Fluid Handling International March/April 2017

HELPING TO KEEP YOUR BUSINESS FLOWING

MARCH/APRIL 2017

Predict your problems Saving costs through predictive maintenance

Leak detection in the spotlight What do oil pipe leaks mean for manufacturers?

Issue 2 Volume 5

COMMENT & CONTENTS

Contents 2

Latest news

10

Protect your assets Latest methods in monitoring and maintenance are required to keep oil and gas operations profitable and safe

March/April 2017 ISSUE 2 • VOLUME 5

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

12

14

Predict your problems Predictive valve maintenance using smart actuators has yielded significant cost savings at a refinery in Italy Leak detection in the spotlight Recent oil spills have brought both positives and negatives for leak detection equipment manufacturers

26

Fair trade for LNG The liquefied natural gas industry is working towards increasing metering accuracy and bringing in international standards

28

Going with the flow Singapore makes mass flow metering for oil bunker deliveries mandatory as the first port in the world

30

Event preview: StocExpo Middle East Africa 2017

32

Non-negotiable quality

34

Oil logistics: The highest level of data exchange fidelity An innovative data exchange solution has enabled a German petroleum refiner to communicate with customers and suppliers effortlessly

MANAGING DIRECTOR Peter Patterson Tel: +44(0)20 8648 7082 peter@woodcotemedia.com EDITOR Ilari Kauppila Tel: +44 (0)20 8687 4146 ilari@woodcotemedia.com DEPUTY EDITOR Liz Gyekye Tel: +44 (0)20 8687 4183 liz@woodcotemedia.com ADVERTISING SALES MANAGER Russell Priestley Tel: +44 (0)208 6487 092 russell@fluidhandlingmag.com PRODUCTION Alison Balmer Tel: +44 (0)1673 876143 alisonbalmer@btconnect.com SUBSCRIPTION RATES A one-year, 6-issue subscription costs £150 (approximately $240/€185 depending on daily exchange rates). Individual back issues can be purchased at a cost of £30 each Contact: Lisa Lee Tel: +44 (0)20 8687 4160 Fax: +44 (0)20 8687 4130 marketing@woodcotemedia.com

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

17

18

21

All the small things By simply choosing a certain type of valve, an Australian mine operator has increased its process efficiency Feeling the pressure to reduce leakage?

Utilising a carefully planned system of pressure relief valves can prove essential for reducing leakage in water systems Large problem, large solution A Chilean copper mine has reached 4,000 hours of continuous operation with the world’s largest mill pumps

22

No seals required A downstream petrochemical refinery chose magnetic sealless pumps for the many benefits they bring to the refining process

24

Down with energy costs!

An underspecified pump can ruck up energy bills, not to mention maintenance costs

36

Safety on many levels A major Middle East refinery benefits from the flexibility, power, and simplicity of a single architecture for both plant and office facilities

38 Keep safe when the pressure is on

A ruptured hydraulic hose will not only cost operators money, but it can also cause grievous personal injury 40

Tackling thieves A telecoms operator in Africa needed a robust monitoring system to thwart fuel thieves

41 Events

HELPING TO KEEP YOUR BUSINESS FLOWING

MARCH/APRIL 2017

Issue 2 Volume 5

Predict your problems Saving costs through predictive maintenance

Leak detection in the spotlight What do oil pipe leaks mean for manufacturers?

FC_FH_march/april_2017.indd 1

Portrait Of A Praying Fortune-teller in costume. ©Kicsiicsi. Picture from bigstockphoto.com

10/03/2017 10:22

Comment Dear reader, Maintenance is an inextricable part of running fluid handling systems. No piece of machinery is built to last forever, even though the industry has made – and continues to make – immense leaps with more durable materials and better manufacturing methods. Nonetheless, the facts of life dictate that eventually every part of a machine will reach the end of its lifecycle and will require either replacement or maintenance.

Waiting for your machinery to stop working before engaging in maintenance activities is one way to go about it, but it’s far from the best as this maintenance method carries with itself enormous financial risks. There will not only be the loss of production to worry about when the system is brought offline to repair parts, there are also the possible health and safety issues. A suddenly failing pipe or hose through which high pressure fluids flow can cause life-changing injuries, as Brammer points out on page 38.

A better strategy, then, is to engage in preventive and predictive maintenance.

Granted, these maintenance methods will require solutions to monitor the condition of equipment, and further systems to transfer that condition data to those who are able to interpret and act on it. However, the installation costs of such systems are rapidly compensated for by the saving in maintenance costs, says Pentair on page 12.

Leak detection systems should also be part of all operations where fluids are moved through pipes or hoses. Not only are they essential for knowing when the plant’s pipework needs maintenance, they will also protect the environment, people, and the company’s image. In this issue we bring you an overview of the current situation regarding oil pipeline leak detection in North America (page 14).

But, as always, we cover more topics in this issue than just maintenance and leak detection.

Without further ado, I wish you pleasant reading moments with Fluid Handling International.

Best wishes, Ilari

ISSN 2399-5602 1

VALVE NEWS

Bonomi NA introduces high pressure ball valves and automated valve packages for hydraulic applications

Nordson releases innovative closed-loop motorised valve assembly for extrusion coating

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 threeway valves (3400 Series NPT/3500 Series SAE) are available in 3/8” through 1” sizes.

Rated working pressures range from 5145 to 7350psi 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 powder-coated 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 120psi. z

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

The new EDI PolyStream is the first such system to provide closed-loop control, minimising human error and the possibility of injury when making manual adjustments, according to a company statement.

“The PolyStream valve assembly is the first completely hands-free system for regulating back pressure in extrusion coating,” said Sam G. Iuliano, business development manager for polymer dies.

Although extrusion coating operates at higher melt temperatures than other extrusion processes and requires use of a back pressure valve to reach these temperatures, excess back pressure can lead to polymer degradation.

Installed between the extruder and the die, the valve assembly uses closed-loop control to maintain back pressure within a range targeted to ensure optimal processing.

“Back pressure conditions are affected by numerous factors and are in a constant state of flux. By making operator intervention unnecessary, our new system helps to ensure coat weight consistency, adequate adhesion to the substrate, and a high level of product quality,” Iuliano said.

The drive for the valve responds to a controller that receives a continuous flow of signals from a pressure transducer, causing the valve to open at varying degrees in accordance with whether back pressure is trending too high or too low.

When the valve reaches its limit of opening as a result of excessive contaminant build-up on the filtration screen, an automated warning indicates that it is time to change the screen.

A human/machine interface (HMI) enables the operator to specify process conditions or to use specifications from a recipe.

The valve assembly can be run manually, although Nordson recommends automated closed-loop operation.

The PolyStream assembly includes a motor, breaker plate screen pack, linear valve, melt pipe, control system, and optional display panel. z

Clarke Industrial Engineering sign 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 at 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 2

Nordson EDI PolyStream is the first hands-free system for regulating back pressure in extrusion coating

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

VALVE NEWS

Andritz Hydro to supply valves Hantemp Controls and electromechanical equipment introduces S4At stainless steel for two hydro projects solenoid valve Andritz Hydro, part of 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 run-of-theriver plant with no intake reservoir.

Andritz has previously been awarded

the 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 MARCH/APRIL 2017

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

3

PUMP NEWS

Thompson pump unveils new pumping products Thompson Pump unveiled its “Pump of the Future” concept at the 2017 CONEXPO-Con/AGG conference in Las Vegas, US, 7-11 March.

Thompson Pump manufactures pumps and related equipment, and provides engineering expertise for dewatering operations for construction, bypass, and emergency applications.

Along with the concept pump with ANC technology, the company also debuted its new Recon control panel with a live demo, showcasing its smart technology.

Additionally, Thompson launched two brand new Final Tier 4 pump offerings in its Rotary and J-Series lines.

Thompson Pump, a 47-year-old family-owned company based in Port Orange, Florida, is a full-service manufacturer and provider of dewatering and construction pumps, pumping equipment and engineering expertise for dewatering, bypass, and emergency pumping applications worldwide. z

Aussie Pumps introduces new self-priming pump for corrosive duties Australian Pump Industries has introduced a new cast 316 stainless steel selfpriming centrifugal pump to handle corrosive liquids in mining applications.

The new pumps – designed to answer a need in mining and chemical industries for cost efficient, ISO9001 quality products capable of handling contaminated and corrosive liquids – feature close coupled electric drives and high efficiencies for both high and low head applications.

“This product line has been developed for mine tailings and other difficult mine liquids including light slurries” said Aussie Pumps product manager, Neil Bennett.

“We perceived a major market opportunity for a top quality stainless steel pump at a realistic price and built strictly in accordance with our quality culture,” he added.

The first pump to be introduced is a 5.5kW 3” pump that delivers a maximum flow of 910l/min with the added ability to handle solids up to 10mm in size.

The pump is self-priming with the ability to draft water from depths of 6m, and it provides a maximum pump head of 40m, making it suitable for high pressure water transfer or even machinery washdown.

Power for the machine comes from a 5.5kW TEFC three-phase, two-pole electric drive motor, installed from the factory on a heavy duty steel base for ease of installation with optional stainless steel or hot galvanised steel bases also available.

“The pump’s big advantage for miners is its ease of repair in the field and simplicity of operation. Even changing the seals is simple,” said Bennett.

“The pump is close coupled to the motor with a 316 stainless steel stub shaft.

Disassembly of the pump body from the motor is a matter of minutes, giving access to the pump chamber for cleanout or service.”

Behind the pump’s self-priming characteristics are the big “shoulders” in the priming tank, and a high-mounted suction port also helps fast self-priming without the need for additional aids like vacuum pumps or compressors.

The new pump is available in nickel aluminium bronze, as well with a semitrash version available in a cast iron configuration.

The pump seals are heavy duty mechanical style with Nitrile elastomers, but optional viton and silicon carbide are also available.

The first pumps are going to Kalgoorlie, Western Australia, where they will be used for mine tailings and wash stand applications in high PH level liquids. z 4

KSB receives major pump order for new Zhangzhou power plant The KSB Group has been awarded a contract for the supply of six reactor coolant pumps for a new power plant in China.

To be used in the first two units of the new Zhangzhou power plant, the pumps will be delivered by SEC-KSB Nuclear Pumps & Valves Co., a joint venture is handling the order together with KSB, Germany.

The order, worth “triple digit” million euros according to KSB, includes the supply of six type RSR 750 reactor coolant pumps, each driven by a 10,000V highvoltage motor with a rating of 6,600kW. The maximum flow rate of each set, consisting of a pump and motor, is around 24,500m3/h and the total weight per pump set amounts to approximately 110 tonnes.

The scope of supply will additionally include accessories, such as special tools and spare parts, with the delivery date for the entire order set to be in 2020 and 2021.

Zhangzhou, with two power producing units that when commissioned will have an output of 1,200MW each, is located in the Fujian province in the southeast of China.

A total of six units with an overall output of 7,200MW are planned for the Zhangzhou site. z

KSB’s type RSR 750 pumps will be put to work at the new Zhangzhou power plant in China

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

PUMP NEWS

Vogelsang presents pump series for chemical and paint applications Hugo Vogelsang Maschinenbau, a Germany-based machinery manufacturer, presents the IQ and VX series of rotary lobe pumps from Vogelsang for the chemical paint industry.

“Pumps that are used to pump paint, adhesives, and similar chemicals have to satisfy high requirements. To pump viscous or abrasive fluids, or fluids with high solids content, the industry needs highly developed technology,” said Harald Vogelsang, managing director at Hugo Vogelsang Maschinenbau.

In the rotary lobe pumps of the IQ series, all parts that come into contact with the pumped media, such as the pump cover, pump housing and connectors, are made from stainless steel and are therefore resistant to aggressive fluids.

The lobes can be made from a variety of materials (elastomeric coating, solid stainless steel or polyurethane), depending on the properties of the pumped media.

The fluid buffer is integrated as a standard feature, preventing dry running of the pump while at the same time increasing its suction capacity.

The IQ series pumps are user-friendly in their design, with the pump chamber consisting of one centrally located part and it can be dismounted in a few easy steps.

This allows on-site access to the pumping elements for servicing and maintenance work while the pump itself remains securely screwed into the pipe.

The number of essential spare parts has been halved, resulting in a reduction in cost and time required to replace wear parts.

Variable connectors make installation suitable and easier for all common scenarios.

The pumps of the VX series are reliable in abrasive and viscous media with high foreign matter content, such as paints, sealants, adhesives and similar chemicals.

Their design makes them robust and easy to maintain, and they also have good priming properties and are resistant to dry running.

The flow direction of these pumps can be reversed in order for containers and tanks to be filled and emptied.

Pulsation-free HiFlo rotary lobes ensure gentle pumping, being ideal for media and substances that are sensitive to shearing forces. z

New Armstrong parallel sensorless pump offers high efficiency Armstrong Fluid Technology has unveiled the new Tango line of pumps featuring the next level of innovation in design envelope technology.

Ranging from 1hp to 10hp, the new line of Tango pumps is a completely integrated offering designed to further reduce the first installed costs, as well as ongoing lifetime costs by more than 30% over traditional approaches.

New features include a hydraulic design optimised for intelligent variable speed operation and new Armstrong iECM permanent magnet motors with integrated drive and controls that deliver IE4 levels of energy efficiency, extended by the on-board intelligence.

The pumps improve efficiency by 3-6% on hydraulics and 2-7% on motor efficiency for reduced energy usage and carbon footprint.

Built-in parallel sensorless pump control

capabilities provide high-efficiency staging and built-in redundancy to deliver up to 30% savings over traditional duty-standby approaches.

Significant reductions in size and weight provide for easier installation and space savings, and simple servicing using a blanking plate allows on-going single pump operation.

Both wireless and wired connectivity are available, as well as on-board web services.

“The new Tango line represents the embodiment of the complete design envelope technology capabilities, delivering the pinnacle of operational performance,” said Lex van der Weerd, CEO at Armstrong. ”The extended intelligence and connectivity of our full design envelope range allow us to actively support real-time building performance management,” added. z

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

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

5

FLOWMETER NEWS

Alicat mass flow controllers chosen

by VIC for air pollution analyser calibrators Alicat Scientific’s Basis mass flow controllers (MFCs) have been selected by Valco Instruments Co. (VIC) to control gas flow rates in its Dynacal permeation devices.

Alicat Basis OEM instruments provide the control required by VIC to create gas mixes down to fractions of a nanogram per minute, in a compact footprint for easy integration.

Designed specifically for original equipment manufacture and process integration, Basis is Alicat’s smallest footprint instrument, controlling gas flow rates used for mixing or diluting or supplied into processes such as gas analysers, custom blending manifolds, and burners.

Introduced in 2015, Basis has been qualified and accepted by customers within gas chromatography, gas mixing, and sputtering for film coating, as well as burner applications.

VIC has incorporated multiple Basis MFCs into its Dynacal permeation devices, an integral component of its Metronics Dynacalibrators, which are used to calibrate air pollution analysers.

The Dynacal generates the gas concentrations necessary for accurate calibration, and Basis handles the mass flow rates needed by the Dynacal to produce precisely measured mixes of trace quantities of gases with high precision, including two very low flow rates.

Several features of the Basis product line have been instrumental in meeting VIC’s specifications, including the device’s accuracy at very low flow rates (e.g., 1cm3/min).

Its high turndown ratio – as high as 200:1 – means that fewer devices are needed to control a wide range of flow, providing space and cost savings without sacrificing performance.

Basis also has a rapid control response time of 100ms, not attainable on most flow controllers of its size, and ease of use. Its industrial interface facilitates rapid integration into gas flow systems.

The Basis line of mass flow controllers come in three flow ranges, from 1-100cm3/ min to 5-1,000 cm3/min and 0.1-20l/min.

They can be configured with six selectable gases – air, Ar, CO2, N2, O2, and N2O – or with He or H2. z

6

Singapore grants tankers extension approval tests for older mass flowmeter systems The Maritime and Port Authority of Singapore (MPA) has made available alternative extension approval tests to validate already installed mass flowmeter (MFM) systems on tankers.

The MPA said tankers that had been fitted with MFMs three years ago and require recalibration for compliance can now utilise an alternative extension approval test in order to validate the systems against current requirements, Platts reported.

A spokeswoman told Platts that MPA, along with TR48 technical experts, had developed an “extension approval test to validate the MFM systems as an alternative to recalibration, which will minimise downtime and reduce costs.”

Barge operators have been concerned that the MFM recalibration would require pulling their barges out of operation for multiple weeks in order for the meters to be sent to SPRING Singapore’s

recognised testing laboratories, many of which are located in Europe.

As of February, five bunker tankers are reported to have utilised the extension approval test, which is conducted on board and does not require the bunker tanker to be taken out of service.

Owners of the vessels Emissary, Oigawa, and Marine Kingsly have confirmed that they were among those to have received the extension approval test, receiving a one-year extension as a result.

“The extension helped as it cut the downtime of the barge to a few days, and we could resume operations soon after,” said Desmond Chong, general manager at Sinanju Tankers, owner of Marine Kingsly.

In January, MPA made the use of MFMs mandatory for its bunkering operations as the first port in the world. z

Mass Flow Online expands flow measurement range to gas applications Mass Flow Online, the e-commerce channel of Bronkhorst High-Tech, has released two new models in its Mass-View series, the MV-108 mass flowmeter and MV-308 mass flow regulator.

With the introduction of the new models, the Mass-View product line has been extended to gas flow rates up to 500ln/min (N2-equivalent), fulfilling

the demand from industrial users e.g. for gas supply in burner applications, chemical processes, and systems in the food and beverage industry.

The instruments provide local display as well as an electronic output signal and feature an accuracy of ±1% RD plus ±0.5% FS up to 250ln/min and ±2% RD for higher flow rates.

Both models have four pre-installed ranges (100%, 40%, 20% and 10% of maximum FS range) selectable via a user-friendly menu, using a four-way navigation button.

The user can easily select one out of the ten pre-installed gases – air, N2, O2, Ar, CO, CO2, N2O, CH4, C3H8, C4H10 – which eliminates the need to recalibrate for different gases.

The maximum operating pressure is to 10bar(g)/150psi(g). z The MV-308 mass flow regulator FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

FLOWMETER NEWS

Macnaught resumes production of M-Series mechanical flowmeters to answer renewed demand Australian fluid measurement and handling equipment designer Macnaught has restarted the manufacture of the M-Series mechanical display flowmeters after distributor feedback and resurgence of customer demand.

The company put a stop to producing the mechanical meters in 2016, replacing the product in its portfolio with digital models.

Oval gear meters are popularly held as one of the most versatile flow measurement devices, as they are able to accurately meter fluids over a wide viscosity range without the need for flow conditioning.

Incorporating this unique oval rotor principle into its design has enabled M-Series positive displacement flowmeters from Macnaught to offer proven reliability and high levels of accuracy and repeatability, the company said.

The meters include a rugged design that minimises the number of wearable and replaceable parts and extends product life, easily fitted and operated mechanical registers, and flexibility of installation options.

They can be mounted horizontally or vertically without flow conditioning and they exert minimal pressure drop allowing for economical pump selection or gravity flow applications.

With moving parts inside the meter body limited to a pair of oval gear rotors, maintenance is minimal.

Unlike more complicated technologies, M-Series meters can

Customers and distributors proved reluctant to let go of Macnaught’s MSeries mechanical flowmeters

be quickly and easily disassembled, serviced and reassembled whilst still in the line without the need for special tools or training.

The M-Series model range covers sizes from 0.5-4” with flowrates from 2-1200l/min and an accuracy reading of ±0.5%.

Offering a choice of construction materials ensures effective use in industrial applications with a wide range of fluid viscosities. z

Level Measurement ■ Visual Level Indicators VLI ■ Tank Level Instruments TLI ■ Meets the design standards of the oil & gas,

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ARCA Flow Group worldwide: Competence in valves, pumps & cryogenics

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

7

OTHER NEWS

New filter elements provide safer changeouts, greater efficiencies for gas processing industry Clark-Reliance Corp. has announced a new line of coalescing filter elements for the gas processing industry, designed to eliminate unsafe filter element changeout techniques while increasing filtration efficiencies.

The new VertexCore filter elements have a fixed extension that is welded to the element end cap, which allows maintenance staff to easily remove and replace elements without exposing their head, shoulders, torso, or legs to a confined space.

This design feature eliminates the widespread behaviour of climbing into or reaching into filtration pressure vessels to remove or replace elements.

The VertexCore extensions and hold-down rods, while facilitating element replacement, also provide a barrier to prevent operator entry, a positive reinforcement to confined space safety regulations.

The coalescing filter elements feature multi-layer construction

The new Clark-Reliance filter elements increase operator safety

to maximise efficiency, with thirdparty testing confirming they meet ANSI/CAGI 400 test standards.

Removal efficiencies are down to 0.3 micron at 99.98% with maximum carryover of 0.1 ppm by weight.

Because they are more efficient, VertexCore elements can be retrofitted

to existing pressure vessels to eliminate carryover created by inadequate element spacing of standard elements.

VertexCore coalescing filter elements are designed for critical use applications in the power generation, oil, and gas industries, or wherever gas processing occurs. z

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FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

OTHER NEWS

Asco introduces new 617 Series pressure regulators Asco has introduced the Asco Numatics 617 Series Sentronic^LP proportional electronic regulator for accurate pneumatic pressure control in applications with limited power supplies.

“The 617 Series’ 4W power consumption offers design and control engineers a highly reliable and cost-effective solution for pressure regulation in lowpower environments,” said Andy Duffy, VP of sales for the Americas at Asco.

“With its advanced DaS software, the regulator can be optimised for maximum performance and safety in any application.”

With hysteresis of less than 1%, high linearity and repeatability, and stable control under flowing conditions, the proportional valve is suited for applications where precise pressure control is required.

These include manufacturing applications in food and beverage, and packaging industries.

The 617 Series regulator is available in three sizes – ¼” (4 mm), 3/8” (8 mm), and ½” (15 mm) – to cover a wide range of flow requirements.

It also incorporates high flow rates – with the ½” model’s 5,200Nl/ min flow rate the highest in its class – along with versatile, compact, and

Dust Plugs and Caps with Pressure Relieve Valves.

Asco Numatics’ new 617 Series electronic pressure regulator is a good fit for food and beverage industries among others

lightweight design and intelligent digital communication with simple operation.

The 617 Series’ ¼” model is available in a compact manifold mount that holds up to ten valves.

The space-saving design requires only one pressure supply, enabling economic, simple, and quick installation. z

Stirloch to construct new drinking water treatment plant in Australia

Australian engineering company Stirloch has been awarded a AUS$9.8 million (€7m) contact to construct a water treatment plant in New South Wales.

The Nabiac water treatment plant is part of a AUS$34.6 million Nabiac Inland Dune Aquifer Water Supply project, which is planned to deliver a second water supply to the area.

The plant was commissioned by Australian water utility MidCoast Water, which chose Stirloch as the constructor after an extensive process to ensure best value and demonstrated capability, reported Great Lakes Advocate news site.

“The other pleasing news is that the tender assessment process resulted in a reduction in the planned budget for the project in the order of AUS$800,000,” said John Turner, chairman at MidCoast Water “When operational, the Nabiac system will allow us to reduce the

Let off Pressure.

volume of water we extract from the Manning River during times of low flow, which both improves water security and environmental outcomes for our communities,” MidCoast Water’s general manager Ken Gouldthorp added.

The Nabiac project consists of three main components, which include the establishment of an extensive bore network, a water treatment plant approximately five kilometres southeast of the Nabiac township, and a pumping station at Darawank.

Both the bore network and pumping station elements of the project have been completed.

The project is supported by an Australian government allocation of AUS$9.43 million under the National Stronger Regions Fund and a New South Wales government allocation of AUS$2.47 million under the Restart NSW programme. z

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

p to NEW DDC Dust Ca

ADR

The ADR 2015 requires a third closing device, which enables a safe release of pressure in filling or bottom discharge pipes before the cap is completely removed. This protects the operator and environment.

Elaflex provides dust plugs and caps with integrated pressure relief valves according to ADR requirements.

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These dust caps PN 10 made of aluminium are used for Dry Disconnect male adapters on road tankers and allows a safe and easy operation.

ELAFLEX - Gummi Ehlers GmbH Schnackenburgallee 121 · 22525 Hamburg Tel. +49 40 540 005-0 · info@elafl ex.de 9 www.elafl ex.de/en

Protect your assets

MAINTENANCE

Oil and gas operators must utilise the latest methods in monitoring and maintenance to keep their operations profitable and safe

The oil and gas (O&G) industry presents great opportunities for profit and growth, but as with many businesses, O&G operations are not without risk.

Companies within the industry must contend with increased emissions regulation, hostile environments, and potentially dangerous working conditions.

Asset management solutions ensure O&G companies maintain productivity and maximise return on investment.

This is important during exploration to ensure expensive rigs do not sit idle while parts are sourced and maintenance is carried out. Regular maintenance will reduce costly operational interruptions, provide more accurate emissions data, improve employee safety and boost overall site productivity.

Companies are moving away from manual measurement processes and introducing more accurate technology, more focused calibration, and improved maintenance schemes. This best practice is positioning companies to meet the regulatory demands of the future. When maintenance tasks were performed 10

manually, personnel would need to carry out tests and confirm whether assets were working or not. Hiring personnel to do this job not only cost significant time and money, but it meant placing a human being into a potentially dangerous environment.

The remote monitoring of O&G equipment means that dangerous testing does not need to be completed by humans. In late 2015, dozens of oil workers were killed in a fire aboard a rig in the Caspian Sea, which was caused by a gas pipeline that was damaged in high winds. By recording critical data remotely, companies can understand the impact of extreme weather on oil rigs and implement procedures to reduce the risk of a similar incident. Had the owners of the rig been more aware of the likelihood of an incident happening, the site could have been evacuated earlier.

Safety first

O&G operations can be dangerous.

Although rare, there is a risk of on-site explosions. The Deepwater Horizon oil spill (also referred to as the BP oil spill) began on 20 April, 2010, in the Gulf of Mexico on the BP-operated Macondo Prospect. At approximately 9:45pm, highpressure or methane gas from the well expanded into the drilling riser and rose into the drilling rig, where it ignited and exploded, engulfing the platform. At the time, 126 crew members were on board – seven BP employees, 79 from Transocean, and employees of various other companies. Despite a three-day US Coast Guard search, 11 missing workers were never found.

The Deepwater Horizon sank on the morning of 22 April, 2010. Considered the largest accidental marine oil spill in the history of the petroleum industry,

the US government estimated the total discharge at 4.9 million barrels.

There are many potential causes of such an accident, including the sudden release of gas under pressure or the introduction of an ignition source into an explosive or flammable environment. The hydrocarbon releases (HCRs) that cause explosions like these are, in simple terms, leaks. Regular reporting of asset well-being and asset monitoring will alert operators when equipment is malfunctioning – or is about to do so – helping to reduce the risk of a leak and the loss of human life.

With continuous measurement, operators can also discover leaks through a process called mass balancing. By accounting for material entering and leaving pipes, mass flows that might have been unknown or previously difficult to measure can be identified. For example, operators can use mass balancing to identify faulty valves within their pipe systems that may be causing dangerous leaks.

Operating in a hostile environment O&G operations can often take place in extreme environments – in the middle of the ocean, in extreme heat or cold. Monitoring assets in hostile environments is crucial for risk reduction, but these punishing conditions can make maintenance difficult.

Consider the Deepwater Horizon oil rig.

It was a semi-submersible mobile floating drilling rig that operated in waters up to 10,000ft deep. Sea water could impact asset performance, underwater debris could affect flow, and cold deep-water temperatures could freeze equipment. With regular maintenance, the effects of hostile environments can be counteracted. This means potential issues can be identified and dealt with before they become a highcost, time intensive problem for operators.

The emissions focus Another major consideration for the O&G industry is reducing emissions. Consider gas flaring – a process in the industry that has been recognised as a leading contributor to greenhouse gas emissions,

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

MAINTENANCE and consequently global warming.

Based on satellite data, more than 150 billion cubic metres (or 5.3 trillion cubic feet) of natural gas is released into the atmosphere each year through natural gas flaring and cold flaring operations.

In November 2015, the COP21 climate change conference in Paris saw a number of O&G companies sign a pledge to reduce routine gas flaring to zero by the year 2030. This means an increased focus on emissions being recorded and shared with regulators. The O&G industry has come a long way in its recognition and reduction of emissions. However, under increased regulatory scrutiny, it is crucial that gas flares are accurately measured and recorded.

To comply with national emissions regulations, O&G companies must adhere to strict rules around measurement accuracy. Whilst national regulation requirements may differ depending on country, global regulation in gas flaring is predicted to intensify over the next decade.

The Comisión Nacional de Hidrocarburos (CNH) – the independent body responsible for regulating fossil fuel production in Mexico – requires all gas and vent meters to be installed and maintained to manufacturer specifications, setting the maximum allowable measurement uncertainty for gas flaring at 3%. Russia also has stringent regulations covering flare gas measurement, requiring operators to maintain an uncertainty of just 5%. All measuring equipment must hold approval certificates and be registered with the State Register of Measuring Devices.

How can O&G companies ensure their emissions information is accurately reported? They use measurement tools, such as Fluenta’s ultrasonic flare gas meter, to gather emissions data. However, it is important that flare gas measurement equipment is recalibrated and recertified to maintain accurate reporting.

A poorly maintained flare gas meter will inevitably lose accuracy over time, which could result in companies misreporting important environmental statistics. A build-up of debris, ice, or condensation in the pipes and a change in gas composition could all drastically affect reporting. In many parts of the world, these inaccuracies can lead to significant fines, penalties, and even imprisonment.

and share data on a periodic basis. However, connected measurement technology means that this information can now be monitored and measured in real time through secure hosting in the cloud.

Cloud infrastructure enables the constant monitoring and storage of data on remote servers anywhere in the world in real time via the Internet of Things (IoT).

Monitoring equipment installed on local assets transmits information to software that is stored on central servers, rather than physically on an O&G site. When real-time data is fed into a continuous emission monitoring system (CEMS), organisations can collect, record, and report data remotely. This method has several benefits.

Providing they are connected to the internet, businesses can access CEMS data and analyse it using a variety of devices. With internet connectivity available almost anywhere, businesses can access the real-time data feeds of remote assets from multiple sites anywhere in the world. It is not necessary to store and run the software on a machine onsite, which reduces cost and removes the need to have on-site staff. Additionally, the data is stored securely on multiple remote servers with backup and is not dependent on the health and reliability of an on-site machine. Remote action can be taken to update software, shut down failing or faulty systems, and if there is a danger of explosion, extract on-site personnel immediately.

IoT and emissions measuring

a full shutdown of operations. Conditionbased monitoring (CBM) is a maintenance strategy that monitors the condition of an asset to decide what maintenance needs to be done and when. CBM dictates that maintenance should be performed when certain indicators show signs of decreasing performance or upcoming failure. This new monitoring system will minimise the cost and disruption of meter repairs.

It is far easier to schedule regular maintenance calls with expert engineers and identify a problem early on than to deal with an unexpected repair in the future. The breakdown of a meter could delay environmental reporting – a serious breach of regulation in many regions – and greatly impact production if pipelines need to be shut down for repairs. With CBM, potential issues can be identified and dealt with before they become a high-cost, time-intensive problem.

Asset monitoring and maintenance is needed in every industry to ensure the effective and productive running of operations. However, as a risk-heavy industry, O&G companies need to dedicate time and money to maintain equipment and regularly check sites for manufacturing issues or leaks. In hostile, hard-to-access areas, the need for asset monitoring intensifies and new regulations have put increased pressure on operators to improve the accuracy of emissions reporting. Traditionally asset monitoring was a manual process, with humans having to test equipment and access dangerous environments – at great cost and risk. However, IoT has introduced a new way to remotely monitor assets at a fraction of the cost and from a much safer distance. Connected technologies can greatly reduce the risk of accident or injury in O&G operations, improve emissions monitoring, and provide insightful data to advance on-site operations. z

Historically, O&G companies had to record the volume of gas flared locally

This article was written by Lana Ginns, marketing manager at Fluenta. Visit: www.fluenta.com

The tech effect For many operators every hour of downtime costs money. O&G companies could be caught off guard by equipment issues and may be forced to implement

For more information:

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 11

MAINTENANCE

Predict your problems Predictive valve maintenance using smart actuators has yielded significant cost savings at a refinery in Italy

Owners and operators of industrial plants throughout the world continuously seek to reduce their operating costs without compromising the safety and reliability of their equipment and processes.

Because reducing total cost of ownership is a key business goal, selecting and implementing the most effective maintenance approach for valves and other essential equipment is critical.

Maintenance within a plant environment has two main purposes – to restore failed equipment to a given operating condition or to prevent failures of the equipment.

What is needed is not so much a general increase in maintenance activities, but instead more rational planning for and management of these maintenance activities. The lack of sensitivity toward optimising maintenance planning tends to arise not only from a lack of awareness of the benefits that can be derived from investing in maintenance, but also a poor attitude related to adopting a strategic maintenance approach that includes predictive techniques and long-term results-based decisions.

Given that plant leaders understand maintenance costs can represent a significant percentage of the overall cost of ownership, adopting and implementing a new philosophy towards maintenance will prove to be extremely effective. A more progressive view of maintenance is founded upon three principles: 1. Maintenance is a key factor in the plant’s ability to guarantee continuous production 2. Maintenance should be factored in as early as the initial design phase 3. Predictive methodologies, programmes, and schedules of maintenance activities and planning to allow for appropriate resources and activities should be outlined and accepted in advance Fortunately, the evolution of the maintenance culture has shifted the focus from maintenance directed at a specific 12

Fig 1: Through valve automation system architecture, the end user can monitor in real time the health and performance of each motorised valve

piece of equipment or system towards a more comprehensive maintenance strategy. Typically, one of three maintenance strategies is considered. This is either corrective maintenance (usually an unscheduled maintenance action that is valid for easy repairs that do not cause serious production losses or safety concerns), preventative maintenance (which includes static planned maintenance, dynamic planned maintenance, and condition maintenance), or predictive maintenance (also referred to as predictive testing and inspections - PTI - or condition monitoring).

Technical and economic factors should drive the decision to adopt a specific maintenance strategy or to employ a combination of these three approaches.

Demonstrating the value of predictive maintenance A good example of predictive maintenance applied to valves surfaced in a refinery in Italy starting in 2014. This refinery has a processing capacity of 10 million tonnes per year and a fleet of 170 tanks for storage capacity of over 2.3 million cubic metres. The architecture consists of intelligent electric valve actuators connected to the control system by a communication infrastructure.

Working with the end user, the Biffi

team of Pentair Valves & Controls developed and implemented a predictive maintenance approach based on smart electrical actuators and a diagnostic master station. This approach has been effective, having yielded significant measurable results related to the reliability of the system and reduced production costs over a two-year period: • Availability of actuated valves has been improved from 97.2 to 98.6% • Maintenance costs have been reduced by 53% • Emergency related costs have been reduced to zero • An important maintenance performance index (maintenance costs/assets value) has been reduced from 13 to 6% The diagnostic functions of the actuators and the digital control system (DCS) effectively monitored and classified the health status of the installed valves to define and prioritise scheduled maintenance aimed at prevention of failure. The refinery area that is the focus here is called Island 13 and comprises a park of 7 storage tanks, a pumping station, and a set of pipes and connection manifolds.

In the Island 13 area are installed 101 on-off and modulating valves motorised by intelligent electric actuators. These actuators have been fitted with valve condition monitoring and connected via

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

MAINTENANCE

Fig 2: The most important parameter about the operating status of a valve is the torque-valve position curve

actuator with a remote control system. A command and control station takes care of data collection and transmission in a redundant configuration, and an advanced diagnostics software performs data analysis and representation duties. The architecture of the system is represented in figure 1.

Through the described architecture, the

end user can monitor in real time the health and performance of each motorised valve. Diagnostic software allows for the collection and visualisation of a large amount Fig 3: Through the monitoring of critical parameters made available by of actuator and actuators to control system and advanced diagnostics, the end user/Pentair team can segment the valves into this maintenance nine-block matrix plant data for maintenance LonWorks fieldbus control system (Diagnostic and control purposes. The software is Communication Master Station), in turn installed on a separate laptop computer connected via MODBUS to the refinery’s connected to the DCM via Ethernet.

DCS. LonWorks is a well-established open Through this software, the operator can standard bus, which is installed yearly on easily access a plethora of information. millions of applications worldwide. It is an This includes visualisation via a graphic open non-proprietary protocol based on representation of the field of actuators, internationally recognised standards. either by logical grouping or physical layout The command and control system (cable sequence). At a glance, it is possible is installed in the control room and is to view the position and status of all the responsible for monitoring and assessing the actuators in the field. The system can control condition of the valves, including remote single actuators and issue commands Island 13, reporting the status of all valves or configurations, access complete and gaining control for the same through data logs of each single actuator, and interaction with the refinery’s DCS using memorise historical data, warnings alarms, a MODBUS communication protocol. and status information from actuators.

Collection and memorization of operational Main technical features data (torque curves, temperature logs, contactor cycles, and other The command and control system of parameters) for maintenance purposes, electric actuators consists of four key and elaboration of data collected for elements. It includes 101 smart electric the creation of statistics, graphs, reports, actuators equipped with an electronic or for distribution to other users on the card of interface with the communication customer network is also possible. line, and two-wire serial trunk two loops, The program is capable of running a redundant communication card link schematic representation of the devices

making up the system, representing device data on screen, detecting position/torque curves and their storage, and detecting and logging of field events and diagnostics.

Furthermore, it enables the display of plate data of each device connected, sending controls to a single device with password protection, and processing stored data to create statistical reports.

The parameters that are analysed include valve state (open, closed, or intermediate position), valve closing and opening time, alarms, warnings, valve signature (torque versus position), diagnostics electronic cards, and availability of the valve.

The most important parameter about the operating status of a valve is the torque-valve position curve recorded at each opening or closing manoeuvre.

Figure 2 exemplifies the different valve types and the different failure modes to the variation of this curve in the life cycle valve. Analysis of significant variations of this curve makes it possible to define the health status of the valve and prevent onset of unexpected failures.

Enter the matrix Through the monitoring of critical parameters made available by actuators to control system and advanced diagnostics, the end user and the Pentair team can segment the valves in a nineblock maintenance matrix (figure 3). The 101 valves have been classified into nine groups according to criticality (non-critical, critical for production, critical for safety) and probability of failure (low, medium and high) depending on the parameters recorded by condition monitoring system.

Each category is associated to a colour code and a priority from 1 (highest priority) to 9 (non-priority). The colour legend shows red for a state of emergency and urgent maintenance interventions, yellow for a state of alert and scheduled maintenance interventions, green for status of ordinary administration, routine maintenance, and strategic spare parts sourcing, and white for maintenance on failure. This approach allowed the end user and the Pentair team to prioritise maintenance and the type of preventive interventions according to the category of valve maintenance. More than two years later, this matrix continues to be updated by the maintenance team daily. z For more information:

This article was written by Stefano Martinelli, actuation and controls service product manager at Pentair Valves & Controls, Biffi Team. Visit: www.pentair.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 13

LEAK DETECTION

Leak detection in the spotlight

By Ilari Kauppila

A recent increase in the number of oil spills has both brought the efficiency of current leak detection technologies into question and increased their demand

There are certain pieces of equipment that those working in the fluid processing and production industries spend a lot of money on, but hope never to use. These kit pieces include all kinds of emergency and safety devices, such as pressure relief valves, emergency shutdown systems, and leak detection solutions.

And the operators are right to hope so, as the bill for emergency situations can quickly become very expensive, not only because of lost production, but also because of the related environmental and health and safety issues.

Unfortunately, leak detection solutions have recently come into the spotlight, particularly in the oil and gas industry. A slew of high profile spill incidents in the US and Canada, coupled with several new Three oil spills in North America have highlighted the need for effective leak detection

development projects, has increased the pressure on oil operators to ensure their pipelines are in good shape and not likely to spring a leak any time soon. Ensuring smooth operation is particularly important as governments in countries around the world with major oil and gas pipelines running through their area are cracking down on leaks and tightening regulatory requirements on leak detection solutions.

While oil leaks are never good news, for leak detection equipment manufacturers – among them big names such as Honeywell, Siemens, and Krohne – the situation could open new doors.

The tightening regulatory requirements will drive technological development and the new pipeline projects, such as the controversial Keystone XL and Dakota Access that were recently re-approved by US President Donald Trump, should give the leak detection device market a significant boost.

Increased incidents As mentioned, there has recently been a good number of cases where an oil pipeline has ruptured and released its contents into the environment. Starting with the latest one, in late January, Tundra Energy Marketing was confirmed to be the operator of an oil pipeline that spilled 200,000 litres of oil onto Aboriginal lands in Saskatchewan, Canada. Located

14

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

LEAK DETECTION some 140km southeast from the city of Regina, the leak was detected by locals nearly a week before Tundra Energy was confirmed as the owner of the pipeline.

At the time of writing, Tundra Energy had told the media that it was working with regulators and the Ocean Man First Nation indigenous group to determine the cause of the leak. The company has sent the affected part of the pipeline to testing, and according to Reuters, 174,000 litres of oil had been recovered and 185m3 of soil had been removed from the area. The leak occurred on a feeder artery at the 1,600km long pipeline. Tundra Energy did not respond to Fluid Handling International’s request for comment.

South of the border from Saskatchewan, two incidents occurred in the US both before and after New Year’s Eve. In late December, a segment of the North Dakota Belle Fourche pipeline, operated by True Companies, spilled 176,000 gallons of crude oil into a Little Missouri River tributary.

More than 130,200 gallons of oil, 73% of the total amount released, contaminated nearly 6 miles of Ash Coulee Creek before clean-up workers could contain it, with the remaining 46,200 gallons soaking into a hillside along which the pipeline runs.

Wendy Owen, spokeswoman for True Companies, says the pipeline is buried on a hill near Ash Coulee Creek, and the “hillside sloughed,” which may have ruptured the line. “That is our number one theory, but nothing is definitive,” Owen said. “We have several working theories and the investigation is ongoing.”

In early January, then, another misfortune struck the Enbridge-operated Ozark pipeline in Missouri, which ruptured and released 15,330 gallons of crude oil before it was shut down and isolated.

Some of the leaked oil made its way into a drainage area some 600 metres away from the Enbridge property, where most of the release was contained. The drainage area has been contained as well, but the company has no specific timeline for when the pipeline, transporting oil from Cushing, Oklahoma, to Wood River, Illinois, would return to service.

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

Questioning efficiency The bad news for leak detection system manufacturers in these cases is that only in the Enbridge leak did the system actually detect the leak. In both the Tundra

Energy and True Companies incidents, the installed leak detection system failed to alert the operators of the compromised pipeline, which exacerbated the caused damage. Why the systems did not work was unclear at the time of writing, with Owen from True Companies stating that an investigation was ongoing.

The US tracks pipeline data centrally, and a 2012 study for the Pipeline and Hazardous Materials Safety Administration found that only 17% of oil spills were detected in operator control rooms. In Canada, similar tracking of pipeline leak discoveries was started by the National Energy Board only in 2015, but results already show that control rooms detected only 20 of the 128 leaks of oil, gas, or other substances since the programme started.

The failure of leak detection systems highlights both the difficulties in detecting leaks in oil pipelines and the shortcomings of existing technologies. As Carl Weimer, executive director of the Washingtonbased Pipeline Safety Trust put it in an interview with Canadian CBC News: “The current leak detection [systems] companies use aren’t particularly effective.”

The perceived inefficiency of leak detection systems has garnered more attention with the US approvals of Keystone XL and Dakota Access, and due to Canadian authorities giving the green light to Kinder Morgan’s Trans Mountain pipeline expansion and the replacement of a part of its Line 3. These projects are feared to cause leaks similar to the Tundra Energy and True Companies cases.

“The [Tundra] spill confirms the worst fears of indigenous communities and environmental organisations and no doubt strengthens their resolve to resist and fight back the approved Kinder Morgan and Line 3,” Rauna Kuokkanen, an associate professor of political science and indigenous studies at the University of Toronto, told Reuters.

Kinder Morgan told Fluid Handling International that the computational pipeline monitoring (CPM) system that is currently in use on the existing Trans Mountain pipeline system will be extended to the expanded pipeline system, including the delivery pipelines to the Westridge dock. The system used real-time transient modelling (RTTM), which provides “one of the most sensitive” leak detection methods commercially available, the company said. Within the CPM system, detailed computer models of the pipeline system are developed using engineering data, including pipeline lengths, diameters,

elevation profiles, fluid properties, and instrumentation accuracy/repeatability.

The models are used to simulate pipeline conditions using advanced fluid mechanics and hydraulic modelling.

The RTTM method automatically adjusts sensitivity based on supervisory control and data acquisition (SCADA) data quality, operational events such as pump starts/stops, valve movements, shut-in conditions, and batch changes along the pipeline, so that the best balance of leak detection performance and minimum false alarms can be achieved.

“While current regulations in Canada require only a single leak detection system, regulations in Germany require two systems running in parallel on a single pipeline. In recognition of this higher standard and in an effort to continuously improve leak detection, Trans Mountain will be putting into production a second complementary CPM system that will operate in parallel with the existing system,” Ali Hounsell, spokesman at Kinder Morgan, says. “The new CPM system will use a different technology to recognise leaks and it will also be implemented for the [expansion] project, ensuring that Trans Mountain not only meets, but exceeds regulatory requirements and maximises CPM leak detection capability.”

Regulatory back and forth While on the topic of regulatory requirements, lawmakers are considering making them tighter to combat the possibility of pipeline leakage. For example, in Montana, US, the authorities are debating a measure that would ban locating large pipelines under rivers or lakes. Introduced by Montana representative George Kipp III, Democrat, the bill is intended to protect rivers and streams, as well as underground aquifers.

It would also tighten the regulations for aboveground pipelines, including rules on casings and leak detection.

Such measures, however, are possibly to be undone, at least in the US. President Trump, who made a campaign promise of rolling back on a number of US federal regulations, has hinted at wanting to ease the rules governing US oil and gas pipelines.

A new rule, tightening the requirements on inspection and repair demands and dictating – among other measures – that leak detection systems should be used on pipelines in populated areas, was enacted seven days before Barack Obama passed the keys to the White

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 15

LEAK DETECTION

New technologies are being developed to detect ever smaller pipeline leaks

House to Trump. The rule, set to take effect in July, has been characterised by the oil and gas industry as overreaching and unnecessary, and the Trump administration has put it on hold for the time being.

In Canada, the government seems to be playing a different tune. Speaking in the aftermath of the Tundra Energy incident, Prime Minister Justin Trudeau said the handling of the spill and the investigation is the province’s area of responsibility, but the federal government is there to support the province in any way if needed.

“I think this highlights the expectation that Canadians have that while we grow the economy, while we create good jobs, we also are responsible and mindful of the impact on the environment, that we expect high standards of response to accidents but we also do a better job of being proactive on ensuring that our communities and our land is safe and protected,” Trudeau said.

Each Canadian province has a different approach to handling oil spills. In Alberta, for example, the Alberta Energy Regulator (AER) requires all pipeline incidents, including those in which a pipeline is hit but does not leak, to be reported to the AER. AER staff gather information regarding incidents including the location, date, and time of the release, a description of the release location, area affected, and immediate surrounding area, a description of the circumstances leading up to the release, including how it was discovered, the type and quantity of the substance released, and details of any actions taken and proposed to be taken at the release site to contain, recover, and remediate the release.

16

“Pipeline operators are required to inspect and patrol their pipeline rightof-ways to detect evidence of leaks or other issues that could affect the integrity of the pipeline and require further action by the operator,” Monica Hermany, advisor for media and issues management on public affairs at AER, told Fluid Handling International.

“The AER expects that every operator has adequate maintenance and leak detection programmes according to AER’s requirements, including the standards outlined in the Canadian Association Standard’s CSA Z662-15: Oil and Gas Pipeline Systems, and that they continually monitor the effectiveness of its systems and improve them as needed,” she adds.

Effect on markets But, despite the failed leak detection in two of the three mentioned cases, the current climate is favourable for leak detection system manufacturers, as the requirements posed by new regulations increase the demand for brand new systems in the marketplace. Additionally, there is a drive to develop new technology that will succeed where the current systems failed, namely in detecting smaller leaks.

Such a view was echoed by two recent market studied by MarketsandMarkets and Credence Research. Both estimate that the leak detection market for oil and gas will keep growing at a compound annual growth rate (CAGR) of more than 6% (6.9% according to MarketsandMarkets, 6.4% according to Credence) and reach a value of more than $3.2 billion (€2.9bn) by 2023. Both

studies attribute the growth to increasing incidents of leakages in oil and gas pipelines and storage tanks at production facilities, development and expansion of existing pipelines and construction of new pipelines, and stringent government regulations pertaining to the implementation of leak detection systems.

The RTTM market is expected to grow rapidly, particularly as it can provide an answer to the need to detect smaller leakages and it provides more accurate results and leak locations in fractions of time. Acoustic/ultrasonic technology, widely used in single-phase and multiphase flow pipelines, is expected to lead the market, owing to its advantages, such as quick leak detection capabilities, suitability for leak detection in large pipelines, and the simplified sensor and software setup with minimal calibration.

Oil companies are also trying to provide their own answers to the leak detection conundrum. Kinder Morgan, among others, is currently participating in two joint industry projects using large scale testing to investigate the viability of commercially available external leak detection systems and aerial surveillance systems for detection of oil spills. The testing is being completed using a test apparatus that is the first of its kind and enables testing of commercially available products under real-world conditions in a lab environment.

“The testing will help Trans Mountain and the pipeline industry determine which technology is optimal for external leak detection on liquids pipelines,” Hounsell says. “The first project is testing four external leak detection technologies – vapour-sensing tubes, fibre-optic distributed temperature sensing (DTS) systems, hydrocarbon-sensing cables, and distributed acoustic sensing (DAS) systems.

The second project is testing aerial surveillance systems that provide the ability to sense oil spills from a helicopter or fixed-wing aircraft flying over a pipeline.

Two different technologies, volatile organic compound (VOC) sensing and temperature sensing, are being studied.”

Despite the questioning of the efficiency of their technologies, the market does not seem to be dismissing leak detection technology developers. Quite the opposite, there is more demand for their products than before, and perhaps the recent unfortunate oil spills will spur the development of ever more reliable and accurate detection methods.

The industry seems poised to make the best out of a difficult situation. z

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

All the small things VALVES

By simply choosing a certain type of valve, an Australian mine operator has increased its process efficiency Often it is the small things that matter, especially when it comes to critical operations and de-bottlenecking.

Tasmania Mines (TMM) is a public company listed on the Australian Stock Exchange. It is involved in the mining, crushing and concentration of scheelite and magnetite from the Kara Mine in Tasmania. Scheelite is sold to customers in Europe who use it in the production of specialty steel and also to the US where it is used in the lighting industry. The magnetite is sold to the Australian coal industry where it is used as a dense medium to wash coal.

Many mine sites are under pressure to keep costs low. “The biggest challenges that mine sites face in their daily operations is keeping the labour cost low with maximised availability. The resources are often limited, so there is no room for surprises. Reliability really is the key. The gradual change towards more automated operations and solutions can bring more advantages,” states Martti Lahtinen, managing director of Australian operations at Flowrox.

Valves for cyclones Two years ago, TMM decided to install new pinch valves for its hydrocyclones. A

Flowrox PVEG 100M valve

hydrocyclone is a device to classify, separate or sort particles in a liquid suspension based on the ratio of their centripetal force to fluid resistance.

Solids-laden water enters the machine, A hydrocyclone used in mining operations where a rotating motion separates the solids “All application and slurry characteristics and the water, disgorging them are different, so we provide tailorfrom two separate outlets. made flow control solutions precisely “Practicality and occupational in accordance with the customer health and safety (OH&S) issues were specification. To meet the customer the key when choosing the valves for requirements, we offer a comprehensive our hydrocyclones, but of course the sizing and selection service to ensure price played a role too,” states one the right product with the right material of the process managers from TMM. in the right place,” he concludes.

“The steel housings are heavy and vulnerable to corrosion, and various The inside is what counts types of metal pass through them, so the valves need to meet very tough At the heart of the valve is the sleeve. challenges and conditions,” he adds.

The sleeves are critical, and many times After reviewing its options, TMM they will be the first part to wear out in chose Flowrox PVEG pinch valves to a valve. Often, this can happen very operate its hydrocyclones. Now, after quickly. “Our operators like the fact that two years of service, the company is they can really rely on the equipment,” very happy with its choice. TMM has TMM’s process manager confirms. found the main benefit to be reliability.

The sleeve is the only part of the valve “Price is always an issue when we that is in contact with the medium, calculate the total cost of ownership, and and it is also the only replaceable we have been satisfied with the PVEG part. “What makes our valves so easy pricing. In addition, our management to maintain is that the sleeves can be is satisfied with our choice of supplier quickly changed on site,” Lahtinen says. for the valves in terms of the safety “What we also like about the PVEGs of the equipment and the reduced is that they are easy to install and risk in OH&S. Reliability cannot be handle,” TMM’s process manager adds. emphasised too much, and the price The valve recommended for TMM for is right. I would recommend the PVEGs the process, a PVEG50M with 50 mm for my peers at other sites as well,” manual polyamide body, has been TMM’s process manager concludes. operating well for the past two years. z “The PVEGs are an ideal solution where shut-off applications involve abrasive or For more information: This article was written by Inka corrosive slurries, and they are designed Tuononen, head of communications to meet even the most demanding and marketing communications at Flowrox. Visit: www.flowrox.com customer specifications,” states Lahtinen.

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 17

Feeling the pressure to reduce leakage?

VALVES

Utilising a carefully planned system of pressure relief valves can prove essential for reducing leakage in water systems

Battery-operated control with two pressure settings

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Water is a resource that is often taken for granted. As we see the effects of climate change and population growth, the challenges we will face regarding water supply and availability will only increase. But what does pressure management have to do with scarcity of water? Every water utility has some degree of leakage or water loss within their systems, which can be greatly reduced by pressure management.

According to the European Environment Agency, between 4% and 50% of the water pumped or fed into distribution systems simply leaks out of the system and into the ground. The majority of European countries fall in between 10-30% leakage while developing countries can be as high as 70%.

So what is the cause of these leaks?

Ageing infrastructure (old pipes and valves), cracked pipes, poorly maintained valves, leaking gaskets, and leaking threaded connections at curb or corporation stops are only a few examples of where these leaks or water loss occurs.

The costs are far greater than the actual cost of the water being lost as we are also wasting the energy required to pump this water and losing the chemicals we use to treat it. We are also building additional reservoirs to store more water to provide reasonable storage of this precious resource. The International Water Association (IWA) and the American Water Works Association (AWWA) have many water

audit tools that can easily determine the levels of water loss that a water utility might be encountering.

So what can we do about this lost water? In an ideal world we would replace our entire infrastructure – old pipes, valves, poorly threaded connections – and make sure our systems do not leak. While this would be a very effective way to solve this problem, it is impossible due to the incredible replacement costs. Proactive water utilities replace a small percentage of challenged systems every year to eliminate or greatly reduce leakage within that particular pipe section. This approach is sound and is practiced in many utilities around the world and helps mitigate the problem, but does not eliminate it. Pressure management is recognised as the most immediate, cost effective approach to reduce water loss and leakage.

Managing pressure So what is the big deal about pressure in a system? If the pressure in a system can be decreased by 1%, leakage rate will also decrease by 1.15% (average and subject to variation). During daytime, consumers use a lot of water to shower, wash, cook, etc., and so demand for flow increases. When this happens, pressure is almost always lower. At night time, as demand is reduced, the pressure increases in the system. It is not uncommon to see pressure change by 1-2 bar from day to night time.

Additionally, pressure in a distribution system is almost always higher at the source (pump station or reservoir) and drops due to pressure loss as it gets further away, even more so if there is a topographic increase. If distribution lines feeding customers are in areas close to the source, they are likely to be supplied too much pressure for what is required in order to serve the most distant or highest elevation customers. To reduce

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

VALVES teams can then be directed into the most challenged zones and identify areas with the greatest need. DMAs are always most effective if the specific zone can be provided with one source and avoid multiple meters and PRVs feeding off a looped system. With this approach the PRV can be adjusted specifically to each zone and the pressure in that zone can be set to supply exactly what the customers require. In a small town or city of 10,000 people or less, operators may end up with four or five DMAs or pressure zones. In a large city with many millions of residents there may be 100-200 pressure zones. Each DMA will often give a payback of six months to a year when evaluating the cost of the water that would otherwise be lost.

Another interesting characteristic of pressure management is the reduction of pipe bursts that coincides with a sound pressure management programme.

Antiquated leaking valve on Catalina Island, California

leakage, it is best to give customers just enough pressure to get the job done as an increased pressure would simply be adding to leakage or wasted water.

A sound approach in reviewing water loss reduction would include a pipe/ system annual replacement programme (focused on the most challenging areas) and a leakage location plan, where teams locate leaks and then expedite the repair of those leaks. If the system is not gravity fed and pumps are involved, variable frequency drives (VFDs) can be one of many tools that can help mitigate this problem. It should be noted that while VFDs can be used as an effective tool, they should always be used in conjunction with a pressure management approach.

overall flow into that specific pressure zone while the consumer, industrial, and commercial meters used for billing measures flows out of the zone. Assuming the meters are calibrated, this will provide leakage rates in that zone.

With this information, leakage location

It is a well-known fact that pipe bursts are usually a fairly significant portion of annual maintenance budgets. Pipe bursts often happen in off peak periods or night time. The reason why these bursts occur is the same as previously discussed due to demand being lower and pressure being higher. By managing

District metered areas When considering a comprehensive water loss and leakage programme, it is common practice for water utilities to hire a consulting firm that specialises in this discipline. After completing a water audit, a consultant will usually analyse the system and begin to establish district metered areas (DMAs), which typically consists of a meter and a pressure reducing valve (PRV). These DMAs are often designed to be a dedicated pressure zone for between 2,000 and 3,000 service connections, but this number can vary subject to population and utilities’ desire to find the smallest leak. The meter then measures the

Single rolling diaphragm technology

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VALVES

Typical DMA zone with a meter and pressure reducing valve

pressures better with DMAs or pressure zones, annual maintenance budgets can be decreased and water loss associated with pipe bursts plus consequential damages can be reduced.

incorporated in the initial PRVs to make this valve have different functions. With a standard PRV, the only limit is that there is only one pressure setting downstream, which cannot be changed without staff manually adjusting the pressure.

Choosing the right valve When selecting a PRV, it is important to have the highest quality product available and minimum maintenance.

Not all manufacturers build these valves the same way, so it is important to specify things like 316 stainless steel seats (no bronze/brass as this soft yellow metal will wear), stainless steel fasteners on the external portion of the valve (no plated or galvanised, which are prone to rust), and always insist on heat fusion epoxy coatings on both the external portion of the valve as well as internally on all wetted surfaces (avoids rusting in the bare ductile iron on the inside of the valve).

There are emerging technologies that can assist in ensuring pressure reducing control valves are stable throughout their entire stroke. Traditionally flat diaphragms have been used in most diaphragm operated PRVs. These valves can operate very effectively when operating midstroke, but they can be challenged at very low flows to be stable. There is a technology available called “single rolling diaphragm�, which can supply very consistent pressure throughout the entire stroke of the valve virtually from shutoff to the highest flow required.

This is best for pressure management systems during low flow periods.

A standard PRV can be a very effective tool to control pressure. Once installed, there are many options that can be 20

Pressure management is becoming a very popular topic as water utilities are being pressured to maximise the efficiencies of their systems There must also be some pressure at the inlet to the valve (minimum of 0.6 bar) for the valve to function.

Another approach that can assist a pressure management scheme is to use a standard PRV and use two mechanical pilots (two pilots specific to night time pressure and day time pressure) and use a simple inexpensive battery operated timer (IP-68) and a solenoid to change pressures based on time. This approach can supply higher pressures in the daytime but cut pressures back at night time or off peak periods.

A third approach is to have a special mechanical pilot modulate pressure based on flow. This approach includes the use of a proprietary pilot system and can change pressures based on flow.

For this technology to be most effective the system must have a minimum of 3 bar at the inlet to the valve and only one supply point into your DMA. This valve

can mechanically change (no batteries or power required) pressure based on flow by up to 2 bar (fully adjustable). This means it will lower pressure at night time, when demand is low and pressure high, and will increase pressure in daytime when demand is high and pressure is low.

A fourth approach can be full SCADA control of PRVs. By adding a 4-20mA motor and incorporating pressure switches and flow information, a complete system can be operated remotely through SCADA, constantly adjusting pressure based on varying flow demands.

In addition to pressure management, a well thought-out programme of PRVs and the associated topic of transients (surge) is an area that is often overlooked. Anywhere pumps are starting and stopping suddenly due to PLC failure or power loss due to lightning storms, there is a risk of surge damage to pumping and piping systems and again water loss and leakage due to pipe bursts or increased stress on the piping system. All pump stations, regardless of having single speed motors or VFD motors, should have some sort of surge protection. There are numerous models of diaphragm operated control valves that can provide this protection. These models include standard pressure relief, surge anticipating, and rate of rise anticipating pressure relief valves.

In conclusion, pressure management is becoming a very popular topic as water utilities are being pressured to maximise the efficiencies of their systems and reduce the water loss and leakage rates. There are many different solutions available and a well thought-out programme utilising various options can often be the best approach. A well-planned pressure management solution can have a very short payback period when reviewing a business plan showing cost of water saved versus capital costs for initial installation. The end result is better use of an increasingly scarce resource, water. z

For more information:

This article was written by Brad Clarke, the VP of sales and marketing at Singer Valve. Visit: www.singervalve.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

PUMPS

A Chilean copper mine has reached 4,000 hours of continuous operation with the world’s largest mill pumps

Large problem, large solution In 2009, after years of dealing with poorly performing mill pumps requiring a costly mill outage every 800 hours, leaders of a major Chilean copper mine began looking for an alternate supplier that could help them maintain a more reliable shutdown schedule, minimise expenses, and meet a high safety standard. GIW Industries, a heavy-duty centrifugal slurry equipment, pumps, and parts designer and manufacturer, helped the mine achieve what it thought impossible: developing a mill pump that can run at least 4,000 hours continuously without shutdown.

Not only did GIW meet the customer’s needs, but its innovative improvements to material developments in the high wear wet end components will save this massive copper mine an estimated $6 million (€5.3m) per mill line. Before GIW engineers were tasked with the project, employees dedicated upfront time to familiarise themselves with the mine’s operations while helping its owners overcome issues with cyclone-feed pumps in their concentrator plants.

“GIW rapidly responded to the customer’s appeal for help by customdesigning an improved suction liner and impeller to be installed inside the existing competitor pump, providing improved hydraulics and wear life,” says Hernan Palavecino, GIW South American regional sales manager. “During the initial run of the new GIW technology, the customer was astonished to see an ‘almost new’ suction liner after first inspection at 1,300 continuous hours. Keep in mind that the customer was accustomed to failures at 800 hours with their old supplier.”

After this improvement in performance, mine personnel noticed the presence of tramp balls in their process. Out of fear of a catastrophic failure that could severely impact worker safety, they again turned to GIW for a solution. As a result, GIW then designed and built a complete jacketed casing in two months to resolve this potential safety issue. The customer was so impressed that it decided to replace the entire competitor pump with a complete GIW MDX-750, the world’s largest mill pump, which provided 2,000

hours of reliable wear life and reduced plant outages to just four per year.

A new target Since that time, GIW has successfully installed seven total MDX-750 pumps in the mine’s concentrator plant. Once the lines were upgraded to GIW technology, the customer set yet another new target for success. It wanted to extend the operational cycle and reduce plant outages from four to two annually. To accomplish this goal, it would need cyclone feed pumps that could run 4,000 hours between shutdowns with no operational interruptions.

The MDX pump design features a large diameter impeller, which results in slower pump operation and extended parts wear life. Thicker cross sections enable the pumps to provide a longer and more reliable service life, while a deep base circle minimises aggressive particle impingement by providing a sliding wear action. This construction reduces abrasive wear significantly when compared to traditional pump designs. Oversized shrouds in the pumps provide enhanced vane performance by performing a clearing action, which minimises recirculation and wear between the suction liner and the impeller.

The patented inlet 5V impeller included in the pumps has been designed to handle both liquid and solid phases within the slurry. A slurry diverter, GWI’s latest technology, increases suction liner life by reducing particle recirculation even further between the impeller and the liner. The pumps are able to handle flow rates up to 14,000m3/h at temperatures up to 120°C and pressures up to 16 bar.

The maximum head is 90 metres.

As a company, GIW has worked diligently to improve its pumps used in cyclone feed applications. This focus has been on using better metallurgy and variable geometry for the wet end during operation. For instance, GIW can alter the geometry of the suction liner impeller interface while the pump is operating using its adjustable suction liner technology.

Ultimately, GIW engineers developed

a brand-new material technology. The innovative material is called Endurasite, and it is capable of resisting the effects of abrasion for extended periods. When applied to the MDX-750 high wear wet end parts, this specially processed, ultrawear-resistant white-iron alloy improves pump wear life and, in turn, extends time between shutdowns. Creating this solution from scratch was undoubtedly complex, and GIW employees and the customer were aware of the potential pitfalls of testing a new material in an active mine.

Cutting costly shutdowns by 50% The customer never had a need to be concerned, though. The GIW team remained present during all testing to perform maintenance and ensure optimal results. And as Palavecino points out, the results were certainly optimal.

“We set a target of 4,500 hours for the first test cycle, but during the campaign, we saw that it was possible to extend the cycle over 5,000 hours without operational risk,” he says. For this test GIW was pitted directly against its competitor’s cyclone feed pump. Due to the final testing results and GIW’s on-site support, the customer has adopted GIW technology.

GIW not only achieved the customer’s goal but it also managed to exceed it by cutting annual shutdowns in half and drastically improving the total cost of ownership with an estimated savings of $6 million (€5.6m) per mill line. GIW’s continual development mindset has taken the mine’s pumps from 800 to 5,000 hours of continuous operation.

It is an achievement and a long-term responsibility that GIW does not take lightly.

“Reaching this target is the result of several years of continuous improvements and focusing on the customer,” explains Palavecino. “It was achieved and exceeded because of the commitment and teamwork between the customer and supplier.” z For more information

This article was written by Hernan Palavecino, regional sales manager for South America at GIW Industries. Visit: www.giwindustries.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 21

PUMPS A sealless pump package for downstream installations

No seals required A downstream petrochemical refinery chose magnetic sealless pumps for the many benefits they bring to the refining process Sealless pump containment shells

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As part of a continual upgrade process and to ensure the highest levels of health and safety, a refining and petrochemical company in the Far East has recently upgraded several pump installations to meet current American Petroleum Institute (API) standards. The existing single mechanical seal pumps, operating on downstream hydrocarbon processes, were reviewed for suitability against a double mechanical seal upgrade or an entire sealless pump replacement.

The pump applications that were to be upgraded included debutaniser reflux, reformer stabiliser reflux, and pre-treater stripper reflux duties. The liquids included mixed liquefied petroleum gas (LPG) and hydrocarbons. These liquids typically feature low viscosities, low densities, and are of a volatile nature, making them ideal candidates for properly applied magnetic drive pump technologies.

Some of the process liquids also featured low levels of H2S, and thus wetted components of the pumps needed to feature materials that comply with

NACE requirements for sour service.

The process plant is an experienced user of sealless pump technology, with an installed base in excess of 50 magnetic drive pumps. The user has enjoyed the benefits of magnetic drive pumps on a variety of applications for over 15 years, such as the complete elimination of fugitive emissions, reduction of initial installation cost, reduced cost of ownership, and full site serviceability.

It was these reasons, and the proven health and safety benefits provided by a sealless pump, that led to the user choosing API compliant magnetic drive sealless pumps to upgrade its existing sealed pump installation.

Reviewing the options A magnetic drive pump package containing six vertical inline pumps and two horizontal pumps was supplied in accordance to API 685 2nd Edition. This API standard, applicable to sealless centrifugal pumps for petroleum,

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

PUMPS the cooling of the magnetic coupling.

One of the key features of the device is that it is measuring and reacting to the primary cause of a potential problem and not the secondary, which is the case when monitoring power or temperature.

Some of the benefits of condition monitoring systems include providing real time condition monitoring of the internal fluid, detecting the early presence of gas, ensuring correct priming and venting, and eliminating the potential for dry running.

The instrument features a 4-20mA output signal, on-board data logging via microSD card, local visual indicators, and is IECEx/ ATEX/cUL compliant. It can be retrofitted to many existing magnetic drive pump installations, providing increased peace of mind to existing end users.

Sealless pump condition monitoring instrument

petrochemical, and gas industry process service, is based on accumulated knowledge and experience from users, engineering companies, and manufacturers of sealless pumps. Its intent is to facilitate the manufacture and procurement process of sealless pumps and it provides the reader with minimum design requirements, safety features, and application guidance needed to successfully use sealless technology.

During the process of evaluation for the upgrade, the latest magnetic drive pump technologies and designs were reviewed, ensuring that the eventual solution reflected the most recent technological advancements available to magnetic drive sealless pumps. Such technologies and designs include condition monitoring of the pumps’ internal flow regime, high efficiency composite containment shells, and vertical inline pump design.

It was these features that helped the user choose sealless magnetic drive pumps for its upgrade project.

High efficiency, engineered composite containment shells Composite containment shells feature a non-magnetic material that virtually eliminates all induction losses (eddy current losses) associated with metallic containment shells. By eliminating the induction losses, several benefits are realised, including significantly reduced heating of the pumped product that is circulated to lubricate the internal bearings of the magnetic drive pump, improved handling of volatile and heat sensitive liquids, and an enhancement in overall pump efficiency, when compared to a similarly sized pump featuring a metallic containment shell.

A further, and often overlooked,

Condition monitoring of the internal flow regime Condition monitoring instruments utilise non-intrusive ultrasonic technology to constantly monitor the state of the fluid inside the pump. The device detects the early presence of gas in the internal cooling and lubrication circuit from outside the confines of the pump pressure boundary, and provides an early warning of adverse conditions that are likely to impact internal bearing lubrication and

benefit is that the shells also provide a more robust design for magnetic drive pump installations that might experience system upset conditions. It is these features that make engineered composite containment shells ideal for use on hydrocarbon installations. The containment shells are produced to comply with the 40 bar (580 psi) API 685 design pressure requirements and feature a highly chemical resistant composite material that is tough, durable and robust.

API compliant vertical inline pumps Vertical inline pumps have all the features of a horizontal magnetic drive sealless pump combined with the benefits of a vertical inline configuration, such as a streamlined footprint and minimal requirements for piping modifications when upgrading from other inline designs.

The hydraulic designs feature radial diffusers, ensuring hydraulic optimisation, and, dimensionally, the pumps comply with the requirements of BS4082. The design pressure is 40 bar (580psi) and such pumps are suitable for operating temperatures up to 205°C. A wide variety of material options is available, including stainless steel (A8), carbon steel (S5), and duplex stainless steels (D1 and D2).

Another benefit when choosing magnetic drive pump technology is one of a commercial nature. Because a sealless pump installation does not require all the ancillaries and support systems typically associated with a pressurised double mechanical seal installation (particularly if the seal installation is to API standards), an entire sealless pump solution is often a more economical design solution.

When the pump package that featured the above technologies and design features was compared to the double mechanical seal upgrade option, it was found to be more cost effective, as well as providing the already mentioned benefits associated with magnetic drive sealless pumps. This, coupled with the dedicated service and support provided by the pump manufacturer’s local in-territory representative, enabled the user to make a decision based on commercial and technical compliance. z

For more information:

This article was written by David Clark, senior engineering manager at Sundyne HMD Kontro Sealless Pumps.

Visit: www.sundyne.com/hmdkontro David Clark, senior engineering manager at Sundyne HMD Kontro

Sundyne HMD Kontro is a long-standing member of the British Pump Manufacturers Association

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 23

Down with energy costs!

PUMPS

A UK battery manufacturer’s experience illustrates how an underspecified pump can rack up energy bills, not to mention maintenance costs Entek, an international manufacturer of lead-acid battery separators, is making massive savings in energy costs at its European plant in Newcastle-uponTyne, UK, having changed the type of pumps used for cooling water duties.

Having experienced poor economic performance and breakdowns over several years with submersible pumps, the company decided to replace them with end-suction water pumps, which has had a significant impact at the plant.

Entek is the global leader for designing and manufacturing lead acid battery separators and provides battery manufacturers with reliable, highquality products for SLI, start-stop, deep cycle, motive and stationary batteries.

The Killingworth-based firm is the only manufacturer of its kind in the UK, and exports 100% of everything it produces. The company’s 0.15mm backweb separators are manufactured from polythene and precipitated silica. Its production lines, which run on a 24/7 basis, continually mix and extrude materials at an elevated temperature into continuous polyethylene sheets, which are then subjected to specialised process treatments.

Fundamental to production is the constant availability of cooling and chilling water, which is held in cooling towers and pumped around the plant. Historically, water circulation has been performed using submersible pumps located inside the towers. However, modifications to the plant had resulted in the pumps having to deliver flow rates far in excess of their original design specification. In this 24

Installation involved core drilling the tower bunds, inserting valves and pipework, followed by installation of the Aturia pumps and variable speed drives

situation, it was inevitable that the pumps would suffer, with many of the problems being related to cavitation and vibration, plus the ensuing costs of pump removal.

Quite evidently, when the plant was constructed, installing two submersible pumps in each tower was considered to be a good idea. However, it took several years of frequent repairs, maintenance and even the replacement of one pump before the issue of pump performance became a major cost issue. According to Robert Stobbs, Entek maintenance engineer, there was no method of monitoring the flow rates, and modifications to the plant did not take

into account the impact on the pumps.

“We cannot fault the pumps because their failings were as a result of the application and changes in demands,” comments Stobbs. “We believe that the original pumps were originally shaft-driven submersible pumps. When problems were first encountered, a decision should have been taken to change to a more appropriate pump type, which is what we have now done” The technology Pump distributor and maintenance company AxFlow had first-hand

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

PUMPS experience of the problems being faced robust and offer high pumping efficiency Cooling Tower 1

by Entek as it was AxFlow’s Durham and low NPSH requirements. The robust Service centre that was regularly being oversized shaft gives good rigidity and Old pump output power 62.5kW called into to carry out repairs. the presence of a thrower reduces New pump output power 24kW “The time taken in overhauling a condensation formed on the shaft New pump frequency 40Hz submersible pump could be as long from passing to the bearing areas.

Flow 3100l/min as three weeks, because every time The installation involved undertaking Energy savings (kW/yr) 314,160kW a pump had to be removed we had alterations to the pumping system on Energy savings (£/yr) £30,000 to bring in a crane and remove the each tower and various groundworks. pump to our workshops. Thus, the costs It was necessary to core drill the tower in keeping these pumps in running bunds and insert valves and pipework, Cooling Tower 2 order were not inconsiderable,” says followed by installation of the pumps and Old pump output power 62.5kW David McTeer, service sales engineer variable speed drives. This programme New pump output power 25.5kW at AxFlow. “With externally mounted of work required close co-operation.

New pump frequency 43Hz Aturia NE water pumps, it is possible to Because of the plant’s 24/7 operation, it Flow 285m³/hr do the work that would have previously was necessary to keep one submersible taken three weeks in 24 hours.” pump continually operating in each tower Energy savings (kW/yr) 301,920kW In 2015, a decision was taken by during the pump replacement project.

Energy savings (£/yr) £29,000 Entek to find a long-term solution to the problems with the pumps. AxFlow was Energy savings Cooling Tower 3 one of several companies called in to Old pump output power 62.5kW examine the problem and come up with The amount of power that the old pumps New pump output power 38kW a remedy. “We started by looking at the used was a factor that was taken into manufacturer’s pump curves and this account when selecting new pumps. In New pump frequency 50Hz revealed that the pumps were pushing far order to arrive at a comparison, Entek Flow 283m³/hr more water than was physically possible monitored the energy consumption of Energy savings (kW/yr) 199,920kW and it was this that was causing cavitation the old pumps and this revealed what Energy savings (£/yr) £20,000 and excessive vibration,” says McTeer. type of costs savings could be achieved.

The AxFlow strategy was to remove “We identified energy savings almost the submersible pumps and replace immediately as the new pumps were them with Aturia NE Series pumps, all switched on,” says Stobbs. “The variable was £112,400, so the payback period is of which would be located externally speed drives provide us with this just 1.4 years. To put this in perspective, and connected to each tower by new information and over the months that it is approximately 5% reduction in total pipework. The Aturia NE Series is a wellAturia pumps have been running, we site energy use,” Stobbs concluded. z proven, high performance horizontal have been able to identify the energy long coupled centrifugal water pump costs and savings for each tower. that offers a maximum flow of 2,000m³/ “Annual total energy savings (see For more information: The hose pump is the pump solution for the is a simple Thefutur. hoseItpump is the and pump solution for the is a simple This article was written byfutur.

BryanItOrchard, an and hr. Fitted with dynamically balanced table 1) of 816,000kW have been well proven construction in one sense butwell alsoproven a “newthinker” in independent the international working in the construction in one sense but also journalist a “newthinker” impellers without balancing holes thatonly the hose achieved, givingwith an energy saving areas of pump and valve technologies, fact that is in contact thefact fluidthat thatonly is of being pumped. the hose isin inthe contact with the fluid that is being pumped. for Axflow. Visit: www.axflow.com are susceptible to blockage, This they minimises are £79,000 from (€93,516).

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This minimises downtime from maintenance and simplifies pump use.

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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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METERS

Fair trade for LNG The liquefied natural gas industry is working towards increasing metering accuracy and bringing in international standards Compared to traditional fuels, such as natural gas or petrol, the energy content measurement of liquefied natural gas (LNG) suffers from a large uncertainty, which has been estimated to be up to 1%.

One of the hurdles that must be overcome before this relatively clean fuel can be introduced as a common transport fuel is establishing a reliable traceability chain conforming to primary standards.

Nearly ten years ago, the Dutch Metrology Institute VSL started exploratory research into accurate measurement of LNG flow and composition. Since 2010, a consortium of metrology institutes, end users, manufacturers, and universities has been working to establish the required metrology infrastructure.

As part of this collaboration, the first midscale LNG calibration facility in the world will be opened this June.

In the light of the objective to fight climate change, the EU launched its Clean Fuel Strategy in 2013. The roll-out of LNG as a transport fuel is one of the pillars of this strategy, since LNG offers a cleaner alternative to conventional fuels, specifically when it comes to particulate emissions. LNG is also 26

perceived to be an important transition fuel, the infrastructure of which can later be used for the roll-out of bio-LNG. It comes as no surprise, then, that the EU granted funding for a European research project called “Metrology for LNG”.

Traceable measurements The metrological framework is still under development for LNG as a transport fuel.

Fuel dispensers for trucks are already in use, as well as flow metering systems for bunkering and midscale transport, but more accurate measurements are needed. One of the biggest challenges in the accurate measurement of LNG and other cryogenic fuels is the lack of high-precision testing facilities that operate reliably under these lowtemperature conditions. The few facilities in the world that are available all perform their tests with liquid nitrogen, but little is known about the effects of the differences in fluids on meter test results.

Some preliminary data using LNG is available, but it is unclear exactly how to interpret these results. The absence of suitable calibration facilities means

these measurements are not traceable to a primary standard in the same way as with conventional fuels. A new test facility, which is being built at the Maasvlakte area of the Port of Rotterdam just behind the GATE terminal, will enable traceable calibrations for LNG flow.

To tackle the measurement challenges associated with LNG quantity and quality, as well as with the cryogenic conditions, VSL and its partners have been collaborating on designing the calibration and research facility. This world-class facility, to be opened in June 2017, consists of a primary standard loop (PSL) and a midscale standard loop (MSL). The PSL has been developed in an earlier research project and serves as a direct link to the international kilogram standard in Paris.

VSL’s Peter Lucas, stakeholder manager of metrology for the LNG project says: “In the past year, this PSL has been upgraded to reduce the measurement uncertainty with the aim to achieve a target of 0.1% accuracy for mass flowrate, which currently is approximately 0.17%. The cryogenic test loop will also be used to test LNG

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

METERS analysers and potential new technologies and devices for the measurement of LNG’s physical properties.”

“The PSL is capable of calibrations up to 25m3/hr. The MSL has a capacity of 200m3/h volumetric flow rate, expandable to at least 400m3/h in the future, with a target uncertainty of 0.15%. The midscale standard is traceable to the PSL and scales the flowrate up using bootstrapping techniques,” Lucas adds.

Furthermore, the MSL incorporates a composition standard based on ISO EN 12838. LNG contains many components that together determine its energy content. It is known that LNG composition – and thus energy content – varies significantly depending on its origin and the production method. In addition, during storage and transport, the “LNG ageing” phenomenon contributes to composition changes. To track the energy value and emissions of greenhouse gas to the environment, it is important to have accurate and costeffective LNG composition measurements throughout the entire distribution chain.

Onwards with OIML LNG has been included in the European Measurement Instruments Directive (MID) since its introduction in 2006. When it comes to OIML regulations, LNG has sadly fallen through the cracks so far. OIML R81 (cryogenic liquids) is outdated and not really meant for direct sales for public purposes, while OIML R117 (liquids other than water) does not include LNG. Marc Schmidt, the oil and gas team leader at certification institute NMi Certin, explains the current situation: “For approval for LNG dispensers, we check against the essential requirements in the MID and the current normative document OIML R117. Officially, an accuracy of 2.5% is allowed, but we strongly advise to certify against accuracy class 1.5% to make sure the dispenser is future-proof.

However, one should keep in mind that most of the standard fuel dispensers have an uncertainty of better than 0.2%. For most end users, especially in midscale transport and bunkering, an accuracy of 1.5% is way too much. Outside of Europe, national regulations apply.”

Meanwhile, a group of experts is revising OIML R117. One of the most important changes in the document will be the addition of a specific chapter on LNG, including requirements for LNG installations and a required accuracy of 1.5% instead

of the current requirement of 2.5%, no matter if the installations are large or small.

“One of the things that will be included in OIML R117 is how to deal with vapour return lines. When LNG warms up, the evaporation of a part of it leads to an increase in pressure. Therefore, vapour return lines are indispensable. But then the question arises what should be done if gas is measured and paid for, but then recovered via the vapour return line? The revised OIML R117 will include information on how to deal with this and correct for it,” says Schmidt.

Another topic that will be included is how to include the impact of the filling hose. “Compared to compressed natural gas (CNG), the density of LNG is much higher. If a truck’s fuel tank takes in 100kg, and a hose holds about 1 or 2kg, this means an extra 1 or 2% in the uncertainty of the measurement.

This will also be addressed in the revised R117,” Schmidt adds.

Implementing ISO In addition to normative document OIML R117, a group of manufacturers, end users, and metrology institutes is currently establishing an ISO standard. The document describes the metrological and technical guidance for flowmeters intended to be used in the dynamic measurement of LNG and other cryogenic hydrocarbon fluids, based on best practices.

“In the ISO standard, manufacturers and end users can expect to find information on Coriolis and ultrasonic flowmeters.

But what should you be aware of when calibrating and using these meters?

Which specific issues can affect the

performance of the flowmeter in use, e.g. the effects of temperatures and pressure?” asks Mijndert van der Beek, flow expert at VSL and chair of the ISO group.

“The strengths and weaknesses of both meter types are described, which will help end users and testing facilities to make a proper selection and installation of flowmeters for their specific needs.

The ISO standard will also include a calibration guideline for laboratory and on-site conditions, including associated uncertainties. What you should be aware of when calibrating with a master meter or a weighing bridge,” van der Beek adds. The draft ISO standard is expected to be sent out this autumn.

Metrology for LNG Workshop During the Metrology for LNG Workshop that takes place on 4 -5 April, 2017, in Noordwijk, the Netherlands, team members will present the results of the Metrology for LNG project and the new standards will be presented.

An optional trip to the mid-scale LNG calibration facility is included. This workshop has joined forces with the 5th European Flow Measurement Workshop – a very appealing combination, since this successful workshop has been bringing together all important parties in flow metrology since 2013, including end users, manufacturers, researchers and metrology institutes. z

For more information:

This article was written by Eveline Janse, communication advisor at Everlution.

Visit: www.efmws.eu for information on the Metrology for LNG Workshop

A 3D model of an LNG test facility

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 27

METERS

Going with the flow Singapore makes mass flow metering for oil bunker deliveries mandatory as the first port in the world

In a move that has been widely hailed as a landmark moment for the bunker industry, the use of mass flow metering (MFM) for heavy fuel oil bunker deliveries in Singapore became mandatory on 1 January, 2017. The Maritime and Port Authority of Singapore’s (MPA) efforts have been warmly applauded by many in the industry – including World Fuel Services – who see MFM as an important tool for developing more transparency and accountability for the bunker supply chain.

The MPA has been a staunch champion of MFM for years, leading the way in educating stakeholders about the benefits of the technology and introducing ground-breaking procedures and regulations. In order to support the introduction of MFM, the MPA has already prepared a comprehensive technical reference document, which sets out the key requirements for the metering systems’ qualification, installation, testing, procedures and documentation. Developed by a working group from Singapore’s national Technical Committee on Bunkering, this document – known as TR48:2015 – was introduced to the market in June 2016.

Mass flow metering How does MFM work and why is it so important to the bunkering industry?

When a mass of liquid passes through an oscillating tube, the inertia effect of the moving liquid will cause the tube to twist – and the twisting will be in direct proportion to the liquid‘s mass flow. MFMs are composed of one or more tubes, and they use sensors to calculate the degree of vibration, and therefore the mass flow directly. This means there is no requirement to change the conventionally measured volumes of fuel to mass as MFM measures the mass directly.

MFM is an established, proven technology. It has already shown its worth in the bunker industry over the past few years – and it has been employed for many decades in other sectors of the oil industry, especially on land and 28

in refinery operations. MFM is extremely accurate. Indeed, TR48 requires that MFMs operate to an accuracy of ±0.5%.

With the traditional sounding tape method, the depth of the bunker fuel in a barge’s tanks is measured before and after bunkering using a gauging tape. Using the barge sounding tables, these soundings are used to calculate the volume of the fuel supplied. A value for the mass of the fuel is then derived using ISO/API/ASTM/ IP temperature compensation tables.

There are measurements to be taken, assumptions to be made and more factors to consider – all of which means that there is more room for error. MFM removes these areas of uncertainty. Besides being highly accurate, MFMs are also robust.

They contain minimal moving parts, which reduces the risk of failure or malfunction, and the MFMs are also equipped with an uninterruptible power source (UPS).

Technocal guidelines and education

– quarterly in the first year and every six months thereafter – in order to ensure they continue to give accurate readings. The TR48 provides comprehensive operational guidelines and the MPA has also produced placards which ship owners can use to keep their crew up to speed with MFM. Win, win Using MFM should be a “win, win” for both the bunker supplier and the buyer. Firstly, MFM’s greater accuracy ensures that ship owners get exactly the amount of fuel that they paid for and the supplier is not giving away any extra fuel. Secondly, MFM is much faster and more efficient than using soundings, so it saves time and money for both parties.

There are other operational benefits too. MFMs can provide a real-time digital display of critical parameters such as flow rate and pressure, which means that any potential problems or abnormalities can be addressed and corrected immediately on site. Additionally, the actual quantity delivered at any given time is displayed in real time.

Bunker disputes over fuel quantity and quality can be time-consuming, costly and highly damaging to the relationship between buyer and seller. While it will never be possible to eradicate disputes entirely, the procedures that the MPA has put in place will help to remove some of the key causative factors.

With the migration to MFM, the role

The MPA’s TR48 not only gives the technical specifications for MFM equipment. It also clearly sets out the procedures on how the meters should be used. Over the past few years, Singapore’s bunker suppliers have been installing MPAapproved MFMs on their bunker barges and the MPA is confident that the 135 bunker tankers that were fully equipped for the January 2017 deadline will be able to meet the market demand for bunkers.

Importantly, the January 2017 launch will be the start of a continuing process, not just a one-time fix.

TR48 stipulates that all MFMs must be sent to accredited laboratories to undergo re-calibration three years after the date they were approved by the MPA. Furthermore, the MFMs will also be subjected to regular verification checks General bunker operation

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

METERS who will encounter MFMs for the first time in 2017.

They may be sceptical about the benefits of the new technology and unsure of the procedures.

However, World Fuel Services will be at hand to offer practical advice and help.

Next steps A typical MFM barge arrangement

of a key partner in the bunker supply chain – the bunker trader – will be as important as ever. World Fuel Services has been monitoring Singapore’s MFM plans closely, and it has been putting this knowledge and expertise to work for its clients – giving continuous updates on how to navigate the new market conditions with the least possible stress.

Shipping companies who bunker regularly in Singapore may already have some experience of the new technology.

However, there will be some ship owners

The mandatory use of MFMs for fuel oil deliveries in Singapore is part of an ongoing process. In Singapore, the MPA and other stakeholders will be closely monitoring MFM’s progress, checking to see how it is helping to overcome bunker quantity issues. The MPA will also work on the continuing “digitalisation” of the bunkering process, as the live data captured by the MFMs can be used to generate more reports and analysis. And now that all fuel oil barges are employing MFMs, there will be a focus on equipping gas oil barges too.

Singapore is the first port in the world to make MFM mandatory for heavy fuel oil bunker barges. The question is: will it be the first of many? Although no other port authorities have currently indicated that they plan to follow the mandatory route, MFM is steadily gaining traction in markets across the bunkering world. With over 25 marine offices globally, World Fuel Services are set up to support their customers wherever and whenever MFM is implemented.

More suppliers worldwide are introducing MFMs on their barges not because they have to, but because they see a benefit for the industry in doing so. MFM can help to bring greater efficiency, transparency and honesty to the bunker business – and these are qualities that have a global currency.

World Fuel Services applauds the MPA’s leadership, and it also welcomes the opportunity to work with bunker partners and customers who are interested in using MFM in other ports around the world. z For more information:

This article was written by World Fuel Services. Visit: www.wfscorp.com

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EVENT PREVIEW

StocExpo Middle East Africa, held in the Dubai World Trade Centre on 26-27 April, is set to be bigger and better than ever. In this preview you can find out what the attending experts will be talking about and what there will be to see at exhibitor stands

Hitting new heights

StocExpo Middle East Africa, the region’s leading exhibition and conference and the only dedicated event for the bulk liquid storage industry, returns to the Dubai World Trade Centre on 26 and 27 April, 2017. This year will see new exhibitors, a world-leading CPD-certified conference programme, a newlylaunched VIP Club, and enhanced features for maximising business and networking opportunities for attendees.

The Middle East and African tank storage sector is developing at a rapid rate, thanks to continued large scale investments, with the United Arab Emirates (UAE) alone set to double its storage capacity in the next few years. The show, which is supported by the UAE Ministry of Energy, Hamriyah Free Zone Authority, ENOC, Fujairah Oil Terminal, and other major ports and terminals, will bring top regional oil companies, tank terminal operators, ports, traders, financiers, and regulators together with leading manufacturers and suppliers.

Nick Powell, event director for StocExpo Middle East Africa, comments: “Following the launch of Tank World Expo in 2013 and the subsequent acquisition and rebrand to become StocExpo Middle East Africa, the show has become the region’s largest event dedicated to the bulk liquid storage industry. Each year the show has been growing in size and quality of attendees – and this trend looks set to continue.

“Last year StocExpo Middle East 30

Africa attracted around 1,200 industry professionals from 50 different countries, and we expect to exceed this in 2017. Now CPD-certified, the quality of the conference programme this year is better than ever, with topical sessions ranging from international down to project level, with some excellent technical content too.”

“StocExpo Middle East Africa has become the must-attend event in the region for the tank storage community, and we will be living up to that again this year,” Powell adds.

Packed exhibition hall

More than 80 international and local suppliers will be showcasing a broad range of the latest technologies, new products, and valuable industry services, including CTS Middle East, Protego, Emco Wheaton, Loadtec Engineered Systems, Mascoat, and Kanon Loading Equipment.

Exhibitors will reflect the entire supply chain, from tank design, construction and maintenance, through to innovations in metering and measuring, pumps and valves, automation and loading equipment and inspection and certification services. Many exhibitors will use the show to launch new products and services to the tank storage market.

For instance, SafeRack will be displaying its manufactured gangways and loading

platforms that provide turnkey services to carriers of crude oil, natural gas and liquid products. Manufactured using precision laser technology, the systems support safety compliance and offer fall protection that is durable, easy to operate and requires little maintenance.

Dixon Group, exhibiting for the first time, will be promoting its FloTech-branded overfill prevention system and Bayco petroleum products. The Dixon product range consists of petroleum tanker fittings including adaptors, valves, APIs, nozzles, hose assemblies and couplings.

Dixon manufactures a full range of FloTech overfill prevention plug and play sensors, monitors and sockets – all compatible with other leading brands.

New for 2017, the FT7000 electronic rack monitor is being launched at the show.

The FT7000 is designed and manufactured in accordance with the requirements of EN13922 and is compatible with five- and two-wire optic and two-wire thermistor probes. The FT7000 provides clear and precise user diagnostics to inform the user as to the status of the overfill prevention system. Various interfaces are standard on the FT7000 and can be selected by the user to interface with the loading terminal automation system as required.

Timm Elektronik will be presenting, amongst others, its overfill prevention controller EUS-2, in accordance with European standard EN 13922 and

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

EVENT PREVIEW American standard API RP 2004. This new generation of overfill prevention puts future technology into practice today, with bus system interconnectivity specifically for use in hazardous areas. A large graphic display, bright multi-colour signal light, self-explanatory configuration menu and unique joystick control are just a few advantages of the EUS-2.

Cortec Middle East will be unveiling its new CorroLogic aboveground storage tank (AST) dispensing system for the protection of tank bottoms against soilside corrosion. The system is designed to be integrated into the tank foundation structure of new tanks, as well as tanks undergoing complete floor replacement.

The fully automated and modular design of the system ensures uniform distribution of vapour-phase corrosion inhibitors (VpCI) under the tank. The system can be used to provide soil-side corrosion protection during construction and recommissioning.

Cortec VpCI technology, being synergistic with cathodic protection systems, makes the CorroLogic AST system an appealing option for tank owners to implement during tank operation, to minimise future repairs and extend the service life of tank bottoms.

“It is great to see so many big names on the exhibition floor this year, with both new faces and many returning exhibitors,” Powell says. “We are also delighted that so many exhibitors have chosen StocExpo Middle East Africa to launch new products and services – testament to the growing importance of the show for the bulk liquid storage industry, both regionally and globally.”

Topical conference programme The StocExpo Middle East Africa exhibition runs alongside a two-day conference, which features global authorities from the bulk liquid storage, finance and analyst sectors. Experts will provide visitors with an insight into the most significant trends, challenges and opportunities facing the tank storage industry in the Middle East and Africa. The conference will be officially opened on day 1 by the UAE Minister of Energy, who will give a welcome address and overview of the current state of the industry.

Christof Rühl, global head of research at the Abu Dhabi Investment Authority, will give the keynote speech on day one, looking at the Middle East’s role within global oil, impacts of OPEC production cuts, and global oil supply and demand.

The regional outlook continues through

both days of the conference with presentations on the growth expansion opportunities in the Middle East by Kamel Al-Harami, independent oil analyst and former president of Kuwait Petroleum International, on refinery growth across the Middle East by APICORP energy research analyst Ghassan Alakwaa, and on the supply and demand outlook for tank terminals in the Middle East and Africa by the managing director of PJK International, Patrick Kulsen.

Other experts will be diving down to focus on storage in specific markets, including Oman (Erwin Mortelmans, commercial director at the Port of Duqm), Turkey (Aydin Erdemir, VP at Toros Terminal), Kurdistan (Zaid Mohammad, general manager at Beydal Petroleum), and Fujairah (Tamer Masoud, harbour master at Port of Fujairah).

Oil pricing – and its effect on both supply and storage – has been a hot topic ever since 2014 when the downturn in world oil prices began.

Edward Bell, commodity analyst at Emirates NBD Bank, will be examining the impact of oil prices on future supply, with an analysis of oil price trends. To give the analyst perspective, Alan Banniser, Asia and Middle East regional director for oil content at Platts, will be looking into the development of the region as a pricing hub.

Bulk liquid storage is an industry with an inherent degree of risk, which makes

pre-incident and business continuity planning an essential consideration for terminal operators. Waddah Ghanem Al Hashmi, executive director for EHSSQ and corporate affairs at ENOC will be describing the work that ENOC and Horizon have been doing in order to improve resilience in terminals.

Powell concludes: “One look at this year’s programme shows how serious we are about delivering world-class content, finely tailored to global and local needs and the interests of terminal operators in the region. Delegates can expect a stellar mix of regional, international and highly technical content, delivered by world authorities.”

Professional development Brand new for 2017, the StocExpo Middle East Africa Conference programme will be CPD certified as part of its commitment to serving the tank storage community globally. Recently, there has been an increasing expectation for professionals to undertake Continuing Professional Development regardless of industry sector, so this year all delegates will be awarded CPD points for the sessions they attend, allowing them to use the learning time towards individual CPD requirements. z For more information:

To find out more about StocExpo Middle East Africa and to register, visit: www.stocexpomiddleeastafrica.com

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 31

SPONSORED ARTICLE

Non-negotiable quality An Italian valve and actuator manufacturer has strict internal standards for product quality The technology applied in the oil and gas (O&G) industry, and especially in the downstream segment, is getting more sophisticated year by year and consequently also valves and actuators are required to meet more challenging specifications to create reliable and safe plants.

Since its origins in 1981, Italian equipment maker Omal has been committed to supplying quality products and solutions to all markets. Such a client-oriented philosophy has driven Omal to specialise in actuated packages and has enabled it to propose valves and actuators satisfying any demand for custom-made products. Omal has a wide portfolio of products, from ball valves and butterfly valves to pneumatic and electric actuators and pneumatic angle-seat and axial valves. For O&G especially, the company proposes its line of ball valves and pneumatic actuators.

Ball valves Ball valves are designed to comply with the most stringent standards and to ensure the maximum performance in terms of

resistance to severe applications and high frequency of cycles where valves usually encounter failures. Omal’s line of floating ball valves (from 0.5” to 8”) are available in wafer and split-wafer construction (Magnum series) or splitbody (Thor series) to enable its clients to have a wide range of choice.

In particular, wafer construction is required where compact dimensions are preferred. Split-body valves are the generic type adopted by most industries (especially outside Europe), and the splitwafer alternative offers both compact design and easy maintenance as it combines the benefits of two- or threepiece construction with reduced faceto-face dimensions. The line of trunnionmounted ball valves (Supreme series from 2” to 24”) is designed for the most

heavy duty applications and high pressure service up to 2.500 ANSI rating class.

The valves can be supplied in any grade of steel and exotic alloys, and the configuration of seals and gaskets can be selected based on the operating conditions. They can be also customised with special features, like double-blockand-bleed, double-isolation-and-bleed, special arrangement of seats and stem packing, bespoke vent and drain or sealing designs, tilting stem, etc.

Given the experience it has gathered in the chemical and petrochemical industry and in O&G, Omal is already qualified with most end users in Europe, Middle East, and Africa, with a long list of reference projects with good performance. Omal ball valves are API6D-licenced, API607 (fire-safe), TA-LUFT ISO 15848 (fugitive emission), and SIL3 certified, and comply with PED, ATEX, and EAC. In 2014, the line of stainless steel ball valves was expanded with the new Pro-Chemie 60 valve, engineered for the harshest of service in chemical and petrochemical plants. The valve has received a special certification from TUV of reaching Supreme series trunnion-mounted ball valves ready for testing 60,000 cycles with the lowest stem leakage rate in the industry. The TUV standard is one of the most stringent regulations worldwide and Omal is one of the few manufacturers to have been able to reach such an achievement. TUV certified valves are used in dangerous applications to avoid fugitive emissions of the fluid into the atmosphere and to protect people and the environment. The same knowhow applied to this special valve is at the disposal of all of Omal’s clients and is extended to all its valve ranges.

Actuators

Thor series floating ball valves in stainless steel

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Since its founding, Omal has chosen to work on the scotch yoke mechanism FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

SPONSORED ARTICLE in lieu of the more common rack-andpinion mechanism adopted by most actuator suppliers up to 5,000 newton metres (NM) of torque. The curve of output torques of scotch yoke actuators are more similar to the torque required to operate one quarter valves (ball and butterfly) and therefore they provide increased efficiency without over-torque.

The benefits of the scotch yoke mechanism are that the actuators are more compact and light-weight, consume less air (40-60% less) and are certified to have a longer lifetime. They do not suffer from the typical teeth failures in rackand-pinion actuators when valves are jammed or used in heavy duty service.

For end users, scotch yoke actuators provide less downtime and lower energy, investment, and maintenance costs.

Omal’s line of pneumatic actuators delivers torque up to 8,000NM with the aluminium series and up to 32,000NM with the heavy duty actuators in carbon steel designed specifically for O&G. In addition, the company offers special products, like stainless steel actuators for the harshest environments, actuators with integrated manual override in case of power or air failure, or three-stage aluminium actuators that enable the actuated valve to perform a dosing function without using expensive positioners.

Automation One of Omal’s assets has always been its ability to manufacture valves and actuators internally without depending on third party suppliers. This means the company is able to match its valves and actuators to a high standard (meaning actuators are not oversized or undersized), it has total control of the quality of the manufacturing process, and it can assure on-time deliveries, competitiveness and extended knowhow to provide custom-made automated packages complete with control panels and any types of accessories.

Last but not least, as the assembly is done by Omal as well, it eliminates the typical blame game between actuator and valve manufacturers. On the other hand, it also means that Omal has to have higher standards to be sure both of its products are up to standard.

Thor series floating ball valves in Alloy20 with stainless steel actuators for 98% H2S service

9001 (since 1992), AD2000, and API Q1 standards. In addition, all products adhere to a strict internal quality plan and any additional requirements by the client.

Omal is also able to provide any type of non-destructive testing or special testing (endurance, high temperature, fugitive emission, and gas seat testing, etc.).

Furthermore, Omal has its own research and development department where valves and actuators are continuously tested to monitor the quality of the production system and to develop new products to be launched to the market.

In the testing lab the company simulates the specified service conditions to ensure that all products are able to perform as required for their entire service life.

All products are engineered, manufactured, assembled, inspected, and tested in Omal’s two modern facilities in Italy. The Thor and Supreme series are made from hot rolled bar steel or, alternatively, they are forged, with the highest material quality ensured through purchasing from major steel producers. The machining is carried out internally. For the aluminium actuators, the pistons are manufactured in Omal’s internal foundry, and the patented sealing system is manufactured at the integrated plastic moulding operations unit.

Omal has since the beginning adopted an integrated manufacturing system to be more independent from sub-suppliers and to offer more flexibility and assured quality. To increase its capabilities, in 2016 Omal opened a brand new machining facility to be able to better respond to future market requirements.

Such state-of-the-start machining capability and advanced lean manufacturing management enable Omal to meet the requirements of valves used in plant maintenance shutdown.

It can also supply complete packages to EPC projects, offering highly-qualified technical support and a flexible production system to meet any special requirements by engineering contractors. z

For more information:

This article was written by Benedetto Bazzani, export area manager at Omal. Visit: www.omal.it

Quality and manufacturing system At Omal, quality is not negotiable.

The company is certified with the ISO

Omal machining department

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 33

SOFTWARE

Oil logistics: the highest level of data exchange fidelity An innovative data exchange solution has enabled a German petroleum refiner to communicate with customers and suppliers effortlessly

In 2014, Switzerland-based petroleum company Varo Energy experienced a huge jump in profits after it had acquired 45% of the Bayernoil refining company, along with the sales business of various tank storage facilities in southern Germany. To make sure that day-to-day operations would run smoothly from day one after the takeover, software company Implico set up a complex network of data connections in just a few weeks.

Since then, Varo has benefited from high data quality and speed of the order and shipping data transferred between the company’s headquarters in Cham and all of its customers and suppliers.

As is often the case with takeovers, there was a real sense of urgency to get everything completed as quickly as possible. Within just eight weeks, Implico had set up all the communication links in its data centre that were needed to deal with the new business operations in southern Germany. Three companies were involved at that pointa – Varo itself, Bayernoil, and OMV, from which the company had acquired the refinery shares and the sales operation. Because Varo’s business structure is continually changing as the company continues to experience strong growth, regular adjustments have become a fact of life. For example, in late 2015 the company acquired

34

several additional oil companies. Implico expanded the existing communications network at very short notice to include a multiplicity of additional loading points, customers and suppliers.

Over 20 petroleum companies in Germany are now exchanging order and loading data with Varo every minute of the day via iGOS. In January 2016 alone, iGOS handled some 22,000 tank truck loads and 2,000 railcar loads at 31 locations – equivalent to a volume of around half a billion litres of petroleum product.

Standardised data sets This is how it works in practice. A tank truck loaded with 36,000 liters of freshly refined diesel sets off from the Bayernoil refinery in Vohburg. At the exit, the driver swipes his card through a reader, which initiates printing of the loading data.

The data, which includes items such as quantity, time of day, driver and contract number, is sent to the Implico data center together with the data from other loads.

Before iGOS submits the data to Varo, it passes through a number of automated processes, which are monitored by Implico to ensure the quality of the data. Monitoring covers, for example, reviewing the contract and checking

Data sent through iGOS passes through several automated processes

that the data has been converted in accordance with Varo’s specification.

If necessary, a copy of the loading data is also sent to Varo’s customer.

“Each of the networked depots that we deliver to or collect from sends its data to Implico using different encodings and different formats,” says Daniel Wicki, IT manager at Varo.

“Implico processes this data and sends it to us in a standardised format.”

The petroleum industry has its own standards, of course, such as MPKS

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

SOFTWARE software specialist complies with all data privacy and data security regulations.

“Some companies are concerned that third parties might be able to see their sensitive data,” says Kay-Peter Buhtz, managing partner at Implico. “This is, of course, not the case! Only people entitled to access the data can access it.” Implico maintains a web portal for those Varo employees who need access to the data.

Varo’s customers, on the other hand, are able to access their data in-house, as it is transmitted directly to their own IT system.

Further growth expected

Together, Implico and Varo have made data exchange at the Bayernoil facility more straightforward

(Mineral Oil Partner Communication System), the modern IFLEXX format (International FiLe EXchange XML) and PIDX (Petroleum Industry Data Exchange). However, both the encoding, some of which is customer-specific, and the different business logic must be interpreted and converted by iGOS so that accurate billing information can be supplied to Varo’s enterprise resource planning (ERP) system.

Should data be missing or information be entered incorrectly, loading results be transmitted in the wrong order or even be transmitted twice, Implico staff will actively intervene. Only then will the system transfer the data to

Varo’s head office in Switzerland. “It is extremely important for everything to run reliably. After all, we are dealing with data that underpins our entire operation,” stresses Wicki.

Backed by teams of experts Varo decided at an early stage to outsource these services to Implico. The group’s IT and logistics experts have specialised in data communications in the downstream sector for over 30 years.

Implico also operates a high availability IT infrastructure with two modern data centers in Germany. Regular internal and external audits ensure that the

Varo was sufficiently impressed with the successful implementation of the communication links and with the high data quality that it signed a multi-year contract with Implico shortly after go-live.

The signs are that there will be no letup for the business in the future. For one thing, the petroleum company’s suppliers and customers are changing all the time. For another, Varo is enjoying a period of strong growth. Whenever there is a change in customer or supplier relationships, Implico simply adapts the system to suit the new situation.

“What never fails to impress me is how we have so many changes, but are usually not able to tell until the very last minute exactly what changes will be needed. Implico is always very flexible in the way it deals with this”, says Wicki. “It’s only possible because the company has such competent people.”

In iGOS Data Exchange, Varo has found a solution that ensures high-quality, high-speed data exchange between their own and third-party loading points, and between the company and its business partners. At the same time, the current communication system offers a stable and sustainable platform upon which to base its future growth. z

For more information:

The iGOS software manages several parts of the fuel supply chain

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

This article was written by Stefanie Schmidt, technical writer at Implico.

Visit: www.implico.com

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SAFETY

Safety on many levels A major Middle East refinery benefits from the flexibility, power, and simplicity of a single architecture for both plant and office facilities

SafCo Engineering was founded in 2003 for the design and manufacture of fire and gas safety systems and equipment for the industrial sector. Initially focussing on products, the company is now more focussed on system integration.

Highlighting its systems integration capabilities, it was recently called upon by a leading oil and gas company in the Middle East to develop and deploy an integrated, single-platform fire and gas safety solution for all of the assets in one of its major refineries.

This is what makes the project so interesting – it is one of the first in the world to leverage a single architecture for both the refinery and the office buildings, using the PlantPAx process automation solution from Rockwell Automation, alongside the SafCo intelligent fire panel. In this type of installation, the traditional approach is to have separate fire and gas safety systems for the plant and the office buildings. The individual needs of both areas are currently catered for by mature technologies, which are seen in applications around the world, but they often rely on completely different communication protocols and associated networks.

The challenge for SafCo was to develop an integrated solution that would run on a single network using a single protocol – removing many of the communication and complexity barriers present in other systems. In addition to the network/platform issues, it also had to address the different legislation covering the two discrete areas. In addition to this primary requirement, the project required multiple additional features, many of which are commonplace in the oil and gas industry. The refinery needed redundant hot-backup controllers, which employ communication via a 36

redundant fibre optic network ring. It needed redundant object linking and embedding (OLE) for process control data access (OPC DA) to interface with the distributed control system (DCS), and OLE for process control alarm and events (OPC AE) to interface with plant’s alarm managements system, while using the simple network time protocol (SNTP) to provide time synchronisation between the fire and gas system and the DCS. There was also the need to be able to hot swap single components.

Three logical levels The innovative aspect of the solution developed by SafCo was the use of PlantPAx to not only address the plant’s fire and safety requirements, but also to control and communicate with the addressable devices within the office complex for fire protection.

According to Gianbattista Zago, sales

and business development director at SafCo: “The solution was divided into three logical levels using sub networks, which when connected all together, created a global network.”

Each level deploys interlinked equipment from within the PlantPAx solution from Rockwell Automation. At the lower level, a local fire and gas panel is used for building protection, with an HMI providing the operator interface. At the medium level, another fire and gas panel is deployed for building and process area protection. The medium level also exploits a server for data collection and interfacing with the PlantPAx DCS and the higher level. Finally, the higher level contains the main server for data collection, disaster recovery and domain control of the network. The entire network uses EtherNet/IP and ControlNet (with associated switches) to link to both the HMIs and the PlantPAx SCADA solution.

“The solution developed by SafCo,

A major Middle Eastern oil company required a single-platform safety solution

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

SAFETY with support from Rockwell Automation, is, we believe, unique in the market,” Zago explains. “Operators at the refinery can now leverage the capability, reliability, connectivity and open protocols used by the PACs across the whole infrastructure. Normally there are so many product families, but in this instance we have one product family. PACs normally used for process control are being used for buildings for protection as well. The market has not really pursued this way because PACs are not normally linked to fire alarms.”

Benefits The refinery will benefit in multiple ways.

In the first instance, the operators do not have to use several programs or software to make modifications, as RSLogix 5000 is used for all PACS and addressable devices. Zago elaborates: “In the past, at least two software programs were needed, one for the PACs and one for the fire alarm. Some form of software ‘bridge’ was also required to link the two systems.

The HMI is also common across all systems, using FactoryTalk View instead of one display for the PAC and one display for

the fire alarm panel.”

The biggest advantage is the fact that the solution runs on one common system. From each individual point, wherever the user is, they can gain access into the system using password authority to determine the level of access and control, to check The SafCo safety system work on three different levels all the components.

The PanelView HMI display is also available over the internet, support us. The relationship has since so users can gain access from remote grown and Rockwell Automation or off-site locations – answering one of gets deeply involved in many of our the customer’s primary requirements, other projects, and we have the which was: “I want to control it from support of a very knowledgeable my seat, no matter where I am”. local engineer, who understands our “We have a very good relationship issues and unusual questions.” z with Rockwell Automation in Italy,” Zago concludes. “When we started out, we already had an idea that we wanted to develop an integrated approach For more information: and we decided to approach Rockwell This article was written by Mike Corrieri, sales Automation, who, as it turns out, were manager for heavy industries at Rockwell Automation. Visit: www.rockwellautomation.com very flexible and eager to help and

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FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 37

SAFETY

Hydraulic hose equipment – check hose condition, pressures and lubrication quality

A ruptured hydraulic hose will not only cost operators money, but it can also cause grievous personal injury

Keep safe when the pressure is on

Hydraulic safety do’s and don’ts – courtesy of the BFPA

38

As an inexpensive component, it would be easy to assume that failure of a hydraulic hose should not have serious consequences. That is, however, far from the case. Resulting financial losses can be considerable, but over and above that, from a health and safety point of view, the impact can be quite catastrophic. Hydraulic systems can contain up to 2,000 litres of oil carried through pipes and hoses and pressures of up to 400 bar, and frequently at very high temperatures. So if a pinprick hole or small area of wear caused a leak, what could happen?

Even a hole measured in millimetres can quickly compromise the integrity of the whole system and, in fact, the entire quantity of oil can drain out of a damaged hose within just 20 minutes. Simply replacing that quantity of oil could cost in excess of £1,000 (€1,173) and it may not be a straightforward process as few lubricant suppliers keep large volumes in stock. On top of that, there is the associated downtime, cost of clear-up and even the threat of environmental

fines should oil escape down drains.

But what if someone happens to be standing beside – or over – the hose when it fails? While financial consequences could be considerable, the cost in human terms could be even greater. While many modern hydraulic systems sit within a bund to collect waste oil, bursts can be unpredictable. The oil may spurt out at an angle, missing the bund altogether and – if a worker is within its trajectory – life-changing injuries could result.

Risk of injury

To put the level of threat in perspective, a guidance document produced by the British Fluid Power Association states that any fluid injection injury – that is an injury in which the skin has been penetrated – must be treated as a medical emergency.

Fluid injection injuries typically involve pressures in excess of 6.9 bar (100psi) punching a hole in the skin and soft tissue, with fluid from the damaged hose being injected into the body.

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

SAFETY Depending on the entry pressure, the injected fluid can travel a significant distance from the initial site, resulting in more widespread tissue damage.

The results of high pressure injection of a fluid such as oil can be initially deceptive with the injury often being worse than it initially appears. Anyone injured, or with a suspected penetration injury, should therefore be referred immediately to the A&E department of a hospital, and if the injury is to the hand or lower arm, preferably a hospital with a hand trauma unit as surgery is often required.

The severity of the injury will depend on a number of factors, including the type and amount of material injected, but hands are particularly vulnerable.

In some cases where toxicity causes greater tissue damage, amputation may be required. Grease and oil may cause no reaction for the first two days, but then lead to extensive fibrosis and tissue damage. Because the body cannot break down the free oil that has entered, the treatment for this kind of injury is extensive. The more viscous the injected fluid, the greater the volume of tissue that will be affected, but even injected water carries risk of complications due to fungal or chemical contamination.

Time to replace The clearest lesson of all this is that a run-to-failure policy for hydraulic hoses is never acceptable. There are ways of predicting failure, either by calculating usage, using monitoring tools or employing visual checks. Most hoses will last for around a million cycles, so by analysing the run time of a piece of machinery, the average life span of the hose should be easily calculated. Monitoring systems, often based on RFID or infrared technology, offer a high degree of reliability and can account for any unpredictable wear and tear caused by misuse.

Without monitoring technology, best practice is to combine usage calculations with visual checks – and it is essential that before any inspection is carried out, the hydraulic power pack should be shut off and de-pressurised. The symptoms of damage must be assessed by an individual who understands the cause and effect.

For example, if any of the metal braid is visible or if any rubber is visible through the braid, the hose should be changed immediately. Other tell-tale signs of damage are blistering or swelling of the outer casing, which would indicate that

Hydraulic pressure hose system, ©Shutterstock, Dario Sabljak

Hydraulic tubes, fittings and manometers on control panel of lifting mechanism

Hydraulic rig

the inner metal braid is damaged and oil is seeping through. Another cause of blistering could be incompatibility between the hydraulic fluid and the hose materials, again pointing to replacement.

When replacing a hose, it is also important to remember that hoses have a shelf life, so replacements should be checked for their manufacturing date.

While it is mandatory to include this on the component, there is no hard-andfast rule as to how long a hose’s working life will be. It can range anywhere from weeks to months depending on

machine type, heat of application, and whether the machine is inside or outside.

It is therefore a judgement call based on experience of the machine, and maintenance engineers should also make sure that hoses have been professionally swaged to ensure components have not been changed or replaced.

Personnel most at risk of injury are, of course, those who work around hydraulic pressure equipment, but in the event of a hose failure it could simply be a case of someone being in the wrong place at the wrong time. Burst hoses pose significant health and safety risks, so a regular inspection policy is an essential safety requirement – as is an awareness of the implications should an accident occur. Brammer’s fluid power solutions team has been established for more than 20 years and has extensive experience in the inspection, design and repair of hydraulic hose assemblies. z For further information:

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

Visit: www.brammer.co.uk

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 39

FUEL MANAGEMENT

Tackling thieves

Enclosure housing fuel management

A telecoms operator in Africa needed a robust monitoring system to thwart fuel thieves Effective fuel management is essential to any organisation wanting to successfully monitor their fuel levels and prevent fuel thefts from occurring, especially in third world countries. When completed properly, it can make a vitally important contribution to the profitability of such organisations. The cost of fuel and its usage is a significant overhead for any commercial establishment.

Bell Flow Systems was approached by telecoms specialist Alan Dick Co. in Africa to provide a unique solution to a range of problems surrounding supply, delivery, remote reporting and security that it was facing. Operating a network of mobile telephone communications masts within the Congo, which provide vital cell phone infra-structure to widespread rural communities in the country, Alan Dick Co. has been facing an ongoing struggle to keep the masts’ diesel fuel-based electricity supplies running. Fuel theft and generator fuel supply failure have become increasing problems for the company in recent times, leading to frequent network outages.

The company required a reliable monitoring system to remotely provide information on the generator fuel levels at 14 of their sites to ensure fuel re-supply was accomplished at correct intervals.

Alan Dick Co. suggested that these deliveries should be recorded using tamper-resistant equipment, as it was suspected that the delivery drivers were not delivering all of the fuel documented.

There was currently no one single solution on the market to help the company and so it commissioned Bell Flow Systems to supply various integrated products and services.

Bell Flow successfully installed oil flowmeters, remote telemetry equipment, fuel management hardware and software plus accessories and commissioning for this bespoke fuel monitoring project in Gabon, Africa.

Bell Flow Systems successfully developed a lockable and rugged enclosure-based system, housing an accurate supply line Macnaught fuel flowmeter, an independently powered local volume display register for back-up verification, and the AquaLink II – an autonomously powered remote telemetry device providing M2M data transfer over WiFi/GSM/GPRS to the head office. Access is via a cloud-based portal with monitoring, reporting and alarm-based functionality.

Another problem Alan Dick Co. faced was frequent fuel theft, potentially from current employees. The company required the facility at all of its sites to dispense the stored fuel securely and accurately into containers by approved users, logging all transfers and recording this information locally as well as reporting it remotely to the head office. The current manual “trust-based” 40

Fuel management enclosure

Gespasa fuel supply kit

transfer system was open to abuse by corrupt or negligent staff, so a new secure solution was desperately needed.

A secure fuel management system was installed for each of the sites featuring lockable cabinets, hardwired fuel and data lines, remote telemetry over GSM/GPRS, and independent user access logging via RFID key fobs controlled by the system administrator. The Gespasa MINI 88K fuel management system was an ideal solution for this particular application.

“Gespasa fuel management systems offer a rugged design suitable for demanding environments with straightforward user operation and scalable features,” said Adam Taylor, technical sales engineer at Bell Flow Systems. It provides simple installation and operation and a rugged stainless steel construction. The use of these user allocated key fobs, unique to each user, has prevented unwanted fuel dispensing by unauthorised individuals.

Bell Flow Systems offer a wide range of products and solutions suitable for fuel handling applications. z For more information:

This article was written by Adam Taylor, technical sales engineer at Bell Flow Systems. Visit: www.bellflowsystems.co.uk

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017

EVENTS

Fluid Handling International will be distributed at the following events 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

4 Oct 2017 – 5 Oct 2017

10th Biofuels International Conference & Expo

Edinburgh, UK

FLUID HANDLING INTERNATIONAL l MARCH/APRIL 2017 41

MIDDLE EAST AFRICA

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