians to access the electronics modules for repair functions while maintaining protection against dust and contamination.

Local or remote four-line backlit optical displays with a WLAN connection allow access from a handheld device such as a smartphone or a tablet. z

qualification (TQ) for fiscal gas meters from DNV GL

Endress+Hauser Proline product family

8

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

FLOWMETER NEWS

Fluenta flare gas meter accuracy proved by the Netherlands’ National Metrology Institute VSL, the National Metrology Institute in the Netherlands, has proved flare gas flowmeters from Fluenta can operate with an uncertainty of 1.5% even at low flow rates.

Extensive testing at the VSL facility in the Netherlands demonstrated that calibration of the Fluenta 160 flare gas meter can double its accuracy, from 3 to 1.5% uncertainty.

Fluenta’s gas flowmeters use ultrasonic technology to deliver the most accurate measurement of flow against all temperatures and flow rates.

The VSL calibration testing follows a successful testing at the CEESI facility in Colorado, which proved the

Fluenta 160 flare gas meter has an uncertainty of less than 3%, even at low flow velocity without calibration.

During the VSL testing, the Fluenta 160 gas meter was calibrated using air under atmospheric conditions, with a relative humidity of 44.8% and a temperature of 20°C. The 160 meter was calibrated against a VSL multipath master meter for reference, where the volume of flow of the reference meter was converted to a volume flow at the conditions of the 160, taking temperature and pressure into account.

VSL offers the lowest possible uncertainty in the field of volume, mass, and flow and its process analyses the entire

metering system to establish its accuracy and measurement uncertainty.

Sigurd Aase, CEO of Fluenta, said: “Testing of Fluenta’s 160 flare gas meter at the VSL facility was carried out on behalf of a customer that required the highest level of accuracy for its flowmeters to achieve its corporate objective of zero routine flaring by 2030. Introduced by the World Bank, this initiative aims to eliminate routine gas flaring no later than 2030.”

“The additional accuracy provided by calibrated flowmeters enables companies to more effectively manage the transition to zero routine flaring, as well as report non-routine flaring volumes accurately,” Aase continued. z

Indonesian government to mandate installing flowmeters at O&G wells The Indonesian government is planning to force oil and gas contractors to install flowmeters at their wells after years of criticism over lack of production data in the field.

Energy and Mineral Resources Ministry’s oil and gas director general IGN Wiratmaja Puja said the government would stipulate the installation of flowmeters through a ministerial regulation in a bid to increase the accuracy of measuring daily crude production in the country.

The impending regulation comes as Indonesia’s oil and gas production decreases at an average rate of 20% per year as most fields have already shown a natural decline.

The Upstream Oil and Gas Regulatory Special Task Force (SKKMigas) has thus far relied on daily oil and gas production reports submitted by contractors.

There are no regulations making it compulsory to install flowmeters, which measure the real flow rate or the quantity of oil and gas.

“The objective of the flowmeter installation is to monitor production, and the data will be delivered to SKKMigas on a

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

real-time basis, which will also be transferred to the Energy and Mineral Resource Ministry,” Wiratmaja told The Jakarta Post.

He explained that currently flowmeters were only installed at oil and gas points of delivery to measure ready-to-sell production, known as lifting.

Although the variance between oil lifting and total production is limited, at only around 0.25 to 1.6%, it provides greater accuracy for monitoring purposes.

Declining to disclose the exact date of the ministerial regulation issuance, Wiratmaja said the flowmeters would be procured using state funds and the installation will be conducted by SKKMigas.

“The flowmeters will be the state’s property while SKKMigas will be tasked with installing and operating the equipment,” he said.

According to data from SKKMigas, national crude oil production reached 817,900 barrels of oil per day (bopd) and gas production hit 7.9 trillion cubic feet (tcf) a day in the first half of the year. z

9

OTHER NEWS

Sciemetric releases turnkey leak test station to cut testing costs Sciemetric Instruments, headquartered in Ottawa, Canada, has released the Model 3675, a cost-effective turnkey station to boost the speed and accuracy of leak testing.

The 3675 can combine up to three of Sciemetric’s 3520 series leak test units in one stand, controlled by a single sigPOD controller.

The turnkey station can be used to conduct a range of leak tests, including pressure decay, mass flow, and more with pressure or vacuum.

It can be used in production, in a lab, or wherever leak testing must be conducted.

“Discrete manufacturers across various industries now recognise the need for their leak test to deliver more value,” said Mat Daniel, VP of operations at Sciemetric.

“They understand the role that a fast, reliable test solution plays in meeting a new standard for quality assurance, and how big data analytics collected from that test bring new insight to their decision making, but there is no one-size-fits-all solution.

“With our Model 3675, we are giving our customers more choice and more scalability, to make the right investment, at the right time, in a better leak test,” added Daniel.

The 3675 can be customised to accommodate plant requirements, including any geometric concerns (i.e., orientation) with the leak tester and the tested part.

The rugged T-frame construction stands at 28”x33”x62”. z

10

Aon launches loss estimating risk tool for oil, gas and petrochemical sectors Aon Global Risk Consulting, the risk management consulting arm of Aon, in collaboration with research agency TNO, has launched a new modelling tool for the oil and gas sectors.

The Aon Loss Estimating Risk Tool (ALERT) for oil, gas and petrochemical clients is able to model the potential financial impact of a wide range of fire and explosion scenarios in the hydrocarbon processing industry.

“ALERT is a significant enhancement in the modelling tools available for clients within these sectors. It will support clients and insurers in calculating estimated maximum losses from property damage and in assess third party liability exposures,” Robert Robinson, managing director at Aon’s Energy Risk Engineering.

Developed in conjunction with several

leading insurers, ALERT is calibrated to model a full range of known historical losses from across the industry and includes discharge and dispersion models, which are used to evaluate cloud dimensions for vapour cloud explosion events.

Paul van Ruiten, director of environment and sustainability at TNO, said: “The development of ALERT with Aon has enabled our well established consequence models to be deployed in another area of risk management to the benefit of the industry and the insurance market.”

ALERT will become a key tool for all of Aon’s Energy Risk Engineering professionals and will be managed globally from London, UK, with key support from centres of excellence in Houston, Calgary, Dubai, and Singapore. z

Enbridge shuts down Ozark pipeline following crude oil spill Canadian energy company Enbridge has shut down and isolated its Ozark pipeline following a 15,330 gallons (365 barrels) crude oil spill in Missouri, US. “On 14 January, a leak detection alarm notified workers of a potential release on Line 51, the Ozark pipeline, at the Lawrence Pump Station in Lawrence County, Missouri,” Enbridge spokeswoman Jennifer Smith told Reuters in an email.

Some of the leaked oil made its way

into a drainage area some 600m away from the Enbridge property, where most of the release was contained.

The drainage area has been contained as well, according to Smith, but the company has no specific timeline for when the pipeline, transporting oil from Cushing, Oklahoma, to Wood River, Illinois, would return to service.

Enbrige said clean-up procedures are underway and an investigation to the cause of the leak has been launched. z

Georgia water treatment plant to double capacity in multimillion dollar upgrade Fowler Wastewater Reclamation Facility in the US state of Georgia has been approved for a multimillion dollar expansion project set to double its capacity.

Forsyth County board of commissioners voted to greenlight the nearly $64 million (€60m) contract to expand the Fowler facility from treating 2.5 million gallons a day to 5 million gallons.

The county’s procurement director Donna Kukarola told news website AJC that the plant’s capacity would in the future be expanded even

further to 7.5 million gallons a day.

According to Kukarola, the project will take 870 days to complete and the plant will stay at full capacity throughout the period.

The engineering and construction contract has been awarded to Archer Western Construction from Tampa, Florida.

Water and sewer head Tim Perkins said the capacity expansion is being done with upcoming development in mind.

Perkins said projections show the plant will need to be expanded yet again about 2024. z

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

SPONSORED ARTICLE

Dropping the hammer A UK company has developed an innovative valve to deal with water hammer Cheshire, UK-based T-T Flow has an innovative approach to preventing the damaging effects of water hammer, which has seen the company win contracts from water authorities across the globe. The nonslam design of the recoil swing check valve can prevent the problems associated with sudden changes in flow rate.

Water hammer is a pressure surge or wave caused by either a sudden closure of a valve in a pipeline system or when a pump starts or stops, resultantly causing the liquid in the pipe system to suddenly stop or change direction. The pressure caused by the change in motion can cause anything from a noise and vibration to even pipe collapse. Multi-pump systems are more prone to slam than single pump systems. However, water hammer is common in both if the correct equipment is not selected for the application.

These rapid changes in the pressure can cause the flowing water column to undergo a momentum change producing a shockwave that can travel back along the system. The resultant shockwave can cause expensive equipment damage or system failure to both the pump and the pipework.

When flow velocity is suddenly reversed in a piping system, the kinetic energy of the flowing liquid turns into pressure. For every 0.3m/sec change in velocity, there will be approximately a 3 bar pressure surge. It only takes around a 1.5 bar pressure change in velocity to produce a mild slam.

The noise can be irritating to neighbouring personnel, but the detrimental effect of a major slam can cause pipe collapse and therefore be costly and time consuming to repair.

The prevention of water hammer initially depends on closing the valves located close to the pumps in the pipework system as rapidly as possible after the influx of the forward flow terminates.

Furthermore, it is vital the valve door does not slam down onto the valve seat. Therefore, a fast reaction and controlled closure is required to successfully prevent water hammer.

The recoil check valve in action With over 25 years of experience, T-T Flow experts are professionals in the design, manufacture, and distribution of a range of engineered waterworks valves and associated ancillary equipment.

The company is delighted to have recently secured a number of contracts from global water authorities. The contracts are for the supply of performance non-slam check valves that assist in preventing water hammer.

The recoil check valve has been specifically engineered to ensure rapid closure yet negating slamming during flow reversal. Due to the unique metal-seated non-slam design of the check valve, the unit is capable of withstanding velocities up to 5m/sec, whereas a conventional swing check valve is suited to a maximum velocity of approximately 3m/sec.

As standard, the valves feature a precision machined weld overlay deposit copper alloy seat, durable fusion bonded epoxy coated ductile iron body, stainless steel fasteners, and WRAS-listed materials, making the valves suitable for both wastewater and potable water duties.

Recently supplied units have

included ancillaries such as flow sensing switches and integral bypass assembly with isolating valve.

Single door units are available from stock flanged to EN1092 rated to 16 bar, while alternative flange configurations, multi-door units, higher pressure ratings, and materials suitable for saline duties are also available.

T-T Flow is the specialist waterworks valves division of Cheshire-based T-T, which is one of the UK’s leading companies in the design, manufacture, supply, and installation of pumps, controls,

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

T-T Flow recoil check valve

valves, and environmental products and systems. These products are complimented by the company’s support services including project assistance from concept to handover, after-sales support, and service agreements. z For more information:

This article was written by Rebecca Jones, marketing assistant at T-T Flow.

Call +44 (0) 1630 647111 or visit: www.ttflow.com

AIR VALVES Don’t let the potential destructive effects of water hammer cause unnecessary damage and breakdowns to your pumping systems.

Get in touch with T-T Flow today and speak to one of their experienced technicians about their anti-slam air valve range.

01630 647200

www.ttpumps.com 11

Fluid Handling.indd 1

13/01/2017 11:44:41

INTERVIEW

An early bird saves in costs Proactive and preventative maintenance strategies reduce plant operators’ expenses and headaches

Weir Flow Control is a global solutions provider for the power, industrial, oil and gas, and mineral sectors. Consisting of eight businesses around the world, Weir produces 14 brands of valves, actuators, and pumps while also providing asset management services. In the UK, Weir’s facility in Alloa, Scotland, is one of the UK’s largest engineering facilities at 124,000ft2 and is dedicated particularly to helping UK power stations and industrial processes. Ilari Kauppila of Fluid Handling International caught up with the facility’s supervisor.

Could you please introduce yourself to our readers?

My name is Phil Russell. I’m the actuator supervisor for the workshop facilities here in Alloa, central Scotland. I’ve been with company for nearly 12 years now and one of the main things that I’ve investigated and developed is the service exchange on valves and actuators. Our work is all about providing continuing support for the ageing power production fleet here in the UK, but also to a certain extent globally as well, mainly in North America, parts of India, and South Africa.

What are the biggest challenges you currently face in the industry?

The biggest challenge at the moment is the nuclear stations. But it’s a challenge that works in our favour, in that engineering changes can be very difficult within the global nuclear fleet. Say that we have a 40-year-old nuclear power station. The equipment contained within it needs to be maintained to stay as close to the original state as possible, rather than substituting it with old pieces of equipment from the original manufacturer that have become obsolete, unreliable, or just very difficult to deal with. That’s where we’ve been specialising, keeping these older pieces of equipment in a running, often better than new condition, 12

especially if they are particularly important bits of kit that are safety related.

Other challenges exist outside the nuclear fleet in the conventional coaland oil-fired stations. The processes involved are different and in many respects the engineering changes are much easier, cheaper, and simpler, as we can just swap out old pieces of redundant kit for new off-the-shelf items rather than continuing down the bespoke path. We can offer various different solutions to the customer for keeping their old kit or renewing it with more modern kit. We tell them the pros and cons and the cost benefits, and guide them into the decision that’s the best for them.

When you’re called to help out a power station, where do you start?

Generally, from my point of view, it’s a reasonably simple process. We’re not looking at modifying enormous pieces of plant or entire systems, but much smaller, isolated units. These might be valves or actuators or a combination of the two.

It might be a control circuit or a smaller component within an actuator or a valve.

These little things generally come from critical plant ratings where a piece of equipment has been identified as critical to the power station’s safety. That can go hand in hand with any previous failure reports if a unit has been inspected over the last two or three maintenance regimes and it’s been highlighted as needing

Hopkinsons AutoTork actuator on valve

further maintenance, rather than just a basic inspection and commissioning.

So, we’re looking at historical data, and failure modes as well. Quite often, the equipment we’re dealing with has been very reliable over the last 20, 30, or 40 years, but it has been left alone and hasn’t been maintained. That’s when failures are going to occur, because the equipment is not looked after. And then something goes wrong. It can happen in the blink of an eye and it’ll be the first anybody knows about it.

What we would look to do in a scenario like this is to personally identify what’s gone wrong with the particular piece of equipment. We would then look and see what other similar pieces of equipment in a similar condition there are in that plant. Have they been maintained, upgraded, repaired, or overhauled before they reach a critical failure point?

In a very different kind of scenario, moving from reactive maintenance to proactive maintenance, we do a lot of service exchange work. These services come into play when critical plant items have been identified and there are spare items on the shelf. During a suitable shutdown period, these pieces of kit are swapped out with the spare items.

The unit to be maintained then goes off plant and arrives to our workshop, where it will get overhauled, refurbished, and tested, or whatever is required. It will then be sent back to the power station shelf to wait for the next swap-out.

It’s all about having a spare unit on the shelf somewhere that’s ready to go. Having that spare valve or actuator provides for a very quick and easy swap-out time. Any faults that have occurred with the equipment that has just come off the plant can be dealt with in a slow turn-around time. There’s no premium labour rates or rushing around panicking and trying to fix it without doing a full investigation into what’s gone wrong. There are many benefits to it.

Does the trend of reducing spare part inventories at plants affect your service exchange activities?

First of all, this trend is not based on component numbers but on value, and we do see a lot of companies wanting to hold less inventory value. We suffer from the same financial restrictions

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

INTERVIEW

Phil Russell (r) training a colleague on actuator services

Weir’s Alloa facility

Alloa employee working on valves

here at Weir as well. We all want to hold as little stock as possible while still being able to maintain all the pieces of plant that need to be maintained.

It’s all about identifying the critical items.

There’s no point in holding huge amounts of spare stock. For example, let’s look at the reactive and proactive maintenance models. In the reactive model, you have to maintain a piece of equipment during an outage, so it has to happen on a very tight timeframe. You don’t know what you’ll find when you open the item up, so you will inevitably hold a lot more spares than you might perhaps need to cover all your potential defects. You will want to hold contingency parts.

If you’re looking at planned, proactive maintenance where you’re swapping out entire units, you’re essentially holding less stock because you’ll know exactly what you’ll need – one unit to swap. There’s then time for the units that come off the plant to be stripped down and assessed.

You can take your time to order only the required spare parts to bring that unit back to full working order. All this can be done without having a lot of surplus stock littering shelves that essentially never gets used. That’s one way of dealing with the goal of reducing spare part inventories.

The other thing we’re looking at is having a shared pool of equipment, not necessarily between different customers at the moment, but certainly between different applications and stations within the same power station owner.

For example, if we take the UK nuclear fleet run by EDF Energy, we’re identifying certain pieces of equipment. For these pieces, we can then hold one spare in central stores, which can be either EDF- or Weir-owned. That one particular unit could be used anywhere in up to 32 locations at different power stations around the UK. Again, rather than having each power station stocking its own set of spares, we’re identifying units that can be easily transferred between stations, knowing

that – since we’ve done all the technical investigations – these pieces of kit are identical and they will fit straight into the plants without any modifications or fuss.

That also leads to stock cost reductions.

have closed. By that time, we might be looking at developing areas where the more recently built stations need help. For example, we’re not quite sure yet what’s happening with the Somerset-based Hinkley Point C. The new areas is where we will start developing the market. It’s going to be different pieces of equipment, it’s going to be different processes, but that’s where we need to be focusing.

How popular have these kinds of maintenance services been?

We’re not talking about many thousands of units here, but it has been growing steadily since we started introducing this model roughly 12 years ago. We’ve now pushed our methods out more globally, so people in countries like South Africa are now on board. Particularly the people at the Majuba power station in Mpumalanga are very keen to have spare units available. The service has also been very popular with Bruce Power and OPG Pickering in Canada. It is a slow, organic growth where people start seeing the benefits and want some more.

The word starts spreading and we try to answer the demand the best we can, so the service is increasing in popularity.

There is a reasonably finite amount of time to do this, though, since certain older stations, whilst we’re still developing some processes to extend the power station lifetimes, are starting to shut down. At that point, this kind of service becomes not quite so economically viable. The growth, I’d say, is almost coming to a plateau right now. Other parts of the world – like South Africa and Canada – are in the early stages of their service exchange development, while the UK is now starting to trail off a bit. Some of the country’s nuclear sites are going to be closing in six to eight years, maybe in 2022-2024, so they’re asking how much money they want to invest in these strategies or whether it is more viable to repair existing installed equipment. There are areas that are growing, but there are also areas that are starting to peak.

Inevitably, there will come a time when none of this old kit is required at all, because all the older power stations will

Are there any obstacles with trying to break into international markets?

We do have a fair amount of product in India. I think the Indian way of dealing with maintenance is very different from ours.

It’s very reactive, as they don’t do a lot of proactive, preventative maintenance.

As such, they generally find their own ways of fixing and remanufacturing equipment, which makes it difficult for us to penetrate that kind of a market as they also do it very cost effectively for themselves. That brings its own challenges.

With regard to the Middle East, as far as I’m aware, there’s not quite as much ageing equipment. It’s a much smaller base of equipment, and in places like China, for example, a lot of the equipment is very new. There’s a lot of power development in China, but their plants have also been designed, developed, and manufactured in China, which again makes for a really difficult market to penetrate. We tend to look to China these days as suppliers instead of customers.

Finally, what are you looking hoping to get out of 2017?

Tongue in cheek? An easy life, but I’m not sure that will happen. I’m looking to grow and develop what we’re doing already, as well as investigating new solutions that might be useful to our customers. At the end of the day, what we want to get out of 2017 is good customer relationships.

We want to grow as a business, acquire a bigger customer base, and receive good feedback. That’s what we’re aiming for. z

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 13

MARKET ANALYSIS

A year of light and shadows Year

Export 4.782.262,47

Import 7.184.040,93

2007 equipment industry is Having survived 2016, the Spanish fluid handling 5.109.183,94 7.144.553,92

looking to the future 2008

Building business associations is a widespread practice in Spain. The associations’ paramount objective is the defence and strengthening of their represented sector. There are many associations in the country, as the industrial base is wide enough to organise different sectors around associations or clusters (fluid handling equipment, machine tools, telecommunications, and software, among others). The associations usually group manufacturers and also related companies working throughout the value chain. This enables the companies to cooperate, have different business approaches, and take advantage of arising synergies among them.

Fluidex, the Spanish Association of Fluid Handling Equipment Manufacturers, was founded in 1989 by the eight largest exporters at the moment in Spain, with the aim of reinforcing the fluid handling sector through the augmentation of exports and arranging different promotional activities that were not accessible to the companies by that time.

compressors, filters, instrumentation 2009 for fluids, boilers, heat exchangers,

pressure vessels, refrigeration towers, 2010

components for valves, and more.

2011 These companies represent more

than the 70% of the total number of 2012 Spanish fluid handling equipment

exports. The main sectors in which 2013 the companies operate are the oil and gas (upstream, downstream, 2014 Year

petrochemical) and water (desalination,

2007

distribution, treatment, sewage) sectors, 2015 2008 but the equipment also has a wide 2009 2016 presence in mining, energy, marine,

2010

paper, cement, and other industries.

Fluidex tries to promote the overseas 2011

2012 presence of its member companies

through the organisation of trade 2013

delegations (direct or inverse), exhibitions, 2014 technical seminars, and networking 2015 events. Not only does the association 2016 arrange these kinds of activities, it also

develops market intelligence reports and research about markets in order to provide the member companies better tools to access international markets.

Lately, diverse actions focused on innovation has also been undertaken.

The companies, the people

4.068.663,99 5.098.991,84 the oil and gas sectors. Accordingly, the investment in other sectors (like water or 4.561.087,55 5.606.753,56 energy) has also stopped, which means 5.059.640,98 5.889.209,34 there is a lack of dynamism in the world economy that is causing most companies 5.377.434,74 to struggle to maintain5.701.695,39 a market share.

Purchase orders come now mainly from 5.639.553,09 5.589.416,71 maintenance and repair activities and not at a pace that would make companies 5.998.518,05 6.225.082,79

Exportor even maintain Import grow their current level.

4.782.262,47 7.184.040,93 Therefore, we have a complicated 6.372.958,38 7.188.342,71 5.109.183,94 7.144.553,92 economic situation on one hand, but on 4.779.753,33 5.628.871,40 4.068.663,99 5.098.991,84 the other, the lifting of sanctions against Iran in the beginning of 2016 and the 4.561.087,55 5.606.753,56 cautious opening of the Cuban market 5.059.640,98 5.889.209,34 has provided a glimmer of hope to 5.377.434,74 5.701.695,39 the uncertainty of 2016. Nevertheless, 5.639.553,09 5.589.416,71 the potential projects that may be 5.998.518,05 implemented to6.225.082,79 reindustrialise both Cuba 6.372.958,38 7.188.342,71 and Iran after years of sanctions, and some positive news like Eni’s discovery 4.779.753,33 5.628.871,40 of the Zohr gas field in Egypt in 2015 (the biggest of the Mediterranean area), show that there are still opportunities in the markets that may boost the economy and make the pipeline of projects flow. As some companies have mentioned, a rise of the oil price to $70 (€67) per barrel and some stability in it would make the big

Exports (€K)

Sector analysis Fluidex members are companies working together to help each other gain access to new markets. Currently Fluidex has more than 80 member companies, among which are also the largest Spanish manufacturing companies.

The equipment manufactured by members ranges from tubes, pipes, pipe fittings, flanges, and sealing equipment to valves and actuators, pumps, 14

The past year has been a year of both light and shadows for the Spanish fluid handling equipment sector. After the oil price crash in late 2014, the investment of oil producing countries has experienced dramatic cuts despite the timid price increases in the last months. This has resulted in a lower number of new projects and the slowdown of existing ones in

Exports (€K) 8,000,000.00 6,000,000.00 8,000,000.00 6,000,000.00 4,000,000.00 4,000,000.00

2,000,000.00 2,000,000.00 0.00

0.00 2007

2009 2011 2013 2015

2007 2009 2011 2013 2015

Exports (€K)

Spanish fluid handling equipment exports

Exports (€K)

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

MARKET ANALYSIS

If oil prices rise, offshore oil could become a lucrative market for fluid handling equipment makers

Fluidex plans to invite delegates to Spain

international companies (end users like BP, Chevron, and Total) restart investment in exploring, drilling, and refining activities.

The water sector, by contrast, is still weathering the storm, as it is also influenced by the budgetary cuts mainly in oil producing countries. As incomes decrease, the investment in infrastructure is reduced in the same proportion. However, as water is essential for life and societies are more and more aware of climate change and water deficit, developing better performing equipment and adding value to industrial items for water treatment is one of the main challenges that the sector is facing nowadays. Therefore, there is still a gap where companies are working in and where they can find interesting business opportunities, mostly in the water-stressed regions of the world and developing countries.

Regarding the Spanish fluid handling equipment industry, it is undeniable that the current economic situation has had an impact on the equipment exports, and the fall has been almost as bad as it was in 2009 when the effects of the subprime crisis took place. European manufacturers have to deal with Asian

competitors and they have little chances pricewise, even if the European quality is far above the average.

The size of the domestic market is small compared to other competitors, so the manufacturers usually need to look for other opportunities overseas in order to expand their business network and maintain their market share.

Some of the most important markets

for Spanish companies are the NAFTA area, Middle East, and Latin America.

In Spain, where there is a lack of strong R&D policies, innovations come mainly from the companies that invest in developing new equipment, new processes, or whatever the sector is or will be demanding. As public aid to support internationalisation and innovation is almost non-existent, the work of trade associations is vital to stimulate the industry and support the companies introducing new ways of working, cooperation, etc.

For 2017, Fluidex expects to conduct several activities abroad, following the strategic plan approved by its member companies. It is scheduled to visit some Commonwealth of Independent States (CIS) countries, such as Uzbekistan or Turkmenistan, as well as Mexico, the US, and the Philippines, among others. An Inverse Trade Delegation is also expected to be organised, bringing some of the world-leading EPC contractors to Spain in order to show the capabilities of the Spanish fluid handling equipment sector. There will also be a presence of Spanish companies at international exhibitions such as ADIPEC in Abu Dhabi and the Iran Oil Show for the oil and gas sector, and AQUATECH in Amsterdam and WATEX in Tehran for the water sector, among others. z

rmation : Additional Info e/en/camlock w w w.elaflex.d

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 15

PUMPS

Protect your pumps Polymeric repair materials and coatings can extend pump service life in harsh applications

After six years in service, the pump components were still in excellent condition

Sludge pump lifespan keeps on extending

16

Regardless of the pulping methods, paper mill pumps are put under immense strain due to the transfer of viscous material throughout the pulping process. Together, the sludge and slurries combine a high solids content, copious amounts of entrained air, and often processing chemicals used to extract the cellulose from the wood fibre. This resulting combination can cause issues associated with erosion, corrosion, and chemical attack and the subsequent impact of these damage mechanisms can truly affect the pump’s efficiency.

Initially, damage will lead to rough and pitted surfaces, which will increase friction and lead to a drop in the efficiency of the system as well as increased running costs.

If not tackled in time, corrosion-erosion problems may jeopardise the integrity of the component, ultimately causing failure of the equipment. This can be

to the detriment of the pulping process and the operation of the paper mill.

Trouble in Italy In 2010, an Italian paper mill was suffering from particular problems relating to these effects. The casing and internal components of a cast iron, submersible sludge pump were being troubled by immersion in chemically saturated slurries and the pumping of erosive materials. In fact, the stresses were taking a significant toll on the pump, which was barely lasting a maximum of two years in service before requiring major overhaul and replacement.

While replacement might be an obvious solution, this was costly not only in terms of replacing the equipment but the downtime that was associated with dismantling and installation of

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

PUMPS erosion-corrosion protection and impressively, the coating was found to be in excellent condition. However, it was decided to refresh the coatings in order to prepare the pump for more years of service in sludge. Therefore, the original coatings were roughened before applying a new layer on top. Not only did this continue to extend the pump’s service life further, saving the company replacement costs, but ensured that the equipment was protected in the longterm against the dangers of erosion-corrosion.

Enzo Arrabito, CEO for BSl, comments: “This type of application is one that we complete frequently on

Pump components recoated to ensure functionality continues

new pump components. In addition, replacement usually involves long lead times of weeks, or even months. These periods of limited processing power made it necessary that the paper mill reduced output, a seriously expensive problem when taking into consideration the regularity of the pump’s deterioration.

More importantly, this option did not address the underlying problem. Unsatisfied with its current approach and in search of an alternative, the paper mill contacted BS, Belzona’s representative in Italy, looking for a viable solution for its consistently failing pumps. After careful selection, a combination of erosion-corrosion resistant systems was chosen to complete the application.

Initially rebuilding the metal loss in the pump using Belzona 1311 (Ceramic R-Metal), the pump was internally coated with Belzona 1321 (Ceramic S-Metal). These systems form

a durable protective coating for metal repair and erosion and corrosion protection, simultaneously demonstrating excellent chemical resistance in continuous immersion situations. Finally, the pump was coated externally using Belzona 5811 (Immersion Grade), designed to preserve equipment operating under immersed conditions from corrosion damage. This created an essential barrier against the chemicals used in the pulping processes.

Six years strong Overall, this solution aimed to eliminate the need for replacement, reducing the much-maligned downtime associated with regular overhaul. Originally coated in 2010, six years later the customer opened the pump for mechanical maintenance.

Throughout its six-year service life, the pump faced zero downtime due to Belzona

small, medium, and large scale components. The pump in question was suffering immensely from erosioncorrosion damage. Therefore, the client expressed their

satisfaction that the lifespan of the pump could be extended significantly through the use of a polymeric solution. At the same time, this reduced their maintenance costs and allowed them to achieve greater efficiency from their equipment. Its immediate effects on performance will be maintained over a long period, reducing power consumption and saving on operating costs.” z

For more information:

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

PumP EfficiEncy SolutionS Belzona polymeric coatings can restore laminar flow rates and even increase pump efficiency levels beyond the original specification.

REPAIR

Eliminate the cost of component replacement

PROTECT

Extend the pump’s designated life

IMPROVE

Reduce turbulent flow and increase efficiency by up to 20% on worn pumps

For more information on Belzona’s pump efficiency solutions visit: www.belzona.com/pumpefficiency

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 17

SCAFFOLDING

An attractive solution

By Ilari Kauppila

A magnetic scaffold anchoring system helps to promote safety and saves plant owners, not only space, but time and money The use of magnets, both weak and strong, is a proven technology in several professional and industrial sectors. One of them happens to be fluid handling, where magnets are used in break-away couplings, magnetic bearings, valves, and other pieces of equipment. Now magnets are also being brought to scaffolding construction.

Scaffolding is employed to get workers up to hard-to-reach areas in many industries. Within fluid handling, one major application for scaffolding is the construction and maintenance of tanks, both at processing facilities and at tank farms. However, the traditional method of constructing a pyramid-like structure of scaffolds can prove problematic.

The scaffolding pyramid, to begin with, requires large amounts of material to build as the lower parts must support those on top of them. Naturally, these materials have to be paid for, and thus the scaffolding can add a large amount of costs to tank construction. The pyramid structure’s lower portions require a significant amount of floor space, which may not be available at all installations.

Finally, according to regulations, scaffolds must be anchored to the working wall with ball joints, with one joint per 10m2. This anchoring method cannot be used in all environments, such as offshore installations and petrochemical 18

Controlock technology in use at Dow Chemical’s Terneuzen plant

facilities, as it can damage the tank material and lead to explosion risk.

Safety and savings As a solution to this problem, Dutch company McNetiq has developed the Controlock magnet technology.

The Controlock is a unique force measurement technology that establishes the retention force of a magnet with 100% certainty. The anchor points measure the load capacity of the magnet at the anchor location in advance through built-in measurement and

registration devices. The measurements apply to both the perpendicular tensile force and the shear force.

Traditional magnetic anchors are designed around a standard value for the maximum load. However, the maximum load value cannot always be achieved due to an uneven surface, air gaps caused by corrosion, fouling, or paint, or a varying thickness of the wall material.

Edwin van der Heide, co-founder and director of McNetiq, tells Fluid Handling International that the Controlock technology got its start as a tool for scaling metal surfaces.

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

SCAFFOLDING “My partner and I first developed a system to climb on iron surfaces with magnetic tools held at the climber’s hands and feet. A rope access specialist inspired us to look for a way to secure rope accessors during their projects with a magnetic anchor in case there wasn’t a certified anchor point available. My partner then created the principle for a safe, measurable magnet,” van der Heide says.

The Controlock system utilises permanent magnets in order to ensure constant adherence to the wall surface.

Electromagnets used in some other anchoring systems are reliant on an external energy source to function properly. If this power source fails or there is malfunction in the power connection, the results could be catastrophic.

Permanent magnets, on the other hand, always have power and can be relied on even in the case of power loss.

In addition to increased safety, the Controlock technology also offers operators and construction companies savings in material costs. For example, let us assume that a traditional pyramidshaped scaffolding structure takes up 2,100m3 of space and requires 20 tonnes of both construction material and ballast.

By using the Controlock technology, the large support structure on the bottom can be removed, bringing space requirements to 275m3 and reducing the amount of materials to 6 tonnes.

Ballast is not required in this case at all.

Not letting you down McNetiq has already successfully applied the Controlock system in several projects. One of them took place in 2013/14 in Terneuzen, the Netherlands, at Dow Chemical Co.’s plant. The traditional pyramid scaffolding could

Amount of materials needed for traditional pyramid and Controlock scaffolding of same height

Services to devise a solution for its dilemma.

As the tank walls were made of steel, Bilfinger suggested the use of magnetic scaffolding. However, at the time the technology’s use in scaffolding was unproven, so there were some precautions to look at. Bilfinger built a 3D model of the project’s finite elements to determine the forces of each individual anchor point. Test equipment was developed, and external experts such as McNetiq were consulted.

In the end, the project was realised with

In addition to increased safety, magnetic anchor technology also offers operators and construction companies savings in material costs not be used at the plant in conjunction with an ethylene tank, as this method was deemed too labour-intensive and cost-prohibitive. Additionally, no “hot works”, such as welding and grinding were allowed near the tank, making building the pyramid impossible.

Dow contacted Bilfinger Industrial

significant cost savings and high safety.

The scaffolding took five times less room than a traditional pyramid structure, being only 1.5m wide and 5m long.

Michel van der Gracht, manager of the production planning department of Bilfinger, sees a lot more perspective for the technology. “This project marks

the beginning of a new development in scaffolding erection. In consultation with the partners, the standard magnets that are currently being used will be developed continuously for specific applications in scaffolding,” he says.

Van der Heide also agrees that there is much potential for Controlock.

However, instant success is undermined by attitudes in the scaffolding industry. Van der Heide says this is understandable, as the scaffolding companies’ turnover is dependent on the volume of scaffolding they build.

“Our answer to this is to approach the asset owners and explain the benefits of our system, because they have to pay the bill of the scaffold builders. With this approach, we hope that the asset owner convinces the scaffolder to use the Controlock anchors,” says van der Heide.

McNetiq hopes to introduce the scaffold anchor internationally to pull in more business. Should international distributors be attracted to the magnets, van der Heide sees a new avenue for more magnet-based products, such as temporary fall protection anchors. z

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 19

Omal employee cleaning Passirano’s theatre before local schools’ performances

CORPORATE RESPONSIBILITY

For the better of all An Italian valve maker has engaged its community in a social responsibility programme – with good results

By Ilari Kauppila There is currently a trend in the fluid handling industry, as in so many others worldwide, to become more environmentally and socially conscious in the face of global climate change and international agreements, such as the Paris climate agreement of 2015.

Equipment manufacturers throughout oil and gas, chemical and petrochemical, general industrial, and many others are constantly looking for ways to reduce fugitive emissions, make their products more energy efficient, reduce the impacts of their material sourcing, and so forth.

And indeed, significant leaps have already been made in these areas in the industry, and it does not seem like advances in technology will stop any time soon.

But there is more than one aspect to “responsible operation”. Fluid handling equipment manufacturers are not entities isolated from the rest of the world.

They are members of their communities just as any other businesses, and the relationship between a business and a community is essentially a social one. That relationship goes both ways: a socially and environmentally responsible company provides for a more pleasant community for its residents, and the company can enjoy a good reputation and related benefits.

It simply makes good business sense.

One company that has realised this element of corporate responsibility is Italian 20

valve and actuator maker Omal. Founded in 1981 in Palaveno, Italy, the company has laid out its ambitions in an extensive ethical manifesto. In it, Omal describes its approach to ethics as consisting of three pillars – its people, its partners, and its community. Together, they form a strategy the company calls Social Innovation.

Including everyone But what is social innovation? In short, Omal describes it as the driver in improving its social and organisational performance.

The company does not believe that being aware of its place in a bigger community implies the relativisation of its operations, but rather optimisation.

“Social innovation has to do with producing goods and services in a responsible way, including a more

responsible approach to the core business,” explains Lucia Dal Negro, social innovation manager at Omal, while talking to Fluid Handling International.

“This means not only giving money to poor and vulnerable people, but really integrating responsibility into the business – for instance by lowering environmental impacts of our valves and actuators, respecting human rights, and advocating for more responsible business all over the world. That’s social innovation.”

This view is reflected in the three pillars of Omal’s ethical approach. The first pillar, Omal’s people, relates to how the company treats its employees, and in turn, the employees the company. Omal subscribes to national and international regulations concerning anti-discrimination, employee’s right to privacy, and firmly opposes forced and child labour, which is

Social responsibility does not have to come at the expense of business, Omal says

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

CORPORATE RESPONSIBILITY something it expects its suppliers to adhere to as well. Through this approach, the company wants to guarantee a pleasant and safe working environment, for both the employees and the company itself.

“Our entire operation, from the purchasing department to administration, communication, production, and so on, are all linked to a performance indicator that needs to be approved yearly. Therefore, the entire factory floor is linked to environmental and social impacts. We want to be better and better day by day,” Dal Negro says.

The second pillar, Omal’s partners, refers to Omal’s approach to its partners, namely that the company partners with clients to respond to its needs to provide reliable products. For example, Omal requires all its partners to verify through third parties that they do not engage in corruption, bribery, tax evasion, or money laundering. The company also refuses to source metals used to produce its valves and actuators from conflict areas, which is something Omal can prove with a national certification.

but significant activities in such areas.

These were identified as the way to go after my need assessment analysis, carried out to map the needs of the area and define the eight stakeholders most in need of help from our volunteers.”

The company has engaged in community-building exercises. Its volunteers have helped set up village fairs and school plays, visited elderly residents in care homes, and engaged in other activities through which it hopes to increase both the company’s and the residents’ sense of belonging to their communities.

“We work together with our stakeholders to help our communities. For instance, we help our schools, our hospices, and other vulnerable beneficiaries that need help from the profit sector, but not just in terms of money. Instead, we engage in terms of people donating time, doing things with them. This model has been shared with some of our suppliers from other companies who have begun copying the same thing. So, we’re magnifying the social impact by sharing our ideas with our suppliers,” says Dal Negro.

Concerning communities Beyond the standards The third and final pillar, Omal’s community, refers to what the company calls “tangible and intangible” impacts.

The intangible impacts, Dal Negro explains, are the ones on company reputation. They cannot be quantified or measured, but they are worth their proverbial weight in gold. It is the tangible impacts, then, that are the ones visible in the community.

“Passirano, Sarezzo, and Rodengo are the three villages where Omal has its three plants. They are very tiny villages, mostly industrial, so social space is reduced and poorly served by local institutions,” describes Dal Negro. “That is why Omal decided to help with small

An indivisible part of social responsibility is also care for the environment, and Omal has embraced this aspect in its social innovation strategy as well.

The company is a member of several environmental watchdogs and groups, and actively advocates making business more sustainable, not only in its own factories but also worldwide.

Omal is a member of Ecovadis, a global corporate social responsibility accreditor, who accepted Omal based on its “results and performance”.

“It’s not only us saying that we’re responsible, third parties are validating

Omal employee helping Alpini NGO set up tables and chairs for Sarezzo’s village fair

our words. We also have membership in UN Global Compact, the biggest initiative gathering responsible business all over the world. We are also investing a lot in carbon footprint mapping at an organisational level, which means that we’re double checking every fugitive emission that we have in every single production process.

We do this according to the ISO 14064 certification,” Dal Negro explains.

However, Omal is not satisfied with just meeting the standards and regulations. Instead, it wants to surpass them. “We want to be reliable for our buyers. Therefore, we are happy to be certified and to do a bit more than the regulations demand,” says Dal Negro.

Amedeo Bonomi, CEO at Omal, confirms Dal Negro’s statement. In his foreword to Omal’s ethics manifesto, he says the company believes in three basic guidelines – passion, respect, and a sense of duty.

“These are the three threads of principles intertwined with Omal’s activities that inform our mission and vision driving our operations. We do not want to address such values just because the market is asking for that. Nor because we fear to be at risk of external negative comments for not dealing with ethical issues at a company level,” Bonomi says.

Omal has been recognised for its efforts.

In 2016, the company was awarded the first prize at the Procurement Awards in the category “Ethical and Sustainable purchasing practices”. Recognition must surely feel good, but Dal Negro says Omal will not rest on its laurels. Instead, the company aims to enlarge its view and is planning to bring its social innovation model to other Italian regions, and finally to other countries. Omal has seen social and environmental responsibility makes good business sense, and wants others to realise it as well for the best of everybody. z

Omal’s Lucia Dal Negro playing Tombola with grandparents at Rodengo’s hospice

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 21

Never alone

TRANSFER SYSTEMS

Why a single flowmeter is not enough for custody transfer In all areas of industry where measurement of the flow of fluids is important, flowmeters effectively act as cash registers – they directly measure the revenue being accrued by the operating company from the export and sale of produced fluids. Therefore, to reduce levels of financial exposure, it is important that the metering systems are very accurate. This is especially true with the custody transfer of fluids, where ownership of produced fluids is passed from one company to another.

In the United Kingdom Continental Shelf (UKCS), the region of waters surrounding the UK in which the country claims mineral rights, the target uncertainties specified by the Oil and Gas Authority (OGA) are 0.25% on the dry mass of oil (95% confidence) and 1% on the mass of gas (95% confidence). This cannot be achieved by a single meter alone. It requires an integrated system of several different measurement and other devices designed to increase the accuracy of the volume or mass measurement.

Failure to meet these targets could potentially cost an operating company millions of dollars every year. For example, an error of just 0.1% on a field producing 50,000 barrels a day will lose nearly $1 million dollars (€940,000) annually just down to that single mismeasurement (assuming a cost of $50 per barrel).

System components A full custody transfer system requires a range of measuring equipment to achieve the low uncertainties required. As well as the flowmeters themselves, they will require pressure and temperature measurements, density measurement, fluid mixers and flow conditioners, sampling systems, provers, and flow and supervisory computers.

Many custody transfer systems use more than a single flow stream to ensure that the flowmeters are operating in the optimal part of their measurement range. The types of flowmeters commonly used in custody transfer systems have been turbine meters (usually for liquid 22

OIL EXPORT METER PROVING PACKAGE Stream 1

PT

TE

Turbine Meter FE

From booster pumps

Stream 2

PT

TE

Stream 1 Flow Computer

Turbine Meter FE

Stream 3

PT

TE

Turbine Meter FE

Stream 4

PT

TE

Turbine Meter FE

PT TE

PT

Prover Control Computer

TE

Figure 1: Oil export meter proving package

systems) and orifice meters (usually for gas). Over the last few years some of these meters are gradually being replaced with newer technologies, such as ultrasonic and Coriolis meters.

However, there are still a large number of traditional systems in place.

Ultrasonic meters are volume measurement devices, which generally use a flow measurement technique based on the transit time of a beam of ultrasound with and against the direction of the flow of the fluid. They have the advantage that they have a very high turn-down ratio and cause negligible pressure drop. Newer models are becoming increasingly accurate as more Ultrasonic paths are added.

In addition, new diagnostics are continuously being developed. Coriolis meters are direct mass flow measurement devices, which are less sensitive to installation effects than most other instruments and have high accuracy and repeatability over a wide turn-down ratio. Figure 1 shows a four stream turbine

meter system for measurement of liquid.

This is complete with a pipe prover and a densitometer and fast loop sampling system. Note that in many metering systems, especially where space is at a premium, flow conditioners may be added to each of the flow streams. These devices reduce installation effects on the flow measurement by removing some of the asymmetry in the flow caused by pipe bends and valves. However, they cause a significant reduction in static pressure.

Meter proving To keep the uncertainty of the flowmeter within the prescribed uncertainty limits, the system should be “proved” on a regular basis. Proving involves basically calibrating flowmeters on-site against a very accurately known volume and making an adjustment to the meter reading to make it consistent with that volume.

Various types of proving devices are available, including pipe provers, compact provers, and master meters. A

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

TRANSFER SYSTEMS at a defined volume interval, or time proportional, where they are collected over a defined time interval. The Detectors actual sample points can be either in-line or bypass (fast loop) systems.

For gas systems, a gas chromatograph (GC) is used. This involves injecting a sample of the mixture into the column of the chromatograph. As the mixture travels through the column, it is separated out into components. As each component leaves the column, it passes a detector, which identifies it and registers it as a peak on a chart that has a series of peaks that correspond Known Volume to all of the substances in the mixture.

Figure 2: A pipe prover setup Density measurement is a key element simple pipe prover is shown in figure 2. crucial in the accuracy of custody in the custody transfer measurement A length of pipe is fitted with detectors transfer measurement. It is important to of fluids. The most widely implemented such that the volume between the realise that the sample in the laboratory approach for mass flow measurement detectors is known very accurately. If on which a very expensive cargo will be is to use a volumetric flowmeter and a displacer or a sphere (the red ball in based is of the order of 1ml. Therefore a densitometer. In this case, the the figure) is introduced into the flow, fluids should be completely mixed before uncertainty in mass flow measurement is the time it takes to travel between the a sample is taken. This can be done dependent equally on the uncertainty switches will give a measure of the by either using a static or a jet mixer. in volumetric flowmeter measurement flowrate. The switches are used to start A static mixer is used to continuously mix and in densitometer measurement. a pulse counter, totalising pulses from a fluids and is situated in the pipe in which All commercial liquid density meters flowmeter and a determination of the the fluid is flowing. Jet mixing systems use work on the same general principle. k-factor (pulses per litre) can be found. a pump to extract a small portion of the The manufacturers generally model Common types of pipe provers include fluid and re-introduce it into the pipeline the instruments as a simple spring mass uni-directional, bi-directional, and in the form of high velocity jets upstream oscillator system comprising the vibrating piston provers. Another way of proving of the sample point. The effect of these test section and the fluid contained in it. a meter is to use what is known as a jets is to evenly distribute the water in the As the liquid density changes, it in turn master meter. This is an indirect proving crude oil sample over the cross-section changes the total vibrating mass, which method where a meter which itself has of the pipeline, to give a representative is then detected by a change in the been calibrated or proven and which sample at the extraction point. There is resonant frequency. These devices can has very good repeatability is used. a selection of different techniques to try measure the density to an uncertainty Linearity is placed in series with the meter to make the sample as representative of less than 0.05% (95% confidence). under test and the results compared. as possible: flow proportional sampling, Many custody transfer systems SAMPLING FOR CRUDE OIL FLOW Several different meter types can be where small samples are collected determine the volume at standard used as a master meter. For example, positive displacement (PD) meters have been used for years as master meters when checking petrol pumps and other water and oil applications.

Ultrasonic meters are also attractive as master meters because they provide no pressure drop through the line.

A PIPE PROVER SET-UP

Analysis of the measured fluids An accurate knowledge of the fluid composition is very important to minimise uncertainty. The two main ways of determining this are by gas chromatography for gas flow, and by sampling for crude oil flow.

Crude oil is sampled to establish the composition, density, and water content.

The samples should be as representative as possible of the flowing fluid. Proper sample taking and handling is therefore

Jet mixing nozzle

Jet Pump

Sample Probe

Figure 3: Sampling for crude oil flow

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 23

TRANSFER SYSTEMS conditions, that is at 15°C and 1.01325 bar(a). However, the operating conditions in the system are often very different from this, and so it is important to apply corrections to the volume based on variations in the temperature and pressure. This requires accurate temperature measurements at different parts of the custody transfer skid, as even small differences in these quantities can affect the measured standard volume. It is therefore desirable to have temperature and pressure measurement at each of the streams close to the flowmeter, at the prover inlet and outlet and at the point where the density is measured.

Flow computers Flow computers act as the actual cash register of the metering system. They receive signals from the described instrumentation and apply calculations and algorithms to determine the flowrate through the system. Events and alarms can also be recorded, such as loss of flow, or high or low flow alarms.

The computer has an interface that allows the user to enter data, such as

the latest calibration coefficients.

It also performs a range of other tasks, such as accepting dual pulse trains from turbine meters, accepting inputs from temperature and pressure sensors, and accepting a meter k-value via keypad or telemetry. The flow computer can then calculate quantities such as gross observed volume (GOV) flowrate, gross standard volume (GSV) flowrate, as well as gross mass. Some units can also calculate the net volume and standard conditions.

The gold standard Custody transfer metering is the “gold standard” for flow measurement in the oil and gas industry. The very low uncertainties required mean that a single meter cannot be used alone, and should be used along with other ancillary equipment such as provers, flow conditioners, mixing devices, samplers, densitometers, and temperature and pressure measurement. The meters commonly used in custody transfer systems include traditional technologies, such as turbine meters for liquid measurement and orifice meters for gas,

Alick MacGillivray – senior consultant at NEL

as well as newer meters such as multi-path ultrasonic meters and Coriolis devices.

Although the older technologies remain popular, the longer term trends in custody transfer measurement indicate that over the next few years they will gradually be replaced with the newer, more versatile ultrasonic and Coriolis meters. z

For more information:

This article was written by Alick MacGillivray, senior consultant at NEL. Visit: www.tuvnel.com

Don’t miss your chance to appear in the March/April 2017 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 feature: Downstream oil Fluid focus: Maintenance, leak detection Regular features: Pumps, valves, meters

Advertising deadline: 8 March, 2017 24

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

TRANSFER SYSTEMS

Crude oil measurement systems for custody transfer While each application is unique, ultrasonic flowmeters have certain advantages over other technologies in oil transfer applications Of the many products that are bought and sold based on flow rate measurements, liquid hydrocarbons provide us with unique challenges because of the wide range of physical and chemical properties that exist in the various products. Variations in chemical compositions lead to risks such as wax build-up, metal corrosion, or the degradation of elastomer seals.

For measurement transfer systems, the most significant property variation is usually due to viscosity. From light crudes and natural gas liquids (NGL) to heavy oils, this can range from less than 1 centistoke (cSt) to over 1,000cSt. For all of these reasons, it is important to consider all the available options in order to determine the optimum measurement technology for a given crude oil transfer measurement application.

Different metering options The positive displacement (PD) meter is the original custody transfer measurement technology and remains a dependable and highly accurate measurement system to this day. All PD meters separate the fluid flow into a volumetric measurement chamber that passes through the meter by the rotation of mechanical gears or vanes.

The TechnipFMC Smith PD meters use the rotary sliding vane design in sizes from 2” to 16” and offer the advantages of low pressure drop and long service life. These PD meters are versatile in use from high viscosity crude oils to refined products, biofuels, and liquefied petroleum gas (LPG). The rotary sliding vane PD meter has inherent resistance to the build-up of deposits and debris in crude oil, such as wax, because all sides of the measurement chamber are cleaned as the sliding vanes rotate in normal operation. When applied properly in application, this technology commonly lasts for 20 years or more with high accuracy measurement, making it a preferable investment.

Sliding vane type custody transfer PD meter

very reliable in the right application and is inherently repeatable when conducting field proving or calibration in custody transfer installations. Turbine meters are susceptible to effects from swirl and irregular flow profiles and require an upstream straight run with flow conditioning to maintain unbiased accuracy. Turbine meters are used extensively for custody transfer in sizes ranging from 20” high volume pipeline custody transfer to 1” in small marketing terminal applications.

The advent of modern electronics changed many things in our world and flow measurement is no exception.

The Coriolis mass flowmeter follows the ingenious principle of measuring the frequency and deflection in a vibrating tube to calculate the mass flow rate and fluid density. These measurements are combined internally to provide a volumetric flow rate output. The mass and volume flow measurement of a Coriolis meter is very accurate with a factory calibration of up to ±0.05% of reading on the reference fluid.

Key advantages of the Coriolis meter

The conventional turbine meter gained acceptance as a custody transfer accuracy measurement technology in the mid-1970s as a result of the low initial purchase price, small footprint, high flowrate range, and excellent performance characteristics. Due to the effects of viscous drag on the rotor, the turbine meter is limited in application to refined products and light to medium crude oils. The helical rotor turbine meter design extends the technology into heavier viscosity crude oils using a helical shaped rotor designed specifically to evade viscous effects with less surface area and more open area in the rotor design.

The turbine meter can be Sentry conventional turbine meter for pipeline custody transfer

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 25

TRANSFER SYSTEMS include no internal moving parts for excellent reliability and built in diagnostic capabilities that can determine if the meter is operating within normal specifications. The meter can operate over any fluid viscosity range and can successfully handle homogenously entrained contaminants, such as gas bubbles or solids. Limitations when compared to other technologies include an inherently high pressure drop and susceptibility to plugging up with paraffin wax inside the measurement tubes in some crude oil services if not correctly applied. Coriolis meters are very successful in applications where the accuracy, reliability, diagnostics, and density measurement capabilities contribute to the measurement success.

Liquid ultrasonic flow measurement Widely accepted in the custody transfer gas industry, the liquid ultrasonic flowmeter is gaining acceptance in custody transfer applications as the proving performance is being developed. The unique capabilities of the ultrasonic flowmeter make it ideal for many oil transfer applications. In certain applications, the liquid ultrasonic flowmeter has a unique advantage to other measurement technologies.

Of the measurement technologies reviewed so far, the ultrasonic flowmeter is unique in its ability to measure the fluid flow by observing its passage through an open channel without directly influencing the fluid flow itself. The other technologies all require the transferal of inertial energy from the fluid to the meter. This principle allows the ultrasonic flow meter to operate with zero additional pressure drop or obstruction to the passage of flow.

In order to achieve custody transfer levels of accuracy, TechnipFMC’s Ultra series of ultrasonic flowmeters use the transit time measurement principle. With this design, the precision electronics measure the time it takes for an ultrasonic signal to cross the fluid flow and reach the opposite side of the meter. The fluid flowing velocity is calculated from the difference in transit time from a signal travelling diagonally upstream and downstream of the meter. This process also measures the fluid velocity of sound with an accuracy that is enough to detect a change in fluid types.

To calculate a volumetric flow rate from the measured flow velocities, the ultrasonic flowmeter integrates the 26

velocity across the Ultrasonic flowmeter with web server interface area of flow. Changes in viscosity will affect the flow profile in the meter and therefore affect this calculation.

For this reason, custody transfer meters always incorporate multiple measurement paths that are also able to detect these changes in flow profile. The meter can therefore adjust the integration for changes in flow profile using factory calibration parameters that in effect make the measured and inaccessible locations where the output independent of fluid viscosity. benefits of electronic communication Determining the appropriate calibration and diagnostics can ensure the meter range for an ultrasonic flowmeter will is performing to specifications. With no depend upon the range of flow profiles components in the path of flow, the expected to be observed in the field. This ultrasonic meters do not impose additional is achieved by duplicating the Reynolds pressure drop on the pipeline or the number range of the application in maintenance of cleaning strainers. the flow calibration. The exact flow or The accuracy of a leak detection viscosity range does not have to be flowmeter is critical in leak detection covered in such a test as long as the ratio models such as RTTM in order to reduce of these parameters, as determined by the overall pipeline uncertainty and Reynolds number, is duplicated. This allows improve the ability to detect small leaks. operators to verify the performance of The challenge in many cases is to be a meter at a flow rate or viscosity that is able to achieve this over a wide range much higher than what can be achieved of products that could be running in the in a flow laboratory environment. line. It is not uncommon to see viscosities ranging from below 1cSt to 350cSt or Application experience higher in these applications. If calibrated over the equivalent Reynolds number Over 80 years of application experience range, an ultrasonic meter’s output will with crude oil transfer systems has be independent of the viscosity effects provided TechnipFMC with a wealth of and maintain accuracy over this kind of data on how to apply its various custody product range. Leak detection meters transfer measurement technologies. do not typically have provers in place, Certain applications are a natural fit for so an accurate calibration over the the unique capabilities of the ultrasonic complete range of products is essential. flowmeter. For an ultrasonic meter, some The out-of-the-box linearity of all of the key benefits are low pressure ultrasonic flowmeters is non-linear at low drop, high flow capacity, wide viscosity Reynolds numbers, typically 10,000Re calibration ranges, low maintenance, and below. To verify the calibration of an and fluid diagnostics. While there are ultrasonic flowmeter in these situations, it always exceptions, these general will need to be run in a flow lab over the guidelines can prove useful as a starting equivalent Reynolds number range as point for application evaluations. the application. The meter calibration is performed by running the meter over one Pipeline leak detection or more fluid viscosities until the Reynolds One of the best fits for the modern range is fully covered and there is overlap multipath ultrasonic flowmeter is in large between each fluid. To be trusted, it is pipeline leak detection applications. recommended that the flow laboratories These meters are depended upon to be ISO 17025 accredited, thus certifying run for long periods of time with high that all measurements are traceable accuracy and low maintenance. back to national metrological standards.

Meters may be located in remote In many cases it is critical to select FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

TRANSFER SYSTEMS an ultrasonic meter design with built in measurement and cancellation of swirl so that the meter can be installed without flow conditioning. The cancellation of swirl is not an inherent feature of ultrasonic flowmeters. Instead, it is derived from the physical arrangement of the measurement paths. One of the key advantages of ultrasonic flowmeters is the lack of internal components and additional pressure drop. If the flow meter requires flow conditioning, these benefits are lost. Installing a very long upstream straight run as a substitute to flow conditioning is not typically recommended, because the distance required, especially for large sized meters, would typically be prohibitive.

A typical ultrasonic flowmeter design for the cancellation of swirl is the eight-path meter using two crossing measurement paths in four vertical levels in the meter. This design also allows for measurement of swirl and crossflow, as well providing a valuable diagnostic to monitor the flow condition in the pipe.

The eight-path design allows for an accurate measurement of flow profile for a linear measurement over wide Reynolds number ranges, swirl diagnostics, and low drop pressure installations without the need for flow conditioning or long upstream straight runs.

Offshore oil allocation and custody transfer Measuring offshore oil transfers requires a flowmeter technology that is highly robust, reliable, and with built-in diagnostics to remotely monitor the measurement health. These installations are typically inaccessible and expensive to maintain.

Due to limited real estate, the meters may rely on a laboratory calibration in place

of in situ proving. These requirements point to ultrasonic flow measurement as an excellent technology option.

The combination of transducers and electronics in an ultrasonic meter make it inherently a very stable device. The ultrasonic transducers are powered by solid state piezo-electric crystals, which are pre-aged and maintain stable performance over long periods of time. The meter contains no moving components that should wear or shift in performance over time, resulting in a measurement system that is remarkably stable. This stability over time extends the period between proving and allows for the use of laboratory calibration directly.

Pipeline custody transfer There are many good options for pipeline custody transfer meter installations.

The optimum technology may tilt toward ultrasonic flow measurement as the preferred option in high flow rate applications when wide ranges of product viscosities are involved or when the customer is intending to extend prove intervals by using diagnostics.

The ability of an ultrasonic flowmeter to be calibrated over a wide range of product viscosities has been reviewed with regard to the advantages for leak detection. For pipeline custody transfer, the difference is the meter will more likely be proven to establish a meter factor on each product. The ultrasonic flowmeter is expected to maintain a more stable meter factor over a wide range of products and to do so without excessive pressure drop or increased maintenance.

For the optimum performance and transferability of the laboratory calibration to the field, these meters will typically

employ flow conditioning with at least 10D upstream straight run. With a more stable meter factor over the product range, the frequency of proving can be reduced with a direct reduction in measurement system operating costs.

Ultrasonic flowmeters, like other electronic flowmeter technologies, contain extensive diagnostic capabilities useful for analysing and interpreting the system operation and meter performance. For custody transfer applications, the greatest value is in the ability to detect component failures or out of specification operation as soon as the error condition occurs. In a meter without diagnostics, a fault condition could result in erroneous measurement until the flowmeter is proven again.

With diagnostics, many error conditions, such as blocked flow conditioning or a fault with a transducer, can be detected immediately and addressed.

For the purpose of diagnostic analysis, a measurement technology with onboard memory to eliminate the requirement for remote data logging is recommended.

About one month of onboard data is a good value for a safe and reliable record of meter performance. As diagnostics advance, the trend is to move away from the requirement to log data and analyse charts and towards smart systems that recognise faults using self-diagnostic techniques with much less operator intervention.

Conclusion This article has reviewed a variety of custody transfer measurement technologies with a focus on the applications and advantages for the multipath liquid ultrasonic flowmeter.

Every application is unique in its own way and there are no rules without exceptions, but the portfolio approach to crude oil transfers allows us to perform a thorough and individual analysis of each one. As the measurement experts in crude oil and refined product custody transfer, TechnipFMC is able to compare, contrast, and advice on the merits of the generally accepted custody transfer technologies available today for any given application. z

For more information:

Typical ultrasonic flowmeter installation for metering crude oil from tanks into a pipeline

This article was written by Andrew Soddy, product manager at TechnipFMC. Visit: www.technipfmc.com

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 27

TRANSFER SYSTEMS

Many players, one goal Creating compatibility from diversity in LNG operations

In liquefied natural gas (LNG) transfer, diversity is the norm. From traditional import and export terminals to floating storage regasification units (FSRUs), LNG barges and LNG carriers (LNGCs), LNG connections and transfers vary substantially. The LNG market is changing rapidly, and new opportunities are bringing new entrants into the game.

For each of these applications and stakeholders, there are many and diverse solutions and systems available, and constantly changing environmental conditions to adapt to. At the same time, the LNG industry is especially – and necessarily – safety conscious, committed to best practice and premium solutions.

In such a context, managing interfaces at various stages of the LNG supply chain is vital to safe and efficient transfer. Optimising and standardising the interface between all parties involved in the LNG transfer process is critical, as is cutting the time taken to navigate the channel, dock, moor, transfer, de-berth, and depart. This is a considerable challenge when one reflects on the diversity of stakeholders involved in the process: the jetty marine operator, the mooring crew, tugboat operators, pilot, and onshore control room team.

It is somewhat surprising then, given that the industry is usually so focused on “best practice”, that interface management is often not specified until late in the project process. By assessing and ensuring system compatibility early, stakeholders can achieve the flexibility they need to ensure their business model works now and into the evolving conditions of the future.

Whilst there is much diversity to contend with, whether the project is about expanding the capabilities of existing infrastructure or delivering gas in new and 28

challenging environments, LNG industry project owners have a converging view.

They always look for a business model that accelerates and maximises ROI while meeting their most demanding safety standards. The importance of compatibility between the two parties – or three in the case of FSRU applications – extends to the fender systems, hoses, data transfer and communication, and the docking and mooring solutions used.

Safeguarding transfer

There must be a holistic approach to projects, and this will become even more critical in the burgeoning small-scale sector with the more frequent transfers it will require. To ensure this compatibility, large and small-scale terminals and vessels alike need a robust interface strategy.

It takes knowledge of the overall process to approach planning in the optimum way.

That means sound engineering knowledge

in mechanical and structural engineering, electrical and instrumentation engineering, and software and communication engineering. All of these requirements must also be considered within the broader picture of up to date knowledge of all standards – electrical, class, and regional – and the interpretation of these within the individual operating conditions.

A good example of a successful up front holistic approach is the ship-shore link (SSL). The majority of the world’s LNG cargo fleets and terminals are equipped with SSL technology, a system for communicating the emergency shutdown (ESD) signals, telephone, and process data required when cargo transfer is undertaken from ship-to-shore and from shore-to-ship.

International regulations require ships and terminals to have two independent links available and also present a minimum of one system for compatibility requirements for passing along mutual ESD signals between ship and shore. The SSL system can handle all known types of links from fibre optic to electric: pyle national, Miyaki, ITT Cannon, and “SIGTTO style connectors” and pneumatic. The SSL-ESD ensures secure ESD signalling to mutually shut down ship and shore pumping and transfer systems in the event of an abnormal condition or emergency.

Case in point

Dave Pendleton, managing director at Trelleborg’s marine systems operation in the UK

In 2016, a major milestone was reached when the 600th Trelleborg SeaTechnik SSL was shipped for installation on a 174 000m3 LNGC (Hull number 2411) being built by Daewoo Shipbuilding & Marine Engineering (DSME) at their Okpo shipyard at Goeje Island in South Korea, for Teekay Shipping.

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TRANSFER SYSTEMS

Robust interface strategies help operators working with LNG vessels

David Glendinning, president at Teekay Gas Services, comments: “Our business is the safe, efficient transport of LNG for our customers. The SSL is a mission critical system in the cargo transfer process. Additionally, each of our vessels is also backed by Trelleborg’s Fleet Support Service, which ensures an expert is always at the end of the telephone and email 24/7.”

“As one of the world leaders in the supply of LNGCs and FSRUs, we recognise that the SSL is vital to the performance of our customers’ vessels as a trading asset,” Odin Kwon of DSME shipyard confirms.

The SSL-ESD helps to prevent damaging surge pressures that could lead to spillages of cryogenic liquid, which could in turn compromise the hull integrity through “cold-cracking”. The SSL, which should be ATEX, IECEx and SIL2 certified, handles the ESD, telephony, process information, and mooring load monitor data.

While a variety of different solutions were used up to the late 90s, the SeaTechnik integrated SSL assured full compatibility between the ship and any of the main systems installed at terminals around the world. This cost-effective flexibility was a significant factor in facilitating the LNG trade to change from the liner to the spot market in a decade when the world fleet expanded three-fold.

Richard Hepworth, business unit president at Trelleborg‘s marine systems operation, says: “We are very proud of our track record in customer service and innovation. Teekay and DSME have been key customers for us since the introduction

of our first SSL product 15 years ago.

“Innovation is an essential part of who we are and what we do and in that time we have constantly evolved our technology from the first analogue systems to the latest digital systems controlling complex FSRUs and LNG fuelling for marine vessels, including full process data transfer between vessels and terminals.”

An ongoing evolution Trelleborg is working to evolve its solutions for the LNG industry, and the Trelleborg’s fluid handling solutions operation recently marked a major milestone too, with the launch of a first of its kind Cryoline floating LNG hose-in-hose transfer system, which improves safety and lowers operator costs – improving access to LNG fuel.

The cryogenic floating hose system enables rethinking of the conventional wisdom in LNG ship-to-shore transfer for regasification, liquefaction, and terminal storage, as well as for gas power generation projects. It also offers a more viable and innovative alternative to existing ship-to-ship transfer systems, ensuring higher safety and operability standards through optional increased distances between vessels. And in utilising aerial hoses with large inner diameters ranging from 16” to 20”, operators have a greater choice of configuration, more flexibility, and a less strenuous replacement to conventional ship-to-ship systems.

“The Cryoline hose-in-hose transfer system with its full extended range from 6” to 20”

inner diameters is truly a ‘game changing’ technology, which will contribute to making it easier and cheaper to transfer LNG. It fulfils our philosophy of providing our customers with feasible solutions that improve productivity levels, protect the environment, save valuable resources, and make a genuine difference to the bottom line for operators and suppliers,” Vincent Lagarrigue, sales manager for Trelleborg’s fluid handling solutions operation, says.

“In today’s challenging markets, optimising operability is crucial. Trelleborg’s cryogenic floating hose is the only solution that could potentially offer up to 80% in operating cost reductions compared with traditional transfer solutions, equating to significant savings.”

Key applications for the Cryoline hose-in-hose transfer system include ship-to-shore configuration, ship-toship floating configuration (FSRU), and ship-to-ship aerial configuration.

Conclusion Trelleborg is currently working to raise awareness of the need to specify interface management early in the design process, and the need for stakeholders to do so in conjunction with a systems integrator experienced in project management, application engineering, mechanical, electrical, and software engineering expertise, and the ability to interpret and apply local, global, and class standards.

For the LNG industry, project diversity is the norm, as is looking for the quickest ROI whilst meeting the most demanding safety standards. The industry requires the most reliable and experienced partners to optimise the business model of any LNG transfer operation. The most integrated and configurable equipment solutions are critical to ensure safe, efficient, and cost-effective LNG transfer operations and ultimately, to sell more gas.

Overall, solutions for LNG transfer must be designed to optimise the business equation of LNG loading and unloading operations.

That means engineering infrastructure with all major key performance indicators in mind, from reduced time to operation, to capex optimisation and competitive operational lifecycle costs. From new market entrants to the traditional players, all LNG project owners should have this common goal and focus. z For more information:

This article was written by Dave Pendleton, managing director at Trelleborg’s marine systems operation in the UK. Visit: www.trelleborg.com

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ACTUATORS

Driving toward actuation success

Despite initial costs, upgrading hydraulic actuators can bring significant savings

Looking back with nostalgia on early driving days as a teenager and young adult in the 1970s and 1980s, the first cars were generally used cars and relatively inexpensive. As such, they required a lot of maintenance. It was not uncommon in those days to see drivers and their brokendown cars on the side of the road in need of rescue. Engine overheating, carburettor problems, broken V-belts, and flat tyres were common causes of the breakdowns.

Nowadays, it is rare to pass a car with even a headlight out. About the only time you see cars on the side of the road is when they are accompanied by police vehicles with flashing lights when users test the vehicles max governor rpm. The technology used in the automotive field 30 to 40 years ago seems primitive by today’s standards, as electronic governing systems are standard equipment in cars today, and have been for several years.

In industrial processing plants and refineries, however, decades-old, lowtech mechanical and hydro-mechanical governor equipment continue to operate still, controlling steam turbines and compressor trains in many refineries and process plants. This equipment, like the automobile technology of 30 to 40 years ago, can present maintenance and operational challenges, and can lead to reduced efficiency and reliability in the production process.

The turbine speed governor’s job is to provide accurate speed control, thus preventing process oscillations. To achieve this goal and prevent unplanned process shutdowns, upgrading governor valve actuation to a more precise and dependable operator becomes necessary. Higher performance expectations of the governor valve actuator may go against the traditional thinking that such expectations lead to greater expense. But the economic advantages are significant enough that an upgrade should be considered.

The return on investment of a new governor valve actuator is realised immediately after retrofit due to significantly 30

improved process throughput. Two of the main advantages of high precision actuation are stabilising equipment speed with tighter rpm control and avoiding nuisance process and equipment trips. Thus, the new technology that comes with modern turbine actuation control systems can now operate the turbine at its maximum potential without interruptions. The reliability of the turbine is increased tremendously, and many of the mechanical governor challenges are removed from the unit.

Problem at a refinery Recently, Compressor Controls Corp.

(CCC) implemented a mechanical retrofit for a mid-Continent refinery that was experiencing large swings (100-200 rpm) in the speed control of its steam turbine. The speed instability was caused by a subpar steam turbine governor valve actuation system. The sticking actuator could not maintain the setpoint target and had recently caused a process trip of the main air blower (MAB).

Speed control of the turbine had become so difficult that it had to be operated manually and at a higher target speed than desired. In addition, load sharing with a secondary air blower could not be implemented, and the customer had to use the blow-off valve to make adjustments to the air flow. Finally, the steam turbine could not utilise the existing CCC automatic start-up sequence because of the sticking actuator. These challenges not only took time away from the operator’s priorities but also created an inefficient process, ultimately wasting a great deal of energy.

“power piston” arrangement that drives a bar or rack, allowing multiple steam valves that are mechanically coupled together to be opened sequentially.

For turbines with chest-mounted control valves, it may be a globe-style valve external to the turbine that is providing the control. In some configurations, a pilot valve assembly with a small stroke and a low thrust requirement may be used to port lube oil to the power piston.

This is also a good candidate for an actuator upgrade. The key to success for optimal steam turbine actuation upgrade is selecting a technology that offers high frequency response and precise resolution in a highly reliable package.

Typical steam turbine control requirements include: • 0.1% repeatability • 100% duty cycle • <100ms dead time • Fail safe capability • Ability to withstand high ambient temperatures • Fast stroking speed (less than 1-2 seconds for full stroke).

Drawbacks with existing technology The existing steam turbine designs at this mid-Continent refinery utilised a hydraulic system comprised of a hydraulic power unit (HPU) and servo or proportional valves for control. These hydraulic systems had proven to meet and exceed turbine control requirements at first, when they were

Understanding the impact of actuation technology Controlling compressor efficiency starts with precision control of the steam turbine driver in order to regulate the speed of the compressor. Depending upon the turbine design, there are different opportunities for actuator upgrades to improve performance.

For turbines with shell-mounted control valves, the actuators may individually drive multiple control An actuator in a turbine application valves, or there may be a single FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

ACTUATORS operating in the condition as they were designed. After some time in real-world operation, however, the challenge with the existing hydraulics was primarily with maintaining the systems to work properly, as they required extensive oil maintenance for proper operation. These systems have a large quantity of oil and basically all utilise the same principal of operation.

Hydraulic fluid is drawn from the reservoir by motors and pumps to facilitate movement of the actuator cylinder and then is drained back to the reservoir when the cylinder moves to position. The oil is continually circulated at high frequency to accomplish the high resolution control performance required for the application. Since the system is not sealed, as it is open to atmosphere at the reservoir, the oil is subject to breakdown.

Communication with the atmosphere adds moisture that causes degradation to the oil system due to moisture ingress, oxidation, and corresponding acid build-up. The continuous circulation of hydraulic fluid adds heat to the oil, which accelerates and exacerbates the breakdown of the hydraulic fluid.

In order to combat the effects of oil breakdown, system owners are required to perform a high level of maintenance on these systems. Extensive filtration systems are used, demanding high maintenance intervals coupled with flushing and replacement of hydraulic fluid. Ultimately, the hydraulic fluid degrades to the point where the servo and proportional valves get stuck, resulting in loss of control and system downtime.

A new solution provides big results Finally, after the refinery had consulted with CCC, the decision was made to retrofit the antiquated governor valve actuator with newer actuation technology. The actuation system specified was a Rexa Electraulic self-contained unit. Electraulic actuation uses a position-controlled power module, driven by a 4-20ma signal, to build pressure with an internal oil gear pump that displaces hydraulic fluid from one side of cylinder piston to the other. A rod extending from the cylinder is then mechanically connected to the steam valve rack and able to precisely position the rack from a fully closed to fully open position.

Electraulic actuators are designed for continuous modulating service with an adjustable dead-band as tight as 0.05% of stroke. The virtual incompressibility of hydraulics provides repeatable, stiff,

and accurate control performance as is required in this demanding application.

The drawbacks associated with HPU-based hydraulics are eliminated by design.

The system utilises Rexa’s patented “flow match valve” (FMV) technology. The FMVs are used in conjunction with a bidirectional gear pump in a positive pressure sealed hydraulic system, eliminating the need for a hydraulic reservoir and the problematic servo and proportional valves. The Rexa hydraulic circuit design completely removes the need for filtration and requires no oil maintenance as part of a preventive maintenance plan. The system design lends itself to minimal oil requirements, as a typical Rexa actuator requires anywhere from 2-5% of the oil of a comparable HPU-based hydraulic system.

Electraulic actuators are also simple to make fail-safe without any detriment to the control precision. With both spring- and accumulator-based fail-safe technology, these actuators achieve trip speeds as fast at 200ms, meeting the requirements for turbine control.

Taking it to the bank The mechanical actuation upgrade to Rexa’s Electraulic actuators on turbine control valves and successful tuning with the CCC controller provided immediate benefits for this refinery.

• Maintenance savings were immediately realised through the cost of replacing faulty servo valves and reducing labour required for the upkeep of antiquated hydraulic systems.

• Improved speed control with high responsive Rexa electro-hydraulic actuation, allowing the turbomachinery train to match its performance with the desired process setpoint more accurately and reliably.

• Removal of the existing control oil and piping, thus eliminating the hassle of oil maintenance and filtration requirements associated with this system.

• Reduced insurance rates for the turbine deck by de-rating the risk of fire through the removal of existing control oil supply.

• Automatic start-up sequencing and load sharing features of the CCC control system could now be utilised, improving the overall process control stability of the process unit.

• A single turbine trip lasting mere 20min – an incident that the customer experienced recently before the actuator retrofit – would cost the refinery more in throughput than the cost of the new Rexa actuator and commissioning.

Customer feedback The improvements in performance are described in the words of several plant employees: “The REXA actuator has allowed proper speed control. The previous hydraulic servo with multiple mechanical linkages often bound up causing FCC upsets. We have not seen these issues since the install.”

“With the better speed control, the load sharing controller can better optimise the load between the auxiliary and main air blowers. This resulted in an approximate air capacity increase of 15% on the overall air system.”

“Prior to the installation, the lube oil system and the hydraulic oil for the servo were on the same system. We were experiencing borderline low lube oil pressures before the install. The install decoupled the system and eliminated the need for hydraulic control oil. This eliminated the need to upgrade the lube oil system to increase the lube oil pressure to OEM specifications.”

“The installation also eliminated pneumatic hand controls that were primarily used during start-ups and shutdowns. The system can now be solely controlled by the console operator. This simplified many procedures for start-up.” z For more information:

This article was written by Mike Murphy, rotating equipment manager at Rexa. Visit: www.rexa.com

Questions to consider for your plant • Do you have turbomachinery that has experienced nuisance trips resulting in loss of production?

• Do you have to live with larger than expected rpm swings resulting in poor control and increased steam expense?

• Does smoothing out your control line to significantly improved process throughput up to 25% sound like cost savings to you?

• Would you like to be able to have automatic start-up sequencing through all control ranges of idle speeds, critical speeds and governor ranges, and have the capability to operate the turbine more effectively from the control room?

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VALVES

Engineering control valves to handle black powder duty How an intelligent OEM retrofit extended control valve life

Black powder is a common iron sulphide contaminant of sales gas pipelines in the Middle East. It clogs and erodes valves, leading to flow losses and reduced process control. One Middle East oil and gas operator was facing significant challenges associated with this contaminant. Some of the operator’s pressure control valves (PCVs) were failing after just 44 days in service due to rapid erosion of internal components which resulted in excessive downtime.

“Black powder contamination is an enduring and expensive problem for gas pipeline operators in the Middle East,” says Parag Ghag, Middle East manager at Severn Glocon. “As well as reducing efficiency and causing loss of flow, it can result in significant damage to core assets such as compressors. Valves also suffer from associated issues, including clogging and corrosion, which can hinder performance or lead to failure.”

As a result, the company commissioned Severn Glocon to develop a solution.

For this application, Severn Glocon developed an advanced OEM retrofit that extended the operational life of these valves by more than five years.

The challenge Rapid control valve failure was being experienced at some of the operator’s metering and pressure reduction stations due to black powder contamination. This microscopic contaminant ravages internal valve components when it travels at velocity within the process medium. It can collect in gas pipelines, leading to flow loss and premature failure of equipment.

In some cases, PCVs were failing after just 44 days in service. The erosion of internal components was also causing a serious safety concern due to the risk of fugitive gas emissions via the valve body.

“Black powder is a solid contaminant 32

Spray coating a control valve

which forms via a reaction between hydrogen sulphide, water, and iron. It can be dry and powdery or wet and tar-like in appearance. In addition to the clogging and corrosion problems, it is pyrophoric in some circumstances,” Ghag explains.

In a bid to turn the situation around, the operator collaborated with Severn Glocon Group to devise a new specification for PCVs deployed in contaminated applications. Severn’s advanced valve services division was then commissioned to develop a highlyengineered control valve retrofit solution.

“Several techniques have been developed to remove black powder from affected pipelines. These range from pigging and traditional filtering to filter-less methods such as powerful magnetic separation technology.

However, it is difficult to eliminate black powder entirely, so additional approaches need to be used in tandem to prevent the contaminant harming assets and compromising productivity,” says Ghag.

To understand the challenge fully, Severn initially conducted a detailed technical review of two high profile OEM PCV failures associated with black

powder. The PCVs were deployed in a highly demanding application involving significant pressure drops. This was exacerbated by black powder contamination, putting them at the extreme end of “severe service”.

The inspection concluded that primary failure causes were related to four major factors: 1. Trim material 2. Trim and pressure envelope flow passage geometry 3. Fluid velocities developed with the pressure let-down process 4. Trim flow passage blockage/seizure These findings were used to develop a control valve retrofit solution addressing the four factors to mitigate risk of failure. The retrofitted PCVs were subject to strict criteria surrounding maximum noise levels and a high level of rangeability was required.

Furthermore, they had to be supplied with a five-year operational warranty.

The solution Severn’s specialist control valve engineers applied their experience in erosion

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VALVES prevention for sand-laden applications to the black powder challenge.

They researched the properties of black powder and overlaid this with specific failure mode information for the two OEM valves and extensive repair intelligence associated with control and choke valve erosion. This combination of insight underpinned the development of a customised design to maximise the longevity of the valves.

“In the case of control valves, it is essential that they are intelligently engineered to withstand the extreme demands of black powder service.

This can be achieved through a combination of trim design to control flow geometry and velocity levels, and the use of hard materials with proven durability,” says Ghag.

Valve design and material selection were underpinned by knowledge of actual valve performance, which was fed into the process to create a continuous improvement cycle. Both donor valves were successfully retrofitted at an approved third party workshop by local Severn technicians, then tested and commissioned. Severn Glocon P-series

A valve undergoing a profiler test

200in2 actuators were also retrofitted to each valve, complete with side mounted hand wheel and instrumentation to provide lock-on air failure.

valves were rebuilt as found, tested, and stored for future use as spare valves.

The outcome

Black powder is a highly erosive contaminant that can significantly compromise plant safety, integrity and productivity. Ten years ago, the operator’s most experienced and talented engineers were tasked with finding a solution to mitigate the problem costeffectively. Severn’s highly-engineered, customised control valve technologies enabled them to achieve this goal.

“Black powder ravages systems. It hinders productivity and can cause millions of dollars’ worth of damage to assets. Mitigating the impact of this harsh contaminant demands a collaborative approach that draws on the expertise of corrosion engineers and specialist third parties to inform the decisionmaking process,” Ghag concludes. z

Following the retrofit, the valves delivered immediate performance improvements and remained in continuous service without incident beyond the fiveyear warranty period. After five and a half years, the valves were made available for inspection as the operator needed to install valves with a higher capacity. Only mild internal erosion was observed and the valves were still functioning within the required performance and safety parameters.

The inspection provided sound evidence for the efficacy and commercial viability of the valve retrofit design. It extended operational life in this very severe application, ensuring continued gas supply to associated industries, and it eliminated the serious safety concern linked to fugitive gas emissions via eroded valve body components.

Upon completion of the inspection, the

Conclusion

For more information:

This article was written by Ken McWirther, Middle East manager at Severn Glocon Group. Visit: www.severnglocon.com

A metal cutter working on a valve

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The next generation

VALVES

A new triple offset valve design offers evolved features and benefits for expanded applications Fugitive emissions is a concern across all facets of the fluid handling industry.

The effects it poses to the environment, employees’ health, and the manufacturers’ bottom line is troubling, and it is no secret that governing agencies around the world are tightening up on policies and regulations surrounding allowable emissions levels.

These challenges, combined with greater production demands, have compelled valve users in all industries to seek solutions that are as efficient as they are effective.

A major contributor to the release of volatile organic compounds (VOC) is the valve, mainly because of its function and placement within a processing system.

When valve seats, seals, and stems are damaged, emissions can occur. The packing can also play a part, especially in the presence of particularly hazardous chemicals and media. With valves serving as a major contributor to the release of VOCs, valve manufacturers are facing the same challenges that plague valve users. They must provide solutions that meet the individual needs of valve users, comply with government regulations, and satisfy industry standards. To address these issues and remain relevant in the industry, valve manufacturers are evolving their technologies to expand their uses, and the recently released Crane FKX 9000 triple offset valve (TOV) is a prime example.

Basics of TOVs Originally designed solely for water shut-off applications over 50 years ago, TOVs were historically selected because of their superior sealing features and cost savings versus other metal seated valve types. Offering a bi-directional zero leakage closure with either metal or soft seats, TOVs can be used in multiple applications and still provide the same level of leak resistance. They are easy to install as a result of their quarterturn design and lightweight structure.

As the name implies, there are 34

three separate offsets designed into the valve. These three offsets work together to provide an uninterrupted sealing surface, minimise wear between the seat and seal, and preserve the sealing integrity over the lifecycle of the valve. The three offsets include: 1. The centre line of the disc/ seat sealing surfaces 2. The location of the shaft with respect to the centre line of the bore 3. The axis of the seat cone angle that is offset from the centre line of the valve bore The valve’s operating torque is lowered as a result of the optimised seat angle, which also minimises sticking or binding of the disc.

A new approach

Recently, however, Crane has worked to incorporate new design enhancements that improve the versatility of TOVs, enhance their safety and performance, and expand their ability to function in demanding environments. For the harsh conditions of critical process applications, steam isolation, and temperature extremes, Crane’s new TOV provides unmatched performance reliability and quality across multiple applications, while delivering exceptional flow control, optimised Cv, and low Delta P in a single valve.

Designed to reduce wedging and binding, the next generation FKX 9000 was engineered with an optimised seat angle and Stellite hard-faced body seat, offering a longer seal life, and improved abrasion resistance, even after extensive cycling. These features combine to reduce the total cost of ownership and extend valve life. To accommodate higher temperatures and pressures, as well as severe service applications, the valve’s precision machined metal seat and seal ring deliver reliable and bi-directional shutoff regardless of these conditions. Additionally, its right-angle conical design facilitates an almost frictionless in-line sealing.

Unlike position-seated ball, butterfly, or plug valves, the torque-seating in this new TOV self-adjusts to evenly distribute seal compression. A “floating” seal ring and a wide seal ring supporting gasket yield a better seal to eliminate binding and enhance performance. Crane’s next

generation TOV delivers superior performance in thermal expansion due to the optimal positioning of the pin connector located in the lower portion of the disk. Its bearing design also helps to prevent shaft deflection and permits longer Crane FKX9000 triple valve life. offset valve With a control classification traditionally associated solely with bellows-sealed valves, the Crane FKX 9000 features an updated stem seal design and packing assembly that provides high fugitive emissions control (ISO 15848, Class AH) under recurrent and extreme thermal cycling, despite the use of graphite packing to accommodate the higher temperatures. But, depending on the application in which it is used, the packing offering of the valve can be differentiated so users can choose which works best for their needs. Available packings include TA-Luft according to VDI 2440, Standard (Process Industry); ISO 15848–1&2; Class BH C03 (< 100 ppmv), or Low-E Option; ISO 15848–1&2; and Class AH C03 (< 50 ppmv). Furthermore, the valves are tested to CO3, which covers four thermal cycles and 1,500 mechanical cycles.

Lightweight, compact, operative in a variety of applications, and incorporating these evolved features into the TOV design, the Crane FKX 9000 could become the epicentre of development as a low-cost option capable of increasing efficiencies and maximising operational performance in numerous process conditions where other valves have historically presented pain points in the past. Its increased emissions control classification alone enables the Crane FKX 9000 to meet great demands in an expanded list of industries, as well as new applications within existing industries. z For more information:

This article was written by Bülent Korkmaz, product sales manager for triple offset valves at Crane ChemPharma & Energy. Visit: www.cranecpe.com

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

METERS

Ball or small?

The pros and cons of leading flowmeter prover technologies

In oil and gas, petrochemicals, and other demanding industries, flowmeters need to be calibrated (i.e., “proved”) to ensure accurate readout and measurement. Flowmeter accuracy is right at the heart of critical applications like custody transfer and legal metrology – making selection of the right calibration and verification system vital.

While ball provers (also known as pipe provers) are widely employed in the industrial sector, some contractors and systems integrators ignore the potential for longer-term issues around their maintenance, safety, and repeatability.

This can make the ball provers an inefficient solution, and poorly adapted for changing process requirements.

Flowmeter accuracy is an essential requirement in a wide range of industrial settings. Maintaining correct liquid flow measurements is necessary for efficient, reliable, and safe operations, as well as fair custody transfer transactions. As such, the choice of a proving technology to establish meter accuracy is an important issue.

The purpose of proving a flowmeter is to determine its deviation from the reference standard, which is the ratio of the actual volume of liquid passed through the meter during proving and the volume registered by the device.

Obtaining a meter factor is a crucial step in calculating the net standard volume of a receipt or delivery of liquid products.

To reduce measurement uncertainty, flowmeters should be proven with the liquid to be measured, and at the operating flow rate, pressure, and temperature. This means the preferred way of proving a flowmeter is in situ under normal operating conditions.

Considerations in prover selection When it comes to flowmeter provers, industrial end users have a range of

The choice of a proving technology to establish flow meter accuracy is an important concern for industrial end users

options – of varying quality. The most common types of displacement provers utilised today are ball or pipe provers, and small volume provers (SVPs). The main difference between the two devices is the size and the way the provers are designed. In a ball prover, the fluid is displaced by a ball or sphere travelling between two electro-mechanical switches. In an SVP, a piston, displaced by the fluid, travels between two high-speed optical switches. Modern counters and high-precision detectors make it possible to accumulate less than 10,000 pulses from the meter, but still meet industry guidelines such as those established by the American Petroleum Institute (API).

Ball provers remain a popular choice among engineering contractors and engineering, procurement, and construction (EPC) firms. With global suppliers, they are able to deal with high flow rates (over 20,000 BPH), can prove manufactured pulses produced

by microprocessor-based flowmeters such as Coriolis and ultrasonic, and – at least initially – offer a rugged and reliable solution. There is little argument that ball provers do work.

Today, however, there is growing recognition of the drawbacks to ball provers in many applications. Although field-proven in a wide range of industrial environments, these systems are bulky and prone to high lifecycle and maintenance costs. They also suffer from accuracy and stability issues in many cases. While a ball prover is static, its lining cannot be changed and the solution has a limited turndown ratio.

Challenges arise over the ball prover system lifecycle in four principal areas: • Safety hazards • Maintenance costs • Uncertainty and repeatability issues • Calibration issues caused by unstable ambient conditions In proving, the size and operating

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 35

METERS A small volume prover

principle of the ball prover inevitably exposes workers and the environment to potentially high temperature and dangerous products. Ball provers rely on a sphere that must fit tight within the prover’s bore, and is loaded and removed from the launch chamber. This unavoidably puts operators in contact with the liquid or vapours of the metered product. Consequently, for products considered hazardous by the OSHA Hazard Communication Standard, 29 CFR 1910.1200, significant precautions are required during prover operation.

Similarly, these environmental and safety concerns dictate that provisions are made for safe, controlled draining and venting of the ball prover for servicing or storage. For a 24” (61cm) bidirectional prover with a 14-second actuated, four-way valve, for example, this means draining 16m3 (4,226 USG) or 16,000 litres of product – a challenge not made any easier by the tight space available around many ball provers.

The limitations of ball or pipe provers in terms of reliability also become more apparent over time. Many operating companies with ageing metering stations that use these provers have already faced rising maintenance costs. Where work is needed as a result of issues associated with a ball prover’s diverter valves, displacement spheres, pipe lining, etc., maintenance and servicing is hampered by a design intended to limit the system footprint. The ball prover is frequently below the metering sections, making access for maintenance difficult.

Requirements for large volumes of liquid complicate the calibration of large, bi-directional ball provers. Readoff errors can also result from multiple measurements during the water draw process. This leads to uncertainty in determining the prover’s base volume, 36

which must be mentioned in the prover WD certificate (ISO 7278).

It is not the prover design that is responsible for the difference in uncertainty, but rather the calibration method in determining the base volume.

In practice, however, this distinction makes little difference. The base volume is what is used to calibrate the flowmeter, and repeatability is what determines the quality of the prover.

Modern alternative in system design

connection and flow rate capabilities.

The development of SVP technology has overcome many of the difficulties common to ball provers, as well as providing potential benefits in terms of versatility and lifecycle costs. The SVP is designed for flexibility: its size means it can be moved, and seal materials can be switched. This prover has also become a mature technology itself, tested and approved by both regulators and major end users for proving all types of meters, including Coriolis and ultrasonic meters.

Most obviously, SVPs are much smaller than ball or pipe provers. The overall volume of an SVP can be 60 times smaller and eight times lighter than the equivalent ball prover. This makes the prover much easier and less expensive to install, and particularly suitable for applications where space is limited. It also has significant consequences for servicing and maintenance throughout the prover’s life.

The reduced size of an SVP means it can be built with higher-grade materials such as stainless steel or even highly corrosionresistant duplex stainless steel without prohibitive cost. The use of AISI 304L flow tube material with hard chrome bore provides greater wear resistance than either epoxy or phenolic material liners in a bi-directional prover. The SVP’s straightthrough design also minimises the potential

No flowmeter prover technology is perfect, of course. However, the issue with ball provers is not just that they may present some drawbacks that become apparent over time. They are also not necessarily the best solution available in any case.

The basic design of an SVP includes a precision bore cylinder, a displacer, a means of positioning and launching the displacer upstream of the calibrated section, displacer detectors that allow fluid flow while the displacer is traveling from one position to the opposite position, pressure and temperature measurement devices, instrumentation with timers, counters, and pulse interpolation, and provisions for proper venting. SVPs come in Loading a ball prover unavoidably puts operators in contact with the various sizes based on their liquid or vapours of the metered product

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

METERS and portable applications, and are available as a standalone unit, mounted onto a purpose-built trailer, or installed onto a modular metering or loading skid.

Conclusion

The latest SVP designs are well suited for stationary, offshore and portable applications

for pressure problems. With a ball prover, the extent to which the ball is inflated can have a major impact on the pressure.

Likewise, the SVP design overcomes problems associated with thermal expansion by employing a smaller volume of metal, as well as facilitating quicker calibration times due to much smaller volumes of liquid used. Draining is significantly less of a problem, too.

The prover can be built as a mobile unit and removed from the meter site for draining and storage in a safe location.

Operators of an SVP are much less likely to come into contact with hazardous products. There is, for instance, no displacer to load or get stuck, and in normal operation the prover is a fully sealed system that does not have to be opened. No four-way valve is used and the piston does not require any grease. Where maintenance is needed, accessing the prover is simple, making it safer and less challenging.

Performance benefits in typical applications Thanks to their versatility, compact size and fast method of operation, SVP systems have increased in popularity during recent years. Sophisticated, computer-based electronics, which are more commonly used on SVPs, give them an advantage over conventional ball provers. They also have a greater range of fluid compatibility and reduced fluid disposal quantities, which minimises the potential for environmental problems.

The SVP has a much wider operational range than a ball prover, as well as a much higher turndown ratio (1200:1

for the SVP vs. 10:1 for unidirectional and 5:1 for bidirectional pipe provers).

Additionally, it overcomes limitations in terms of product temperature and pressure, usually -29°C for a ball prover (unless more expensive low-temperature carbon steel is used) to 100°C, and a maximum of 100 bar (due to the elastomer of the sphere). Improvements in materials of construction enable SVPs to operate in ambient temperatures of -40°C to 60°C and up to 250 bar, and with product temperatures up to 250°C. The lack of a spherical displacer allows for use of the prover with a greater range of viscosities and flows (up to 17,500 BPH), as well as different fluid types.

Without a bore lining or ball to worry about, only the seals in an SVP need to be considered and they can easily be selected for compatibility with a wide range of fluids and conditions. The latest SVPs are well suited for stationary, offshore,

There is no question that ball provers can and do prove meters accurately in a wide range of applications. Nevertheless, they can also impose a significant burden on operators in terms of maintenance – particularly as they age and at the end of their service period. Over the entire system lifecycle, ball provers may not be the most efficient solution. Nor are operational safety and flexibility always ideal. These are all issues that do not receive the attention they deserve from contractors and consultants when specifying the prover. Increasingly, industrial end users are turning to modern SVPs as a reliable, efficient and costeffective alternative to the traditional ball and pipe prover configuration. z

For more information:

This article was written by Pascal Sabatier, global marketing manager, field services at Honeywell Process Solutions.

Visit: www.honeywellprocess.com

References [1] “Areas for Improvement in Hydrocarbon Liquid Metering Systems See Major field problem component”, slide 6, Dr Mohammed Salim, Saudi Aramco, 6th Custody Measurement Technical Exchange Meeting 2011 [2] API Chapter 4 Section 2, 2011 “3.3 Temperature measurement” specifies a max. influence of theCtl factor change of 0.0001 or less.

[3] “Practical Experience of Bi Directional Prover Calibration,” Jim Gray, Sharon Marsh, Julian Cornick and Steve Gwaspari, 32nd International North Sea Flow Measurement Workshop 21-24 October 2014

Model

SVP

Ball prover

Capacity (gal; m3)

25 gal; 0.095m3

400 gal; 1,5m3

Maximum flow rate (GPM; m3/h)

3500 GPM; 795m3/h

2830 GPM ; 650m3/h

Dimensions (m)

4 x 0.9 x 0.95

19 x 3 x 4

Volume (m3)

3.5

228

Dimensions (feet)

13.5 x 3 x 3.1

63 x 10 x 13

Volume (cubic feet)

125

8050

Comparison for a standard 1,500l (400 gallon) prover of 650m3/hour with a maximum flow rate of 795m3/hour

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 37

METERS Row of separators with Optimass 6400 meters

Caught in the flow Entrained gas measurement features provide huge operational benefits A Colorado energy producer is taking advantage of new Coriolis mass flowmeter technology that ensures both stable and uninterrupted measurements of oil with high gas content. Denverbased Bonanza Creek Energy is an exploration and production company focused on extracting oil and associated liquids-rich natural gas in the US. The company has operations in Colorado’s Denver-Julesburg Basin, a major oil and gas field that is being actively developed through the use of horizontal drilling and multi-stage fracture stimulation.

Bonanza Creek is developing its assets in the basin by drilling horizontal lateral wells. They needed an accurate and reliable way to measure how much oil and water each well was producing. Tank gauging is the standard method used to measure the volume of production at each well, and while simple and relatively accurate, tank gauging is time consuming, costly, and entails some safety risks. To account for the production variations among the wells and provide accurate well allocation measurement information, each well on a pad had to flow into a separate tank.

38

Bonanza Creek was looking for a cost effective way to provide an accurate oil meter at each wellhead, where the oil flows into a separator that separates the water, gas, and oil.

They anticipated there would be gas entrained in the fluid coming out of the separator, so they needed an option that could handle entrained gas.

The technology Gas entrainment refers to the presence of gas bubbles in hydrocarbon fluids.

Entrained gas can disturb the sensitivity of mass flow measurement of liquids, decrease accuracy, or even stop measurement completely. It can occur for many reasons, for example due to degassing, leaks upstream of or in a negative pressure area, excessive cavitation and levels falling below the minimum in supply containers and agitators in tanks, or long drop distances for media into tanks. Entrainment can also occur due to status transitions in process control, such as when starting, shutting down, or cleaning the system.

Knowing that Bonanza Creek was

seeking an accurate oil meter that could handle gas entrainment, Bob Phagan, sales engineer for I.C.S. Sales, arranged a demonstration of a new mass flowmeter device that is “gas bubble resistant.” I.C.S. Sales is one of the leading manufacturers’ representatives in the Rocky Mountain Region, specialising in process instrumentation.

The new meter, the Optimass Coriolis mass flowmeter developed by Krohne, offers reliable indication of gas bubbles in a process by using a combination of various measurements to detect a two-phase flow. The meter detects and signals gas entrainment reliably and maintains the active measurement in all measuring conditions with gas content from 0 to 100% by volume. The measuring sensor and signal converter were designed to offer complete digital signal processing, from the production of the drive oscillation of the measuring tube to the evaluation of the sensor signals. The meter maintains continuous mass density measurement and provides measured values at all times. At the same time, it can report the two-phase status and output a

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

METERS preconfigured alarm, in accordance with NAMUR NE 107 requirements.

“We knew the new technology would be the best way for them to handle entrained gas in this application, and the demonstration showed them clearly how the meter could help,” says Phagan. He explains that for this application, the Optimass meters are installed on the crude oil leg of the oil/ water/gas separator. Less expensive metering technology is used to meter the water, since it is of lower value to investors. Gas is metered using differential pressure (DP) devices.

Results speak for themselves After purchasing the first 30 meters in 2013, Bonanza Creek compared the tank volume versus the metered volume over a 24-hour period and found only minor differences in the measured values. These minor differences in the measured volumes were due to a phenomenon known as shrinkage.

The company has since installed more than 400 Optimass meters. Bonanza Creek can now accurately manage wellhead allocation and provide stakeholders critical production data.

The model used depends upon the required accuracy. Private leases use the Optimass 1400, which offers a published accuracy of 0.15%, while the Optimass 6400 model is used for Federal Bureau of Land Management leases, with a published accuracy of 0.10%.

The Optimass 6400 has been approved for custody transfers of both liquids and gases, making it ideal for process industries and specialist applications like liquefied natural gas (LNG), compressed natural gas (CNG), or supercritical gases in terminal or storage/bunkering, along with custody transfer applications.

The meter is the first Coriolis mass flowmeter in the world to feature advanced entrained gas management (EGM), with no loss of measurement with gas entrainment up to 100% of volume. Unlike other mass flowmeters, where relative movement between gas and fluid dampens the amplitude of the measuring tube and interferes with the electronics’ capability to determine the actual resonant frequency, the Optimass models with EGM can follow and correct for the varying amplitudes.

EGM continues to present an actual measured reading, together with an indication or configurable alarm that

improves processes by identifying transient gas entrainments.

“Bonanza Creek has found the meters to be rugged and durable and the price compared to other options is a great benefit to them,” says Phagan.

“They have also found entrained gas management to be another huge benefit to their operations.”

The new meters are now being used at other exploration and production companies working in the Wattenberg Fields. After a head-to-head demonstration and evaluation comparing Optimass meters to a competitor meter without EGM, one major energy company purchased and installed about 180 Optimass meters in 2015, and at the time of writing had scheduled another purchase of at least 60 more for 2016. z

For more information:

This article was written by Malcolm Kelly, publicist at McNeil, Gray & Rice for Krohne. Visit: www.krohne.com

Optimass 6400 (l) and 1400 (r) meters installed on site

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 39

SUSTAINABILITY

A fluid situation: sustainability in compressors

How latest – and earlier – environmental regulations affect the fluid handling equipment industry The COP21 meeting in Paris was a seismic event that will have a huge effect on sustainability. Future legislation and guidelines are likely to be shaped by what was decided at the conference.

Rob Jenkinson, director of corporate sustainability at engineering company SKF, says the agreement reached in Paris must now lead to a raft of sensible and challenging legislation – introducing the practical measures that will restrict future temperature rises to less than 2°C. However, the “Paris effect” will not be felt quite yet. And, as far as the use of refrigerant compressors is concerned, there is a far more significant piece of legislation shaping the industry: the Montreal Protocol. It came into effect way back in 1989 – the same year the Berlin Wall came down – with the intention of reversing damage to the ozone layer by phasing out HFC and HCFC refrigerants.

Some of the phase-outs agreed in Montreal – and in subsequent follow-up meetings – are now coming into effect.

The refrigerant R134A, for example, will be completely banned in different regions and industries from next year, meaning that alternatives must be found.

One potential replacement, a refrigerant known as R-1234yf, is currently being considered. Those who have not previously prepared for this legislation are now under pressure from a ticking deadline.

The rules will affect all use of compressors for refrigeration – from air conditioning units for cars to hospital cooling systems.

Greater efficiency In parallel with this, air conditioning systems will be expected to run with greater energy efficiency – and this is also being addressed. One solution that SKF has developed for AC centrifugal compressors is to make them oil-free. Using magnetic systems eliminates the need for oil – and raise efficiencies by up to 10%.

The main driver for this was a leading 40

HVAC OEM in the US, which was seeking a reduction of energy consumption and efficiency increase for its centrifugal compressors. SKF helped it to meet this goal by supplying magnetic bearings, as well as the motor and control unit. This OEM is a good example of an industry leader that pushes the environmental agenda forwards through its desire for efficiency gains.

The company has recently extended its line of magnetic bearing centrifugal chillers – the YMC2 range – to handle 1,000 tonnes of cooling (3,500kW).

An alternative way of eliminate oil is to use the refrigerant itself as the lubricant, which is possible by using SKF Pure refrigerant lubricated bearings.

“Hermetic” compressors, used in air conditioning systems for hospitals or other large facilities, can be run in this way. The refrigerant then does its normal job – as well as cooling and lubricating the bearings.

Variable benefits Total cost of ownership (TCO) is an important concept that is still not fully understood – though the advent of higherpriced energy is certainly helping to focus people’s minds. Variable speed drives (VSDs) have made a huge contribution to energy efficiency across industry – including fluid machinery. By driving the motor according to process need, the user can save up to 30% on energy costs. That is a huge chunk – bearing in mind that energy accounts for 80% of the total cost of a compressor over its lifetime. There is one small disadvantage to using a VSD: the electrical output of the drive can cause arcing, which can quickly destroy the bearing. The answer is to upgrade the system, such as by fitting insulating bearings that withstand arcing.

Permanent magnet motors (PMMs)

SKF’s magnetic bearing system

can also have a huge effect on energy efficiency, in a variety of industries.

The wastewater treatment industry, for instance, uses blowers to aerate the water.

This helps bacteria to break down organic waste more effectively. One French treatment plant had been using four traditional Roots blowers for this purpose – which accounted for around half of the plant’s total energy consumption.

The plant replaced its four 80kW blowers with two 160kW aeration blowers based on a PMM, active magnetic bearings, SKF control system, and a VSD. As well as reducing noise, the new system cut energy use by 500,000kWh – as well as saving 375 tonnes of CO2 emissions and €54,000. Payback time was just one year.

The technology that underpins the aeration blower – SKF’s high-speed PMM – is from the company’s BeyondZero portfolio of products, which can impart real sustainable benefits. Others that are relevant to this sector are the refrigeration-lubricated bearings and high-speed oil-lubricated bearings.

These are just some practical measures that are helping to improve the sustainability of compressors and other fluid machinery and helping customers meet or even exceed existing environmental legislation. At this moment, at least as far as compressors are concerned, the Montreal Protocol is having the greatest effect in determining sustainability priorities. But we can be sure of one thing: future legislation – enacted in the wake of COP21 in Paris – will not take anywhere near as long to come to fruition. z For more information:

This article was written by Magnus Arvidsson, business engineer at SKF Group. Visit: www.skf.com

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017

EVENTS

Fluid Handling International will be distributed at the following events 8 Feb 2017 - 9 Feb 2017

Pumps & Valves

Zurich, Switzerland

6 Mar 2017 - 9 Mar 2017

20th Middle East Oil & Gas Show and Conference (MEOS)

Bahrain, Middle East

28 Mar 2017 - 30 Mar 2017

StocExpo 2017

Rotterdam, The Netherlands

29 Mar 2017 - 30 Mar 2017

M & R 2017

Antwerp, Belgium

4 Apr 2017 - 7 Apr 2017

Gastech

Chiba, Tokyo

4 Apr 2017 - 7 Apr 2017

LNG & European Flow Measurement Workshop

Noordwijk, The Netherlands

26 Apr 2017 - 27 Apr 2017

StocExpo Middle East Africa

Dubai, UAE

1 May 2017 - 4 May 2017

Offshore Technology Conference (OTC)

Houston, USA

17 May 2017 - 19 May 2017 Indutech 2017

Johannesburg, South Africa

23 May 2017 - 24 May 2017 Utility Week Live 2017

Birmingham, UK

11 Jun 2017 - 14 Jun 2017

ACE 2017 Annual Conference and Exposition

Philadelphia, USA

12 Jun 2017 - 14 Jun 2017

ILTA

Houston, USA

20 Jun 2017 - 21 Jun 2017

Valve World Americas

Houston, USA

12 Jul 2017 - 14 Jul 2017

Indo Water 2017

Jakarta, Indonesia

11 Sep 2017 - 14 Sep 2017

46th Turbomachinery & 33rd Pump Symposia (TPS)

Houston, USA

20 Sep 2017 - 21 Sep 2017

Valve World Asia

Suzhou, China

FLUID HANDLING INTERNATIONAL l JANUARY/FEBRUARY 2017 41

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