Fluid Handling Magazine November/December 2016

HELPING TO KEEP YOUR BUSINESS FLOWING

NOVEMBER/DECEMBER 2016

Issue 6 Volume 4

10 tips for good piping practice What to remember when planning for piping

When steel fails

Battling abrasion in chemical processing

Keeping the World Flowing

Improving efficiency & minimising downtime It’s in our DNA

For sixty years our customers have relied on Rotork for innovative and dependable flow control solutions.

Rotork products and services help companies in the oil & gas, water & waste water, power, marine, mining, chemical, pharmaceutical and food industries around the world.

T +44 (0)1225 733200

Rotork Innovation Pakscan P4 introduces ultra-fast network control for valve actuators • Up to four networks on one master station • Intuitive user interface, multiple host connectivity • Seamless redundancy, low cost installation • Asset management and datalogging

Get the facts. Find your nearest Rotork office at rotork.com

E information@rotork.com

W rotork.com

Improve Efficiency | Assure Safety | Protect the Environment

COMMENT & CONTENTS

Contents 2

Latest news

10

10 tips for good piping practice Keeping a few simple things in mind can save pump operators many a headache

11

A cool solution Pipeline freezing technologies allow plant operators to undertake challenging maintenance operations

13

Design under pressure What does it take to design a pump seal for applications with extreme pressures?

14

Walrus-sized solutions There are some peculiar applications where the standard worm drive clip just will not cut it

16

Sweet relief New pressure and vacuum relief valve models aim to solve problems in storing petroleum and chemical products

November/December 2016 ISSUE 6 • VOLUME 4

Woodcote Media Ltd Marshall House 124 Middleton Road, Morden, Surrey SM4 6RW, UK www.fluidhandlingmag.com MANAGING DIRECTOR Peter Patterson Tel: +44(0)20 8648 7082 peter@woodcotemedia.com EDITOR Ilari Kauppila Tel: +44 (0)20 8687 4146 ilari@woodcotemedia.com DEPUTY EDITOR Liz Gyekye Tel: +44 (0)20 8687 4183 liz@woodcotemedia.com ADVERTISING SALES MANAGER Russell Priestley Tel: +44 (0)208 6487 092 russell@fluidhandlingmag.com PRODUCTION Alison Balmer Tel: +44 (0)1673 876143 alisonbalmer@btconnect.com SUBSCRIPTION RATES A one-year, 6-issue subscription costs £150 (approximately $240/€185 depending on daily exchange rates). Individual back issues can be purchased at a cost of £30 each Contact: Lisa Lee Tel: +44 (0)20 8687 4160 Fax: +44 (0)20 8687 4130 marketing@woodcotemedia.com

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

18 19

22

24

What the Germans want How much will your pump really cost you?

Many companies try to save money when purchasing pumps only to realise later what a costly mistake they have made Screwing it into place A UK pump station’s time-gnawed flood defence pumps were renovated in one major operation Efficient solutions preferred Successful pump replacement for tough operating conditions

26

Lifting the standard A French innovation helps operators bypass traditional potholes associated with lifting stations

28

When steel fails A French zinc manufacturer found stainless steel pumps unreliable for pumping sulphuric acid and sought an alternative from thermoplastics

30

Event preview: Valve World Expo 2016

34

A finger on the pulse A non-intrusive flow measurement solution helps wastewater stations avoid costly shutdowns

36

Save your production A petrochemical company reduced the risk of lost production by using Coriolis flowmeters with meter verification

48 2017: The year of oil

How the oil price crash affected the global flowmeter market HELPING TO KEEP YOUR BUSINESS FLOWING

41

Engineering safety

44

A hot food line Regular maintenance is essential for keeping food production lines using heat transfer fluid in operation

46

Adhesive bonding technologies and applications

NOVEMBER/DECEMBER 2016

48 Events

Issue 6 Volume 4

10 tips for good piping practice What to remember when planning for piping

When steel fails

Battling abrasion in chemical processing

FC_FH_November-December_16.indd 1

A broken pipe that leaks water in all directions. ©Alvinge. Picture from bigstockphoto.com

31/10/2016 12:07

Comment Dear reader, There is probably only one way to start this chemicals-focused issue of Fluid Handling International, and that is unfortunately with bad news.

On 17 October, an explosion in a pipeline at German chemicals giant BASF’s Ludwigshafen plant left four people dead and seven seriously injured. As is understood at the time of writing, a cut had been made into a pipe transporting a butylene mixture.

The explosion originated from sparks produced by an angle grinder that was being operated on an adjacent pipeline, which then ignited the leaked butylene.

The incident’s impacts on the German chemical industry remain to be seen. Germany already has strict regulations in place to ensure safety in chemical manufacturing and processing (pg. 18), and BASF said in a statement that the company considers safety its “first priority”. More than 300 hundred supervisory appointments are carried out at the plant annually, 160 of them announced or unannounced inspections, and a total of €10 billion has been invested in maintenance and repair.

But they say you can never be too careful. We can only speculate until all the facts come out, but perhaps another leak prevention valve could have prevented the loss of life. As such, the incident might provide a boost for safety equipment manufacturers, either in the form of an increased drive for chemical operators to make sure that such accidents don’t happen at their plants or through regulatory change that might spur some equipment to be named unsafe and new ones nominated in their place.

The safety equipment industry might as such get a welcome breeze of fresh air.

Manufacturers – such as BS&B Safety Systems, Fike, and Pentair (pg. 16), who were listed among the leading global vendors of rupture discs by Technavio – could definitely benefit from higher demand. Whether such demand will materialise, though, may be determined by the results of the ongoing incident investigation.

Best wishes, Ilari

ISSN 2057-2808 1

VALVE NEWS

Bürkert expands product range to include electromotive two-way membrane valves Bürkert has expanded its product family of electromotive process valves to include the Type 3323 shut-off valve and the Type 3363 control valve.

The valves with an electromotive actuator are ideal for applications that either do not require compressed air or for which compressed air is not available due to the difficulty of conveying it to the application.

They feature high control accuracy and highly dynamic control, which allows them to reach the set point exactly and instantaneously with dynamic performance of 4mm/s and with a maximum closing time of under 4.5s.

Integration of the piloting function in the compact drive eliminates the need for control cabinet installation, as well as field piping and the power supply for compressed air.

Bürkert Type 3363 electromotive process valve The electromotive drive principle allows adaptation of the driving force to the respective application, which increases the life of the diaphragms and maintenance intervals, thus reducing maintenance costs.

The new valves feature an innovative cogging torque controller, which fixes the position of the valve without additional energy consumption.

If there is a power outage, the safety position can be reached via the optional SAFEPOS energy storage pack and it can also be adapted to the particular process.

A mechanical position indicator with a 360° LED clearly indicates the position and status of the valve at all times.

The linear motion of the field bus-capable Type 3323/3363 is executed by a brushless DC motor with a planetary gear via a low-friction, permanently lubricated ball screw.

This also prevents negative effects from pressure surges, which occur in pneumatic drives.

The robust powder-coated aluminium body with IP65/IP67 protection features an easy-to-clean and closed design.

The shut-off and control valves are resistant to weather, impacts, and vibrations, which makes them ideal for use in harsh environments.

The FDA-, USP-, and EHEDG-compliant valves are especially suitable for cleanroom, filling, packaging, and CIP/SIP applications in the pharmaceutical and health care sectors, for use in the dairy and cosmetics industries, as well as for industrial water treatment. z 2

Asco introduces lead-free brass solenoid valves with drinking water regulation compliance Asco has introduced brass valves that comply with the US Federal Safe Drinking Water Act (SDWA) requirements for lead-free components.

The lead-free brass constructions are available on the company’s lines of general service solenoid valves.

The SDWA’s section 1417 prohibits the use of leaded components in valves handling water intended for human consumption.

Asco’s lead-free brass valves facilitate equipment design by eliminating the need to perform the wetted surface area lead content calculation specified by the SDWA. The valves are available with flexible options, including pipe sizes of 1/8” to 1”, NBR and EPDM elastomer options, coil electrical connection options in conduit (NEMA 4X), DIN coil, and open-frame spade, and hot water constructions.

Asco offers lead-free brass valves with a zero psi minimum pressure differential option, with models of 5 psi minimum pressure differential also available.

The valves are well-suited for applications seeking compliance with the SDWA such as dishwashing equipment and general plumbing uses. z

Husky announces availability of new valve gate nozzles Husky Injection Molding Systems has introduced the Ultra Helix 350 valve gate, expanding its existing product line of the award-winning valve gate technology released in 2015.

The new nozzle series provides more options for creating a wider range of applications, producing better quality parts with the longest gate life of any valve gate currently available, the company says.

Husky conducted extensive research in order to understand the fundamentals of valve gate dynamics, materials, wear, and gate quality while developing the Ultra Helix nozzle.

Coming as close as possible to zero gate vestige performance, the valve gate improves part quality and virtually eliminates mechanical wear on the valve stems and cavity steel.

“Husky’s Ultra Helix valve gates have increased our confidence in hot runner valve gate moulding,” said Casey Miller, senior tooling engineer at C&J Industries, an FDA-registered Husky customer focused on the manufacture of medical devices.

“Although other manufacturers have gates incorporated in the nozzle tips similar to the Ultra Helix, we have not seen one that has the valve stem with continuous guidance throughout the cycle. Because of this, we have gained a lot of confidence in the gate quality and elimination of wear that these valve gates have provided,” Miller added.

Husky won the 2015 Ringier Technology Innovation Award for the development of its Ultra Helix valve gate technology and its contribution to production efficiency and cost-effectiveness. z FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

VALVE NEWS

Rotork actuators support Portugal’s plan for advanced wastewater treatment The Viseu Sul wastewater treatment plant in Portugal’s Viseu County is the first in the country to adopt advanced membrane filtration (MBR) wastewater treatment technology.

The highly automated treatment facility, serving a population of 90,000, was recently inaugurated by the President of Portugal, Marcelo Rebelo de Sousa, and is named as a national environmental benchmark for future developments.

MBR treatment plants work without the addition of chemicals and with relatively low energy consumption, combining secondary and tertiary treatment and eliminating traditional sand and carbon filtration.

Centralised process control and automation at Viseu Sul is facilitated using Profibus DP network technology, utilising Rotork’s latest multi-turn and part-turn intelligent non-intrusive electric actuators (IQ and IQT respectively) to operate penstocks and butterfly valves for flow control throughout the wastewater treatment process.

The Rotork IQ Profibus DP interface card provides comprehensive control and feedback data about the valve and actuator using DPVO cyclic communication.

Extensive actuator diagnostics and

Efficient pump technology from NETZSCH

Rotork actuators have been put to work at Portugal’s first MBR wastewater plant

configuration information is included in the DP-V1 acyclic data supported by the card, enabling valve profiling and diagnostic data collected by the IQ actuator to be incorporated into asset management systems.

In addition to being the most advanced WWTP in Portugal, the new Viseu Sul plant will enable the closure of other treatment plants in the area which do not meet the latest environmental regulations. z

New Flomatic check valves accommodate variable flow rates Flomatic Corp. has introduced a new 1” and 1¼” Model 80DI VFD, a special patented submersible pump check valve for use with variable frequency drive (VFD) control submersible pumps.

Standard check valves will “chatter” and be noisy when a VFD goes to low flow, causing premature wear and eventual failure.

The new unique valve is designed to minimise flow losses and hydraulic shocks in the pumping system.

It features a standard epoxy-coated

Energy efficiency thanks to modern pump technology

(NSF approved powder) ductile iron body to support deep set pumps.

An exclusive stainless steel guided poppet system ensures that the valve automatically adjusts noiselessly from high to very low flow rates.

The radiuses of the valve seat allow a self-cleaning “one point swiping action” by the radius-edged custom-moulded rubber seal disc.

All internal parts are made from corrosion-resistant materials and have a high strength durable design. z

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

You save energy thanks to our latest pump technology and clever design. The reduced energy requirement in parallel to increased pump performance lowers the power consumption and so preserves our environment in a sustainable way.

Our pumps stand for total environmental awareness.

TORNADO® T2 rotary lobe pump

NEMO® progressing cavity pump

NETZSCH Pumpen & Systeme GmbH Tel.: +49 8638 63-0 Fax: +49 8638 67981 info.nps@netzsch.com www.netzsch.com

3

PUMP NEWS

Grundfos upgrades hydraulic wastewater pumps to 42HP

Grundfos SE and SL pumps

Grundfos is extending its SL and SE range of wastewater pumps to include “medium,” “high” and “super high” hydraulic offerings from 12 to 42 horsepower.

Designed to handle raw unscreened sewage, effluent, and large volumes of surface and process water, the extended selection ensures the highest pump efficiencies over a wider range of demand and the largest free passage of solids at the lowest vibrations.

With its simple yet hydraulically efficient S-tube impeller, the extended range enables free passage of solids up to 5”, which is ideal for large flows of raw sewage.

Intelligent and self-adaptive controls allow the pump to adjust to changing operating conditions, while highefficiency motors meet or exceed global standards.

These crucial design elements give the SL and SE range trouble-free operation, best-in-class non-clogging capabilities, and the lowest life cycle cost, Grundfos says. z

Ebsray releases regenerative turbine pump series for liquefied gas duties Ebsray Pumps, a designer and manufacturer of regenerative turbine and positive displacement pump technologies, has released the new RC40 Series regenerative turbine pump.

The new pumps are targeted at liquefied gas applications, including liquefied petroleum gas, autogas, DME, aerosols, industrial refrigerants, and liquid CO2.

Developed as a replacement for the Ebsray R10 model, the new RC40 pump features increased flow rates and features important new design enhancements.

The pumps offer high reliability even under extremely low NPSH operating conditions and possess the ability to handle entrained vapours without loss of efficiency or internal damage.

The close-coupled flange design of the RC40 mounts to both 50Hz and 60Hz (NEMA and IEC) electric motors while the unique three-ported design with two discharge ports provides installation flexibility for lower installed cost.

In addition, the RC40 optimises its class-leading performance and efficiency by using a motor one size smaller than its leading competitors.

RC40 pumps have bronze impellers, ductileiron casings, and high-tensile alloy steel shafts.

The pump features a maximum differential pressure to 14 bar (200psi) and maximum flow rates are 200l/ min (52.8 gpm) with motor speeds up to 3,500 rpm.

RC40 pumps also feature multiple flange port options in one body design, including ANSI, DIN, and NPT. Cartridge design mechanical seals and bearings are interchangeable with RC20 and RC25 models, and RC40 pumps comply with ATEX and AS1596 codes with UL51 certification in progress. z 4

Albin Pumps introduces peristaltic pumps featuring new CIP wheel

French pump manufacturer Albin Pump’s ALH peristaltic hose pump series is now available with an optional clean-in-place (CIP) wheel designed to save time and money during cleaning operations.

By reversing the direction of pump rotation, the CIP wheel Albin peristaltic hose pump with allows users to retract the shoes the CIP wheel automatically in order to clean and sterilise the pump, without disassembly.

This helps the user save time and keep the highest level of functionality in the process.

The design uses a minimum number of moving parts and requires a minimum amount of maintenance, all to guarantee a maximum amount of function and production time, the company says.

The Albin peristaltic pumps are used for the transfer of all types of fluids, including viscous, abrasive, corrosive, and fibrous media with particles.

The pumps are low-shear and maintain a high level of hygiene, as only the inner part of the hose is in contact with the pumped fluid.

The food grade hoses are available in EPDM FDA, NBR FDA, and NR FDA and meet the certifications EC 1935/2004 and FDA CFR21§177.2600.

The internal surface of the hose is white (NR FDA and EPDM FDA) or black (NBR FDA), according to the pumped fluid.

The CIP wheel is available on several models, for flows from 0.5 up to 10m3/h and where the maximum discharge pressure can reach 15 bar.

Albin peristaltic pumps are seal-less and can run dry without damage. z

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

PUMP NEWS

Jump eccentric disc pumps certified for potentially explosive atmospheres French family-owned pump maker Jump has expanded its pump offering, and all of the company’s pumps can now be adapted for ATEX Zone 2 environments.

In a development process and to meet the growing needs of handling flammable liquids or combustible materials, Jump has certified its eccentric disc pump range JE Series for Zone 1.

The product range’s pumps, available in six sizes, comply with the 2014/34/UE Directive on equipment and protection systems and can reach flow rates of up to 96m3/h.

The JE Series technology allows the seamless transfer of various fluids, liquids to viscous, for many industries such as food industry, chemical, Jump JE Series eccentric disc pumps in various sizes pharmaceutical, cosmetics, energy, mines, etc.

Jump manufactures its equipment in ductile iron, stainless cast iron, or 316L stainless steel depending on the application.

The JE Series pumps can be adapted for sensitive, abrasive, or corrosive products and are also compatible with different types of connections (PN16 or PN20 flanges, hose barb, clamp, SMS, DIN, MACON, etc.) allowing for simple integration into existing facilities.

Jump eccentric disc pumps retain the integrity and quality of the pumped product The hose pump is the pump solution for the futur. It is a simple and well proven construction in one sense but also a “newthinker” in the due to a very low shear rate fact that only the hose is in contact with the fluid that is being pumped. and reduced pulsations.

This minimises downtime from maintenance and simplifies pump use.

In addition, all elements For us at ALBIN PUMP this means lower costs and better pumps solucan be removed from the tions. If you want to know more about the technique, test and results front without uncoupling the welcome to www.albinpump.com for more information. pump from the piping and the motor, thus allowing easy access inside the pump to the mechanical seal cartridge.

Now available for use in potentially explosive atmospheres Zone 1, the JE Series pump is manufactured to be conductive to prevent electrical hazards and is designed to protect against internal and external explosions.

The JE Series pumps are also self-priming and reversible, with since 1928 dry run capabilities and strong suction and compression power.

They feature flow rates of up to 96m3/h at a maximum speed of 1,000 rpm, and can handle temperatures from -5°C to 250°C. z

TOUGH INNOVATOR

www.albinpump.com

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

5

FLOWMETER NEWS

Burger & Brown releases electronic flowmeter with vortex shedding technology

Burger & Brown Engineering has released the new Tracer VM electronic flowmeter with a user interface employing vortex shedding technology to monitor liquid flow rate and temperature.

The newly designed control circuit provides some of the same features as the company’s previous Switching Tracer flowmeter such as turbulent flow indication (FCI technology) with a glycol input of up to 30% for FCI calculation.

The meter includes programmable switch set points (1A, 30VAC) for high or low flow or temperature and turbulent flow rate and user-selectable analogue outputs for flow and temperature.

The Tracer VM displays measurements through BTUs per minute calculation, and features selectable temperature and flow rate units and sealed pushbuttons for menu navigation.

New features of the VM model include a totalising function with volume display from a selected point and a bright colour LCD display.

An internal rechargeable battery allows for temporary operation even when unattached to a power source, and optional cables for an AC wall adapter or connection to RJG eDart System are available.

The new flowmeter allows water resource budgeting through the use of the totalising function.

Vortex shedding technology increases reliability with flow sensors that are less susceptible to dirty cooling water conditions.

Connection sizes are available from 3/8” through 1½” NPT or BSPP and the meter can handle flow rates between 1-15l/ min through 10-200l/min with a standard operating temperature of 100°C and an upper temperature limit of 120°C. z

New Tricor Coriolis flowmeters for high pressure and hazardous area applications Tricor Coriolis Technology has released the new TCMH-0450 high pressure Coriolis flowmeter with certification for use in hazardous areas.

This meter is particularly well suited to the oil and gas industry for high pressure chemical injection applications, as well as gas measurement applications such as engine test benches, hydrogen fuel stations, and high pressure gas measurement in numerous other industries.

The meter is available in three different pressure ratings of up to 1,050 bar, 690 bar, and 414 bar, and the hazardous area approvals for the device include CSA – US & Canada, ATEX, and IECEx. “As Tricor Coriolis meters become a more mainstream choice for companies in processing industries, in particular within the oil and gas market, we are confident that the quality of our Coriolis flowmeters will continue to exceed customer expectations,” stated Mark Iverson, Tricor programme director and general manager of AW-Lake Co. z

Fluenta flare gas meter accuracy proved by CEESI Fluenta, a global ultrasonic flare meter manufacturer, has announced that the Colorado Engineering Experiment Station (CEESI) has proved Fluenta meters perform with an uncertainty of less than 3% without prior calibration.

Fluenta tested its 160 Flare Gas Meter at the CEESI testing facility in Colorado, US. The results show that taken “straight out of the box” – without any initial calibration – the Fluenta 160 flare gas meter performs with an uncertainty of less than 3%, even at low flow velocity.

When Fluenta products are installed and calibrated by its specialist engineers, uncertainties of between 1-2% can be achieved, Fluenta said in a statement.

CEESI offers a custom piping set-up, which enables Fluenta to test its meters on a 30” spool piece and at low flow conditions, from 1 to 20m per second.

Data from the reference meter and the Fluenta meter was fed to the CEESI data acquisition centre for 6

a period of 30 seconds to calculate the average value, including error for that period to reflect stable flow conditions, the company said.

Fluenta conducted CEESI testing on behalf of Kuwait Oil Company (KOC) to assure the company of the accuracy of Fluenta flare gas meters before it committed to a large-scale purchase.

After successful CEESI certification, Fluenta’s specialist engineers carried out a successful factory acceptance test (FAT) to ensure the meters were ready to be installed and tested on site by KOC. Sigurd Aase, CEO of Fluenta, said: “Low velocity accuracy is typically challenging in flow measurement and the CEESI findings are confirmed by multiple results from just one test session – a rare occurrence at any test site.

“This confirms Fluenta ultrasonic meters are the most accurate and reliable products available, and the results show that when properly calibrated, even higher accuracies can be achieved.” z

Krohne adds entrained gas management to Optimass Coriolis flowmeter range Flow measurement specialist Krohne has upgraded its entire range of Optimass Coriolis mass flowmeters to feature entrained gas management (EGM) technology.

With the latest additions of Optimass 3400 and 7400, the whole Optimass series now offers continuous and repeatable mass flow or density measurement with two-phase flows, such as liquids mixed with gas, slurries with gases, or highly viscous fluids with gas entrainments.

In the past, this presented a huge challenge for mass flowmeters, as without gas entrainments the measuring tubes in the Coriolis mass flowmeter do not have the desired regular oscillation. z

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

FLOWMETER NEWS

FCI obtains SIL compliance for compact thermal mass flowmeters

Fluid Components International (FCI) has released the new advanced, SIL IEC 61508 compliant ST51A and ST75A thermal mass flowmeters as a solution for air/gas flow measurement.

For engineers designing safety instrumented systems, these models provide compact, low-cost thermal flow metering solutions carrying a SIL rating.

They were independently evaluated by world leading functional safety experts, Exida, and found to meet SIL 1 compliance.

The Model ST51A flowmeter is an insertion-style instrument designed for use in pipe diameters larger than 2” (51 mm).

It is optimised for flow measurement of air, compressed air, nitrogen, natural gas, digester gas, and all other biogases.

The ST75A flowmeter is an inline-style instrument designed for use in pipe diameters from 0.25” to 2” (6-51 mm) in

air, all inert gases, natural gas and other hydrocarbon gas applications.

Both models feature wide 100:1 turndown, have no moving parts, carry global agency approvals for Div.1/Zone 1 Ex installations, high IP67 dust/water ingress protection, and rugged, all metal enclosures.

For interface and communications, the meters include dual 4-20mA which meets NAMUR 43, HART Version 7 as certified by the FieldComm Group (HART), and a 500Hz pulse.

Optionally available is two-line LCD readout to display flow rate and either temperature or totalised flow.

The transmitter/electronics can be integrally mounted with the flow element or remote mounted up to 100ft (30m) away.

The transmitter enclosure is available in either painted aluminium or stainless

Titan supplies Atrato flowmeters to Peruvian mining operator

FCI’s ST51A flowmeter excels in biogas applications

steel, and can be ordered with either NPT or metric threaded cable ports.

Both the ST51A and ST75A meters are temperature compensated and calibrated to the user’s actual installation conditions in one of FCI’s 19 flow stands using NIST and ISO/IEC 17025 traceable equipment.

For applications with limited straightrun, the ST51A and ST75A can be supplied with and calibrated specifically for use with Vortab flow conditioners. z

WATERWORKS VALVES

Resilient seat wedge gate valve used for pipeline isolation.

Titan Enterprises, through its agent JLC International for North and South America, has shipped 39 Atrato ultrasonic flowmeters to Peruvian engineering company Dynaflux.

Working collaboratively on a complex project with Minas Buenaventura, Peru’s largest publicly-traded precious metals company, the team sought a flowmeter that offered high accuracy and repeatability at low flow rates.

The Atrato line of ultrasonic flowmeters consists of four meters operating over flow ranges of 2ml/min up to 20l/min.

The flowmeters were selected to enable accurate and reliable dosing of expensive mining reagents in the flotation stage of the mineral extraction process.

In the past, Dynaflux had used the Atrato ultrasonic flowmeter in other smaller installations, reporting satisfying results.

The rugged, clean bore construction of the Atrato flowmeters makes them a suitable choice for a whole range of low flow applications.

Taking advantage of proprietary embedded signal processing software developed by Titan Enterprises, both viscous and non-viscous liquids can be routinely measured with high accuracy. z

- BS5163-1 and 2:2004 - EN1074-1 and 2:2000 - Unique lightweight ductile iron - Low maintenance design suitable for buried service.

Sinking ball check valve used to prevent reverse flow.

- Suitable for water and wastewater applications up to 60°C - Can be installed both horizontally and vertically.

METAL SEAT GATE VALVE Metal seat gate valve used for pipeline isolation.

- BS5163-1 and 2:2004 - EN1074-1 and 2:2000 - Unique lightweight ductile iron - Low maintenance design suitable for buried service.

- WRAS listed www.ttflow.com materials

Tel: +44(0)1630647111

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 Fluid Handling_European Valves.indd 1

7 20/10/2016 16:17:13

OTHER NEWS

Xylem wins $1.5m contract for Chinese wastewater plant upgrade

New basic compact low pressure sensor from All Sensors

Water technology company Xylem has won a contract worth almost $1.5 million (€1.37m) to provide wastewater treatment technology as part of a sewage plant upgrade project in China.

A recent report undertaken as part of the Bengbu Integrated Environment Improvement Project found that the urban sewerage and wastewater facilities of Bengbu City (known locally as Pearl City) in Anhui Province were inadequate, with coverage of only about 50%.

As such, expanding sewerage networks and treatment capacity was deemed a high and urgent priority to achieving sustainable water quality and improving the urban environment.

Jiangbo Hu, general manager at Anhui Sunshine Water Service Co., said: “This plant upgrade project in Bengbu City will benefit more than two million people living in the city, easing the pressure on the city’s

All Sensors Corp. of Morgan Hill, California, has released new low pressure sensor, the BLC Series, offering design engineers high performance over pressure ranges of ±1inH2O through ±30inH2O and 15psia.

The BLC Series basic low pressure compact sensor is based on All Sensors’ CoBeam 2 technology.

The devices provide a high output signal at a low operating voltage, maintaining comparable output levels to traditional equivalent basic sensing elements.

This lower supply voltage gives rise to improved warm-up shift, while the CoBeam 2 technology itself reduces package stress susceptibility, resulting in improved overall long term stability.

The technology also improves position sensitivity compared to conventional single die devices.

The series is intended for use with non-corrosive, non-ionic working fluids such as air, dry gases, and others. z

stretched wastewater networks.”

Xylem’s Leopold Elimi-NITE denitrification system will be used in what will be the largest biological denitrification system in the city.

It will provide tertiary treatment, removing suspended solids and total phosphorus, and delivering biological denitrification of the wastewater.

Heng Zhang, senior sales engineer at Xylem, said the timeline for the project is challenging.

“However, the depth and breadth of our team will allow us to deliver on time. The new plant will have a capacity of 200,000m3/day and will deliver the high effluent quality required by the Chinese government as it seeks to improve effluent quality across the country,” Zhang said.

Construction of the plant is currently underway and it is expected to be operational in December 2016. z

When failure is not an option: Egger SINCE 1947

www.eggerpumps.com

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

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

Turo® Series High solids concentrations and shear sensitive products

8

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

OTHER NEWS

New DuPont perfluoroelastomer KSB releases material provides longer seal life easy-to-service mechanical seal for wastewater pumps DuPont has launched a new perfluoroelastomer part for use in demanding high volume industrial markets for applications such as sensors, sprayers, injectors, diving seals, and microvalves.

The Kalrez CP222 can enable manufacturers to reduce total operating sealing costs due to its longer seal life and high chemical and temperature resistance.

The material is well-positioned for O-rings and custom parts with an outer diameter up to 2” (50.8 mm).

Other sizes and shapes can be addressed through developmental projects in cooperation with the customer.

DuPont has also developed Kalrez LS222 to complement Kalrez CP222 for customers serving multiple markets such as the life science industry.

Kalrez LS222 is an FDA- and USP VI-compliant high volume seal and is manufactured to meet the high standards of safety, hygiene, and quality control of the food and pharmaceutical industries.

DuPont Kalrez parts last longer and seal more effectively than other elastomers in demanding processing environments.

They resist over 1,800 different chemicals, while offering the high temperature stability of PTFE (327°C).

The long-term, proven performance of Kalrez parts can mean less frequent seal changes, repairs, and inspections, increasing process and equipment uptime for greater productivity and yield.

They are used across a wide array of sectors including life sciences, industrial, food and beverage, and pharmaceuticals. z

Symbios receives US patent for high-density plasma reactor for water purification The US Patent and Trademark Office (USPTO) has awarded Symbios Technologies, a developer of dynamic aqueous plasma technology platforms, a patent for its tubular high-density plasma reactor, U.S. Patent #9,346,691.

The Symbios Tubular Plasma Reactor (TPR4000) provides improved, lowercost oxidation methods for ultrapure, process, and wastewater applications by simultaneously eliminating organic and microbial contamination without the need for added chemicals or producing a waste stream.

The design of the TPR4000 combines a continuous mixing mechanism with an air-enhanced plasma discharge system.

“This is an important milestone for our company and we are proud of the acknowledgement and protection of our intellectual property provided by this patent award from the USPTO,” said Justin Bzdek, president and CEO at Symbios.

The TPR’s design as an advanced plasma oxidation system for fluid treatment also enables it to be tuned for application in food and beverage, healthcare, power plant, fracking, wastewater treatment, and other industrial and municipal markets.

The TPR4000 is the only technology that combines the action and chemistry of UV, ozone, peroxide, and chlorine-based technologies all in one system, providing high efficacy and lower costs when compared with alternative advanced oxidation processes.

“This cornerstone patent award is part of an ever expanding portfolio of innovation and patent submissions that highlights our capabilities to address the needs of our industrial partners, with technology made possible by research funded by the National Science Foundation (NSF) Small Business Innovation Research (SBIR) programme,” concluded Bzdek. z FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

Frankenthal, Germany-based pump manufacturer KSB has developed a new double mechanical seal in tandem arrangement, which is especially well suited to the particular requirements of dry- and wet-installed wastewater pumps.

During development of the 4STQ – a double mechanical seal module – KSB’s engineers strove to ensure that its installation and removal remained as straightforward as possible.

Assembly fixtures and fastening bolts are not required, and the seal’s modular design minimises downtime during maintenance inspections as well as preventing faulty reassembly.

A multi-spring arrangement provides required pre-loading for the primary rings themselves.

The multiple springs are located outside the fluid handled in the oil reservoir so that the individual springs are protected from contamination.

As the seal installation space and the mechanical seal are optimally matched, the seal faces are exposed to minimal wear and the sealing elements offer long service lives.

The primary rings are made of silicon carbide as standard, with tungsten carbide also available on option.

All metal components are manufactured from corrosion-resistant stainless steels such as 1.4122 or 1.4571 and FKM elastomers are used for the O-rings.

The new 4STQ is suitable for all operating conditions permitted for the pump on which it is fitted.

Seals of this type are already being used with great success in wastewater treatment plants in Germany and South America. z

The new 4STQ mechanical seal is a double mechanical seal module with straightforward installation and removal

9

COMMENT flat gasket, providing a good surface to seal onto. One area that demands flange connections are DIN specification pumps.

Another area where you may be concerned is if you are replacing a pump onto existing piping because you are pumping new or different materials. Again, we would assess the job on its merits and – more often than not – the existing piping will not present a problem.

There are some good rules of thumb for ensuring that your piping design is as good as it can be, however. To help your process run as smoothly as possible, here are our 10 tips for good piping practice:

10 tips for good

piping practice Keeping a few simple things in mind can save pump operators many a headache

Here at Crest we want to ensure that our pumps are always working at their most efficient level. To achieve this, we are often reliant on external factors, such as an effective piping design.

Sometimes there is a pressure to save money on piping, but experience shows us that this can often affect pump operation or, in some cases, result in a large repair bill.

First, the good news. The piping materials you may already be using will not necessarily affect the kind of pump we end up supplying. Whether your pipes are made of metal, plastic, glass, rubber-lined or one of the myriad choice of piping materials out there, rest assured that with careful assessment the right pump will be found for you. In truth, there should be no bar in supplying, for example, a plastic diaphragm pump fitted to stainless steel piping.

Similarly, when it comes to pipe connections, whether they are threaded connections or flange, the choice is yours. Some pipe system designers have a preference one way or the other, and good pump providers can work with that. In general, threaded pipes will work effectively up to 4” wide and are often found on vertical pipes, but increasingly flange connections are seen as the way forward. To that end, they are usually used in new pipe designs.

Flange connections sit flush to each other – again, the materials at either end can be different – and give you a flat face with a 10

1. When you select your suction pipework, keep the diameter to at least the pump suction size or preferably larger to maintain a suction velocity of a maximum 1-1.5m/sec.

2. Turbulence can be caused by tight bends, so use long radius bends where possible alongside full bore valves, which will minimise turbulence.

3. When you use eccentric reducers as opposed to concentric reducers, keep the level side at the top to prevent air being trapped within the pipework.

4. Keep your suction pipework as short as possible, with a length of five to ten times the pipe diameter after any valves or change of pipe direction.

5. Support the pipework securely and ensure the squareness of it to your fitting to prevent straining the casing and branches.

6. Avoid high points in suction pipework if you can, but at the very least include a vent at the highest point. Air getting into a pump can shut down the pump immediately or in the worst case wreck it completely. All suction pipework must be airtight.

7. On priming chamber applications, ensure the suction pipework is the same diameter as the suction branch and as short as possible. Importantly, ensure that the pipework is continuously rising to prevent air getting in and forming an air lock, which could get into the pump (see point 6).

8. Never throttle the suction side of the pump to reduce the flow, always use the discharge side. Throttling the suction side risks cavitation, which is hard to detect.

9. Make sure you include pressure gauges on discharge pipework or at least the provision to check pump duty. Some of the issues we face in trying to trace a problem could be easily solved by a gauge that shows us exactly where that problem exists.

10. Including vent points after the pump, but before non-return valves, enables a complete venting of the pump casing.

So there you have it. We might be telling you things your grandmother taught you, or we might be saving you a whole lot of grief in the future! Happy piping! z For more information:

This article was written by Tony Hillman, marketing manager at Crest Pumps. Visit: www.crestpumps.co.uk

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

PIPING

A cool solution Pipeline freezing technologies allow plant operators to undertake challenging maintenance and replacement procedures without shutting down their whole operation

Pipework users across the entire industrial spectrum, but particularly in the petrochemical sector, regularly face the difficulty of having to repair or replace pipe sections or change in-line components such as valves and instrumentation. The widely used but arguably expensive and time-consuming solution is to access the affected section by draining and drying the pipes. However, the contents need to be disposed of or stored, the systems need to be re-filled following any work, and production obviously needs to be interrupted.

Isolating and exposing sections for attention can thus be very costly.

An attractive and economical solution is to freeze the pipe contents either side of the repair or replacement zone. Only the volume between freezing points

Qwik-Freezer, carbon dioxide pipe freezing system

Petrochemical plants face the challenge of what do to with their piping during maintenance operations

requires emptying. Two solutions are available, the first covering pipe diameters up to 200mm, for which solid carbon dioxide is a suitable freezing medium, and the second up to 300mm, for which liquid nitrogen is more appropriate.

Carbon dioxide freezing Pipes between 8-200mm in diameter are commonly used for the transport of liquids in virtually every processing industry. Petrochemical manufacturing plants in particular employ highly complex pipework, valves, pumps, and monitoring equipment to control product manufacture. Lubrication and fuel systems on aircraft, marine vessels, and power generating plants are also major users of this range of pipework diameters.

Among the liquid CO2 techniques now commonly used across the world is the Qwik-Freezer system. A specially designed jacket is wrapped around the pipe at the point where the freeze is required. A nozzle in the jacket is then coupled to a cylinder of liquid CO2 by means of a high-pressure hose. When the CO2 is injected into the space between the jacket and the pipe at a temperature of -78°C, the pipe

contents freeze and a secure “ice plug” is formed, which seals the pipe. The ice plugs will easily withstand 100 bar pressure.

The plug forms only in the pipe section covered by the jacket, so the resulting rise in pressure is very small and there is no damage to the pipe. The technique can be used safely on steel, lead, copper, brass, and plastic piping.

Petrochemical plant shutdown averted A new compressor installation, to be completed within a short window of time, was going well until a problem was discovered. The design drawings failed to show that a cold water valve extension handle clashed with the air inlet pipe of the compressor. Critically, this was the only isolating valve from the cooling water main header and could not be moved without closing the cooling water system.

This would have also meant shutting down a major section of the processing plant.

Not a commercially acceptable option.

The preferred solution was to use a specialist pipe freezing company to isolate and remove the valve that was welded into the pipeline. Commercial plumber’s freezing kits were unsuitable

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 11

PIPING since they can only accommodate pipes up to 50mm diameter. An internet search discovered a pipe freezing kit for 75mm pipe available from a specialist supplier. The Qwik-Freezer offered was chosen as the only proven option and this was supplied within 24 hours.

Installation was easy and CO2 bottles were obtained from a local gas supplier.

The work went well, taking around an hour to freeze the pipe. This allowed ample time to grind out the welded valve and install a replacement within two hours.

Liquid nitrogen freezing Liquids in pipes up to 300 mm diameter can be frozen using liquid nitrogen.

Of the various products available, the Accu-Freeze system is an example of a well proven product. The procedure creates an in-line ice plug capable of withstanding 140 bar of pressure in pipes up to 300mm in diameter, and can be modified using available options to handle even larger diameters.

Copper tubing is wrapped around the pipe and a specially designed insulating jacket wound around the required section of pipe to be frozen. An advanced temperature-monitoring unit controls the surface wall temperature of the pipe to accurately and safely create an ice plug. The ice plug is formed in the section below the Accu-Freeze coil wrap and jacket, and does not extend outside the jacket parameters.

The Accu-Freeze System is automatic and can be remotely operated. This makes it attractive for use in nuclear applications and other locations where engineer access is restricted.

Space shuttle problem solved by pipe freezing With the space shuttle Atlantis on the launch pad ready to go on mission STS-101 in 2000, a last minute systems check revealed a fault in the power drive unit (PDU). The PDU is a hydraulic power pump, which controls the shuttle’s rear rudder or air brake, so failure of this unit during flight could be catastrophic. Repairing this sensitive system conventionally meant suspending the launch, rolling the shuttle back to the vehicle assembly building and draining out the hydraulic lines to undertake repairs. This would delay the launch for several weeks and be extremely costly.

An engineer suggested the idea of 12

A NASA space shuttle

freezing the hydraulic lines feeding the PDU while the shuttle was still in the launch position. This would enable the repairs to be made without draining out the entire system and in turn keeping the launch on schedule. The job was to freeze six 16mm hydraulic fluid lines. There were three demanding requirements: • The lines were nested in the base of the tail of the shuttle and physical access was restricted • The freezing point of the hydraulic fluid was below -100°C • Shuttle engineers needed to be able to monitor and control the temperature of the pipes in order to ensure that the freeze was being safely and consistently controlled Of the nitrogen freezing products available at very short notice, only the Accu-Freeze system from Huntingdon Fusion Techniques (HFT) met all the requirements. Following several successful trial freezes, the procedure was formally approved by NASA. In drenching rain, the six hydraulic lines were frozen simultaneously. However, the weather caused the operation to be delayed and this required the freeze to be held

in place for over 24 hrs. The Accu-Freeze system performed without a hitch.

Conclusions Pipe freezer technology allows fluids to be frozen below -150°C using liquid carbon dioxide or nitrogen. Specially designed insulation and feeder hoses are used to deliver coolants and continuous temperature control during the freeze operation can be incorporated.

The use of freezing technology affords the opportunity to isolate sections of pipework for maintenance, repair, and replacement of valves, couplings, and instrumentation and thus obviates any need to drain the system. There is no need to disrupt production beyond the time needed to freeze and undertake changes. z

For more information:

This article was written by Michael Fletcher, senior consultant at Huntingdon Fusion Techniques. Visit: www.huntingdonfusion.com

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

SEALS

Design under pressure What does it take to design a pump seal for applications with extreme pressures?

Industrial processes in the oil, petrochemical, chemical, and energy sectors have evolved to use ever higher pressures. The use of high pressure has been found to improve efficiency and reduce costs. Moreover, the introduction of new production methods to meet the changing needs of the industry has led to technological advances. These developments have resulted in the sharp increase in demand for mechanical seals for rotating shafts in machinery designed to withstand high pressure (100 bars or more).

In the oil industry and – in particular – as prescribed in the API 682 standard (the American Petroleum Institute’s guidelines for pump mechanical seals), the trend for processes using increasingly high pressure has lead to the introduction of mechanical seals defined as “engineered”, that is seals subjected to pressure exceeding 40 bar.

These are seals employed in applications in which the operating conditions exceed the limits of those tolerated by standard seal models. The API norms offer solutions for operating conditions within certain limits.

Therefore, it is up to the seal manufacturer to design a customised sealing system for each particular industrial process.

The design questions The use of high pressure processes is very widespread and the hydraulic machines in question are not only centrifugal pumps designed for pipelines, but also those for boiler feed in power plants and volumetric pumps used for oil well extraction. There are also high pressure applications in

Fluiten HPF seal

many other industries, such as chemical and chemical-pharmaceutical, where horizontal and vertical reactors are used.

Developing pumps for highly specialised applications involves a rigorous and long process of dynamic testing in a state-of-the-art test lab and with the use of specialised software programs. The obtained data is used to continually modify the seal until it is able to perform reliably in its intended applications.

At high pressure the mechanical seal must function with a stable liquid film between the two sliding seal surfaces.

The absence of this film can be caused by many factors, including transitional phases such as start-up, which is one of the most critical for the mechanical seal as the torque at start-up can be five times greater than the operational torque. The absence of the film could compromise the correct functioning of the seal and therefore also that of the machine in which it is installed, increasing operational failure and maintenance costs and reducing productivity.

Applications in which there is high stress due to high pressure demand a careful study of fluid dynamics and an accurate finite element method (FEM) analysis of the critical seal parts. The FEM analysis calculates the stress that a seal is subject to in its various parts. Apart from high torque, this stress can also be caused by vibration, cavitation, and shaft movement. These disturbances can cause overheating of the sliding seal faces, resulting in possible seal failure and leakage. The stability of the lubricating liquid must be maintained, but at the same time leakage must be reduced to an absolute minimum.

API norms impose a leakage limit but technologically advanced companies, such as Fluiten, are able to reduce leakage below the API limits without compromising the durability of the seal. Other factors to consider are the chemical/physical characteristics of the sealed liquid whose pressure is exerted on the rings that become deformed compared to their original state, as well as the evaporation of the liquid film or indeed the breakage of the rings or other seal components.

To resist high pressures and the presence

of abrasive particles in the sealing liquid – another problem aggravated by high pressure – special sintered, very hard and resistant materials have been tested and developed in different combinations.

An offered solution Since its founding in 1962, Fluiten has been at the forefront of the design and manufacture of sealing systems for rotating shafts. In recent years, Fluiten’s research and development team at its Pero-Milan plant has developed a range of technologically advanced products intended for high pressure applications.

The seal developed by Fluiten for these operating conditions is equipped with a patented drive device able to withstand high levels of run-out or misalignment even under high stress. Planarity of the seal faces is maintained by using monolithic rings or rings with a reinforced metallic base and rings with regular geometry and thickness. The engineered Fluiten HPF seal model is available in API arrangements 1, 2, or 3, in other words as single seals or non- pressurised and pressurised double seals respectively.

The seal has successfully met the challenges of the extreme operating conditions for which it is designed.

Furthermore, the seal faces can be designed incorporating the Fluiten groove technology, which maintains the stability of the process liquid or that of the barrier between the faces to ensure proper lubrication and cooling of the seal.

It should be noted that in the above applications, high pressure is not the only critical factor. A concomitant factor is the presence of very high temperatures (up to 290°C), which can ruin the O-ring component of the seal and could cause the evaporation of the liquid between the seal faces, resulting in possible catastrophic breakage. For seals in critical operations, Fluiten seals incorporate O-rings in resilient perfluoroestomer, able to withstand temperatures up to 290°C. z

For more information:

This article was written by Rino Campaniello, sales director at Fluiten Italia S.p.A. Visit: www.fluiten.it

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 13

CLAMPS

Walrus-sized solutions

The worm drive clip is one of the most versatile hose clamps available, but there are cases – strange ones too – where a more specialised product is needed As an engineer in the field, there is nothing more infuriating than finding you have the wrong size or type of fitting to complete the job. No matter how well stocked the van is, it is impossible to carry every component for every eventuality. This is ever more so the case in the fluid handling industry, and specifically with hose clamps. With an almost never-ending list of types – including nut and bolt, double ear, single ear, self-closing, over-centre, and herbie clip, to name a few – the decision of what to stock a tool box with is a difficult one. So, which one to choose?

It is important to remember many hose

European hose clip size/torque standards

14

clamps have been designed to do a specific job at the lowest possible price.

As such, many manufacturers will use clamps only suitable for a certain size of hose and which are only convenient in the manufacturing stages. What we need is a strong, easy to use clamp with a large adjustment range to cover many different hose sizes. The only clamp to fulfil all these criteria is the humble worm drive hose clip.

But how can we be sure the worm drive clip is up to the job? For standard duty clips, there are a number of different applicable standards depending on the country and industry. The accompanying chart shows the most common of them.

As evident, operating requirements for the British Standard BS5315 are far in excess of all other standards.

The only way to ensure operators have a clip that meets

this high standard is to look for the British Standard Kitemark.

It is worth mentioning that some manufacturers offer hose clamps with continuous perforations along the band.

These clamps are normally sold on the misconception that the clamp has a larger adjustment range. In reality, the reason for manufacturing clamps this way is because it is cheaper. The BS5315 states the recommended size adjustment range, as – depending on the size – the screw housing is radiused to closely fit against the relevant hose diameter.

A problem and a solution There will of course be applications for which the standard worm drive hose clip will not be suitable, such as wire reinforced hoses or particularly large or high pressure applications.

For these kinds of applications, clamp manufacturers offer specialised solutions.

One such manufacturer is JCS, which produces a range of heavy duty clamps known as Hi-Torque. Although these clamp are similar in appearance to the company’s standard duty Hi-Grip models, the similarities end there.

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

CLAMPS stainless steel banding. A similar system is adopted by many drainage pipe coupling manufacturers, most of which JCS produces clamps for.

Multi-Torque can in effect be used on any size hose or coupling from 70mm diameter, making it a fitting addition to any field service engineers toolbox.

One of the issues with using worm drive hose clamps, particularly on soft wall rubber hose, is the potential for damage to the hose itself. Where clamps are tightened it can be very JCS Hi-Torque hose clamp

The Hi-Torque clamps have a unique straight line housing, which ensures every thread of the hardened rolled stainless steel screw is engaged with the fully perforated band. This special feature, together with the stainless steel band with tensile strength of 75tons/in2, means Hi-Torque offers twice the strength of ordinary worm drive hose clips.

Used correctly, Hi-Torque offers a cheaper, more versatile and easier to use alternative to nut and bolt type clamps. In testing Hi-Torque has proven to consistently provide higher clamping force and sealing ability onto different types of hose over its more elaborately designed and stronger looking rivals, with the added advantage of a much larger adjustment range. Manufactured fully of 304 or 316 stainless steel, Hi-Torque is also suitable for use in marine, offshore, and other corrosive environments. This is supported by Lloyds Register Type Approval, which makes the clamps one of the few in the world with specific approval for the critical application of sealing wet diesel exhaust systems.

For engineers dealing in larger pipe sizes and couplings, there is a variation of Hi-Torque that offers the same quality and strength but increased versatility, called the Multi-Torque. The Multi-Torque system comprises of an adjuster strap with a worm drive housing each end and continuous length of perforated

Different clamp band edge types

What we need is a strong, easy-to-use clamp with a large adjustment range to cover many different hose sizes. The only clamp to fulfil all these criteria is the humble worm drive hose clip easy to cut into the hose slightly. Such damage, compounded with vibration from an engine or a similar source, can cause a complete failure as the hose clamp cuts deeper and deeper. To help prevent such a situation, many companies up-turn the edges of the clamp band.

However, as can be seen in the accompanying diagram, this only moves the sharp point and hose damage can still occur. Uniquely, JCS uses a special material with a rounded edge for the clamp bands on all products. This rounded

band offers increased protection as the sharp point that could cut into the hose is removed completely.

Sealed by a walrus With such a broad range of uses, JCS has supplied clamps to every corner of the globe for some rather peculiar applications. Yet the strangest by far was the application the Hi-Torque clamps found themselves in at a US university. As part of a study, the university was tracking the movements of walruses in Alaska and the biggest challenge for them was not catching the massive animals but instead securing a tracking transmitter to them.

The problem was to find a suitable method of securing the transmitter to one of the walruses’ tusks. It was imperative the transmitter did not become dislodged and cause harm to the animal, but at the same time the securing method had to be impervious to constant immersion in saltwater and very low temperatures.

After several attempts (and expensive losses) using adhesives and various strapping methods, it was decided HiTorque clamps were the answer. Made from Marine Grade BS.304 stainless steel and with the unique rounded band edge, the clamps were successfully used for over two years with no failures and – perhaps most importantly – no harm to the walrus. z For more information:

This article was written by Tom Allen, sales and marketing manager at JCS Hi-Torque. Visit: www.jcshi-torque.co.uk

Not your everyday hose clamp application

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 15

Sweet relief

VALVES

New pressure and vacuum relief valve models aim to solve problems in storing petroleum and chemical products Industrial customers throughout the world who are responsible for the safety and integrity of aboveground and underground storage tanks look to their trusted advisors and suppliers for tank protection products and solutions that deliver a broad range of benefits to their operations. Namely, enhanced productivity and performance, reduced emissions and waste, and lower costs are among some of the most significant and most measurable of these benefits.

Adopting reliable solutions and installing products that meet rigorous industry standards are not options, but necessities.

Earlier this year, Pentair Valves & Controls introduced its new Anderson Greenwood 4000 Series of pressure and vacuum relief valves that have been engineered to provide increased flow capacities and to open fully at 10% overpressure. Playing a key role in protecting storage tanks from physical damage caused by internal pressure fluctuations, the 4000 Series valves are the first high capacity full lift valves that have been verified to meet the requirements of the seventh edition of the American Petroleum Institute (API) 2000 standard. The valves are also referred to as high capacity full lift (HCFL) valves.

Developed over a number of years, along with the development of the API 2000 standard, the pressure and vacuum relief valves are being manufactured at the Pentair Valves & Controls facility in Manchester, UK. Alan West, engineering director for pressure management with Pentair Valves & Controls based in Schaffhausen, Switzerland, contributed to the development and adoption of this standard in 2014.

West is one of several members of the API 2000 Standard Committee.

The API 2000 standard addresses normal and emergency vapour venting requirements for bulk liquid storage tanks installed and operating in oil, petroleum, petrochemical, chemical, power, water, food and beverage, and general purpose bulk liquid storage industry sectors throughout the world. This standard applies to tanks that hold petroleum and petroleum products, and can be applied to 16

Emissions comparison between standard and HCFL valves

tanks that hold other liquids provided that adequate engineering analysis has been conducted and sound judgment has been executed. The API 2000 standard does not apply to external floating-roof tanks.

The standard covers normal and emergency vapour venting requirements for aboveground liquid petroleum or petroleum product storage tanks and aboveground and underground refrigerated storage tanks designed for operation at pressures from full vacuum through 103.4kPa (15psig).

Features

can be set close to maximum allowable working pressure/vacuum (MAWP/ MAWV) and minimise tank emissions.

The large valve body provides for increased capacity and high flow performance, making the products fully compliant with the API 2000/ISO 28300 standard. In other technical details, the valves feature a leakage rate of 0.015m3/ hr or less at 90% of set point, and come in a range of body materials (aluminium, carbon steel, or stainless steel). Their modular design enables all components to be removed and replaced in-situ for quicker, simpler maintenance. Optional

The available four vent-to-atmosphere model variations of the new valves include: • Model 4020H weight-loaded pressure and vacuum relief • Model 4020HP spring-loaded pressure and weight-loaded vacuum relief • Model 4020HC spring-loaded pressure and vacuum relief • Model 4020HV weight-loaded pressure and spring-loaded vacuum relief Both the weight- and spring-loaded valve models are available in 2” to 12” sizes. The valves feature increased flow capacities that reduce the required valve size and the corresponding connections and piping costs. Fully open at 10% overpressure, they

Pentair’s Anderson Greenwood Type 4020 valve

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

VALVES “all-weather” coatings, such as PTFE and ECTFE, prevent corrosion, frozen condensate build-up, and sticking of vital components in cold weather applications.

Key differentiators Conventional valves do not typically reach full lift until 70 to 100% overpressure.

Pentair’s 10% full lift valves reach full lift at 10% overpressure, thus allowing the Series 4000 valves to be set closer to MAWP and MAWV while achieving the same flow. Plant and storage facility personnel can then fill and empty tanks more quickly and operate them at higher pressures. The 4000 Series valves remain closed longer and enhance flow capacity, which results in increased productivity and reduced evaporation and, therefore, provides a major benefit in reducing emissions and wastage.

The 10% full lift valves offer a smaller valve for the same performance, especially when overpressure is low. Even if there is no size advantage, setting the valve higher provides emissions savings to the customer on pressure and reduces air intake for vacuum. API 2000 only requires a seat tightness of 0.5 CFH at 75% of set pressure. The HCFL is factory tested to provide superior seat tightness of 0.5 CFH maximum at 90% of set pressure.

since the valve is set higher, there is less leakage when the valve is closed during normal working pressures in the tank.

Customers often use blanketing systems to reduce their emissions, product loss, and to prevent explosive mixtures. Nitrogen tends to be a major expense in an industrial facility. Unfortunately, excessive loss of nitrogen is common with normal vents since overpressures are high and set pressures are close to the blanketing pressure.

Because many blanketing systems have been installed after the tank design (and vent design), customers tolerate the loss of nitrogen due to the benefits they receive.

If this situation exists, the new Pentair valves can go into the application at a higher setting, thus reducing nitrogen loss.

contains a testing protocol with “built-in” losses, based on a typical connection for a storage tank. Each valve is tested for proper setting for a leakage rate of less than 0.015Nm3/ hr of air at 90% of the set point and for zero measurable leak at 75% of set point as required in the API 2000 standard.

Meeting expectations

The Series 4000 valves are being well received among customers and appear on the lists of approved products from approved vendors. Since the adoption of the API 2000 standard, customers have been specifying API 2000 7th Editioncompliant valves in their bids and purchase orders. The Series 4000 valves have been Testing and certification installed and are currently operating in crude and refined oil storage facilities, Approximately 18 months prior to the air separation plants, chemical storage official launch of the Series 4000 valves, plants, wastewater treatment facilities, and Pentair made them available to customers fertiliser manufacturing plants in Asia, the as a means of securing their feedback on Americas, Europe, and the Middle East. overall product quality and performance.

The valves are available with warranties Early users provided Pentair with valuable of 18 months from the date of purchase field data and input that has contributed or 12 months from the date of installation to improvements in the manufacturing (whichever comes first). Warranties on and production process. Pentair’s Series these and other Pentair valves protect 4000 valves have earned ATEX 94/9 EC customers against manufacturing defects certification, which addresses potentially or material defects. Standard warranty explosive atmospheres (Article 9 of terms are included in the standard cost.

Emissions savings and reduced nitrogen loss Directive 94/9/EC, EN13463-1:2009 Annexes Pentair offers training for field service B &C). Also, in accordance with the API engineers and engineering contractors Industrial facility owners and operators 2000 standard, they have been tested at customer locations throughout the can expectemissions emissions savings ranging on ausual square-edge connection. world on astacks, bi-annual schedule Fugitive do NOT come from the sourcesflange of pollution, such as chimneys, and vents.or in a from 2 tonnes to 15 tonnes or more per Because vent valves do not have customised training session if needed. z year. Breathing losses from independent to follow codes, they are notorious Instead, fugitive emissions are pollutants released into the environment due to leaks in equipment such as tanks can be minimised through the for interpretation. In short, many pipelines, seals, or valves. use of vent settings that are as high as manufacturers will test the valve on For more information: possible and in accordance with the API an “ideal” nozzle to generate the true This article was written by Stuart Brooks, product manager for tank protection 2521 standard. The HCFL valves can be valve performance, thereby leaving products, low pressure pilots and rupture Valves are the #1 source of fugitive emissions: set higher (closer to MAWP and MAWV) the capacity loss determination to discs for pressure management at Pentair Valves & Controls. Visit: valves.pentair.com toSources achieve the same flow.

Additionally, the customer.

The API 2000 7th Edition of Fugitive Emissions by Equipment Type

WHAT ARE FUGITIVE EMISSIONS? AND WHERE DO THEY COME FROM?

60% Fugitive emissions by equipment type

15%

10%

10% 10%

Valves

Relief Valves

Tanks

Pumps / Compressors

Flanges

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 17

PENTAIR

SPONSORED ARTICLE

What the Germans want

An Italian valve maker’s new product has been designed specifically for the German chemicals industry Everyone involved in valve manufacturing knows that German industry has very strict regulations and norms that manufacturers must carefully fulfil in order to be approved for different applications. The German chemical industry, for example, requires valves to be in compliance with the AD2000 Merkblatt code of practice for the choice of materials and sub-supplier. Another important mandatory standard for approval in chemical applications is PAS1085 – a regulation developed by four big players in the chemical industry and released a few years ago - that contains requirements regarding design and performance.

After a long research and testing process, Italian valve maker Omal now has a new product in its hands – a new stainless steel flanged ball valve series developed for German chemical applications and regulations called Prochemie 60. But simply conforming was not enough for Omal, and the company decided that AD2000 and PAS1085 were only the starting points of the development process. So, an additional directive was immediately considered, namely the IGR Guideline Technik 12-000421. This guideline – together with several different datasheets – is an important standard created by an association composed of some of the most important companies in the chemical sector.

The development process Omal chose four of the available IGR datasheets (19021, 19022, 19023, and 19043) for the development of Prochemie 60. One of the most important requirements of these datasheets refers to atmospheric sealing, stating that the valve must not leak through the stem after 60,000 cycles under TA-Luft fugitive emission conditions.

The biggest difficulty to face during the project study was to find a solution that would allow the valve to be tight enough to also block helium, the medium specified by the VDI standard for valve testing. Helium is a gas composed of one of the smallest known molecules. Just to give an idea of the testing requirements, under test conditions the estimated allowed leakage into the atmosphere per year is less than 0.5g of helium.

18

The Prochemie 60 valve has now been certified under the TA-LUFT fugitive emission standard. The name of the new valve also highlights the fact that it is a professional valve dedicated to chemical applications and can reach the specified 60,000 cycles.

The research and testing was performed in Omal’s own facilities, as the company invested in all necessary test benches and on employee training to ensure its engineers were qualified to perform the testing procedures. All results were then confirmed and approved by an authorised third party in the same way Omal’s ball valves’ compliance to the chosen IGR datasheets was confirmed by a third party located in Höchst Chempark in Frankfurt.

Features The new ball valves include as standard an EN 12662-2 specified antistatic device and are certified fire safe according to ISO10497/API607. All are manufactured from stainless steel, 1.4408 for the body, 1.4404/316SS for the stem, and the ball in 1.4408/CF8M. The valve is available with soft seats in PTFE+glass as catalogue configuration, but other sealing materials are available on request, like TFM1600, PTFE+graphite, or PEEK. Depending on the application needs, additional features can also be included, for example a monodirectional construction (in case of fluid overpressure risk inside the body) or stem extension in simple welding construction or with a double sealing system (in case of low or high temperatures).

Reaching the fugitive emission UNI EN ISO 15848-1 and TA-LUFT 60,000 cycle certifications was possible only after careful research and development, in particular of the stem section. Omal started from the proven stem sealing construction of its Magnum and Thor ball valve series and introduced further improvements. Reaching 60,000 cycles on TA-LUFT test VDI2440 conditions (max leak 6.47x10-6 mBar l/s) is not easy. The V-packing sealing geometry of Magnum and Thor has been kept in the design, but the material has been changed to two PEEK sections containing in between them one Devlon section.

A new and important feature of the

Prochemie is that the seals are completely independent from shaft rotation in order to not be subjected to radial wear and to reach high durability and maximum sealing performance throughout the valve’s life. An upper cover (not-in-pressure component) packs the springs that are acting on the V-packing through the gland nut ring and that allow the sealing to self-adapt to the shaft, granting the required tightness but suffering basically no radial friction at all.

The lower part of the stem also features anti-friction sealing washers that are under very low stress as there is no preloading coming from screws or nuts. This construction also makes it possible to avoid the need for O-rings, which are not included in the Prochemie design.

It is important to highlight that even if the valve is using an upper cover, the shaft still features an anti-blowout system through the mechanical stop in the valve geometry (the stem is assembled from the inside of the body). Furthermore, in order not to stress the upper cover in case of actuator assembly, installation holes on the cover allow the actuator to be directly fixed to valve body.

Best when automated Prochemie 60 is available as a manual version with express reliability at the top level, or it can be automated using an Omal scotch-yoke actuator with an aluminium or stainless steel body (mounting kit is as standard always in stainless steel). This allows operators to benefit from the long-lasting high performance of the complete Omal package, available with SIL3 certificates.

This Series is available from DN15 to DN150 in short (F4 face-to-face) or long pattern (F1 face-to-face) in PN16/40 (EN 1092-1) with a double acting, spring return, with or without integrated handwheel pneumatic actuator.

The valve is now available, and its features will be exhibited live at the Omal booth (Hall 3 - 3B64) at the Valve World Expo in Düsseldorf, Germany, on 29 November-1 December. z For more information:

This article was written by Fabio Bugatti, export area manager at Omal S.p.A. Visit: www.omal.it

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

How much will your pump really cost you?

PUMPS

Many companies try to save money by purchasing the cheapest pump for their application, only to realise later what a costly mistake they have made

Steve Schofield, director and CEO at the British Pump Manufacturer’s Association (BPMA)

Pump sizing can be a daunting and difficult task

When it comes to specifying pumping equipment, many companies, particularly those under increasing pressure to cut costs, could actually be making decisions that will cost them more in the long run. Lifecycle costing can help to reveal the true cost of a pump.

The need to cut costs wherever possible is an increasingly familiar requirement for engineers charged with ensuring the continued smooth operation of a plant on a limited budget. When it comes to pumping systems, although choosing the lowest cost option may seem like the best short-term solution to achieving cost savings, it will almost always result in additional costs being incurred that could have been avoided by spending a little more time and money during the specification and design stage.

According to statistics from the US Department of Energy’s Office of Industrial Technologies, pumping systems can account for between 25 and 50% of the total energy consumed by certain industrial processes. Add to this the need for ongoing service, repairs, and maintenance throughout a typical service life of 20 years and pumps quickly begin to represent a substantial area of expense.

The expectations of some pump users can be unrealistic when it comes to the cost of pump ownership. In many cases they focus too much on initial outlay, opting for the least costly alternative, which is not always actually the best solution for the application.

Looking at the whole life story So what is the answer? The British Pump Manufacturers’ Association and many of its members are keen to emphasise the importance of lifecycle costing (LCC) as a vital part of any pump purchasing and ownership strategy. LCC takes into account many factors, all of which impact on the total cost of owning and operating a pump, which includes much more than just the initial outlay. A pump’s life cycle cost encompasses the total overall costs that accumulate throughout the life of a pump, from installation, energy consumption, operation, maintenance and downtime, even environmental, and through to the final decommissioning and disposal of the pump.

By carrying out an analysis of the costs that are likely to be incurred throughout the operational life of the pump, it is possible to objectively compare all the potential options at the outset. LCC can be useful not only for selecting new equipment but also for justifying the upgrade of existing systems. Throughout the lifetime of a pumping system, it is unlikely that the same operating conditions will continue to prevail.

Factors such as the addition of new equipment upstream of the pump or changes in production techniques can all cause variations in pump duty away from the pump’s “best efficiency point” (BEP). This is the point where pump capacity and head pressure combine to provide the maximum efficiency performance from the pump. If the pump is incorrectly sized and is operating too far from the BEP, wear and tear can occur which can shorten its operational life.

An oversized pump, for example, will

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 19

PUMPS not only be inefficient, but will also cost more to maintain because operating too far to the left of its performance curve puts an extra strain on pump bearings and seals. On the other hand, a pump which is undersized for the duty may end up running too quickly, which may potentially ruin the product being pumped and also prematurely wear out parts of the pump.

Its efficiency will also be affected, resulting in excessive energy consumption.

Size matters Although a pump should be sized to an application, achieving this is not always straightforward. Involvement of third parties and the need to meet possible changing future requirements can all affect the sizing of a pump. Overdesign on parameters is very commonplace. If every party involved in specifying a pump adds on even a small percentage to their sizing estimate, the end result can be a highly inefficient pump. The extra cost, both in terms of running and maintaining the pump, can be very high over the life of the plant.

One survey of 4,000 installations showed that water pumps typically operate with a shortfall in efficiency of between 12.5-20% because they are incorrectly specified.

The situation is worse for pumps that handle more unusual or complex media, such as chemicals or pharmaceuticals.

To help with changes in duty and assist with energy reduction, many pump manufacturers are now promoting the use of variable speed drive (VSD) pump systems, frequency drive being the most prominent system used. By using VSDs operators in effect combine electrical and mechanical principles. The addition of the latest controls or ancillary equipment can

Pumps running in parallel in a production plant

often help boost efficiency and enable pumps to meet changes in demand at a fraction of the cost of building a new system from scratch. In some cases, simply upgrading a pumping system can result in energy savings of up to 50%.

The importance of good design Maintenance and energy consumption represent by far the two most significant costs throughout the life of a pump. The answer to minimising these costs lies in ensuring a well-designed pumping system, where the pump is specified as correctly as possible to the demands of the application.

The energy consumption and efficiency of a pump is closely linked to the way that a pumping system is designed and operated.

Every pump manufacturer can, or should, supply characteristic curves for their equipment illustrating pump performance under given conditions. These curves

demonstrate the inter-relationship between discharge capacity, pump head, power, and operating efficiency.

The BPMA and its members have been involved in the writing of the Europump guides to assist users with their selection and operation of pumping equipment.

Looking at the possible energy savings in the entire pumping system, the BPMA in 2010 created the Certified Pump System Auditor (CPSA) scheme. This is a new industry-specific professional qualification developed by an established and highly regarded body within the industry.

The objective of the scheme is to help improve the levels of professionalism in the sector by creating a universally recognised and respected industry “standard” for individuals assessing the performance of a pumping system.

The CPSA scheme training includes: • Pump system requirements and analysis considerations • ISO 14414 pump system energy assessment standard requirements • Pump system optimisation methods How to get it right –top tips from the experts The following are just some of the key factors that should be considered when specifying a pump, which could help ensure it delivers optimum performance and economy throughout its service life.

Life cycle cost percentages of pump ownership

20

1. What sort of pump do you need?

There are many different types of pumps available, each of which is suited to particular applications. The two most popular types are centrifugal pumps and positive displacement pumps.

Centrifugal pumps are generally FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

suited to fast flowing or low viscosity liquid applications, where the pressure is relatively constant. They perform most efficiently and cost-effectively when operating at or near their BEP. Positive displacement pumps, on the other hand, are particularly ideal for high viscosity applications, as they are better able to maintain a constant rate of flow.

It may also be necessary to consider what type of material the pump is manufactured from. Hygienic processes in the pharmaceutical or food and beverage industries, for example, are subject to the strict requirements of the Food and Drug Administration (FDA), which call for equipment to be manufactured from 316L stainless steel. Information on selection and which pump is best suited/used on different applications can also be found within the BPMA buyer’s guide.

Pressure & Level

FLUSH DIAPHRAGM SPECIALIST

2. Is there sufficient pressure for the pump to work effectively?

The efficiency and operation of centrifugal pumps in particular can be affected by the net positive suction head (NPSH) available. Basically, this is the amount of pressure that is required to prevent the liquid being pumped from vaporising inside the pump. If the liquid vaporises, bubbles can be formed, which will be carried into the pump. When these bubbles encounter zones of higher pressure in the pump, they will collapse violently, resulting in a phenomenon known as cavitation which can severely damage the pump. When designing a pump system, it is essential to ensure that the available pressure on the pump inlet is greater than the pressure required within the pump to avoid the occurrence of cavitation.

3. Is the pump positioned in the correct place?

Where a pump is positioned within a pipeline can also greatly affect its performance. As well as determining the amount of pressure available, the positioning of a pump can also affect the quality of the product being pumped. Too much or too little distance in the pipeline before the pump, for example, can lead to friction losses, which can affect the flow rate of the substance being pumped, which in turn can affect the efficiency of the pump. The presence of pipe fittings, such as elbow joints, filters, or other in-line equipment, can also affect the flow rate of a substance to the pump.

4. Do not just purchase on cost alone When it comes to selecting a pump, cheapest is by no means best. Be particularly careful where reductions in the purchase price have been achieved by cuts in supplier back-up and expertise. Ultimately, the most cost-effective installation will be the one where the supplier can offer good technical back-up, an established track record, and a reputation for high-reliability products based on sound research and development.

5. Always take the pump manufacturers’ advice!

It is surprising how many customers do not take advantage of the expertise available from the pump manufacturer when it comes to ways of getting the best performance from their pumps. After all, nobody knows more about how to get the best out of a pump than the company that built it. z

For more information:

This article was written by Steve Schofield, director and CEO at the British Pump Manufacturer’s Association (BPMA). Visit: www.bpma.org.uk

Some Features:

Strong diaphragms Standard polished Minimum oil filling Active Temperature Compensation EHEDG and 3A Certified High overpressures Klay Flush Diaphragm Technology

www.klay-instruments.com

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 21

PUMPS Fig 1: Removing the No.3 screw from the pumping station

Screwing it into place A UK pump station’s time-gnawed flood defence pumps were renovated in one major operation Located in Lincolnshire, UK, the town of Grimsby’s Freshney pumping station is a key element of its flood defences, which were first enshrined in statute way back in the Grimsby Haven Act of 1796. When the pumping station was first built more than half a century ago, it was equipped with three large Archimedes screw pumps.

These were replaced some years later, but time and exposure to the elements have resulted in corrosion and wear, so in 2016 a major refurbishment programme was implemented in respect of the No. 3 pump.

Over the years, the pumping station has been called into action on several occasions, but it is more than five decades since all three screws were operated simultaneously to prevent flooding.

Almost a decade has also passed since the last time that two of the screws ran simultaneously, indicating that should circumstances arise, the station has adequate capacity to cope. Each of the three screws weighs seven tonnes and the station has the pumping capacity to shift 6,000l/s. In the words of Phil Christy, Grimsby Dockmaster: “It’s a pretty impressive piece of kit when it is running. It is simple to use 22

and runs the same as a ship’s propeller.”

Like all pumps, wear and tear eventually takes its toll, and in the case of the No. 3 pump, Swedish pump manufacturer AxFlow’s Huddersfield Service Base was contracted to undertake extensive and essential remedial work in the early part of 2016. Although the condition of the pump could be seen before removal of the screw itself, extensive examination undertaken once the pump was removed (fig 1) from service revealed serious corrosion of the deflector plates and all the cover grids were completely rotten.

What did emerge was some fairly major works to be undertaken to replace two of the gears within the gearbox, though.

A good deal of work “The extent of our tender for the No. 3 pump included removing the screw, the cover grids, deflector plates, top and bottom bearings, motor, and hand railing,” reports Mark Redgrove, AxFlow technical support manager. “The screw was shotblasted and coated with a polyurethane coating supplied by Resimac to a thickness

of 2mm to provide the 10-year life requested by the customer. The deflector plates, cover grids, and handrails were all badly corroded and replaced with new items in galvanised 3mm steel plate.”

Not content with this amount of work, AxFlow also took the opportunity to make repairs to the No. 2 pump. In the case of the No. 2 pump, AxFlow repaired the bottom bearing, which had failed prematurely after just three years of service. Fortunately, this job did not involve having to remove the entire pump and it was completed before the No. 3 pump was re-installed.

Therefore, at no time was the capacity of the pumping station impaired.

All the work was undertaken at AxFlow’s Huddersfield service base, where there are specialised pump repair facilities capable of taking in pumps up to 50 tonnes in weight. However, the job of removing and re-installing the No. 3 pump screw required AxFlow to draw on its logistics capabilities.

“Given the size of the seven-tonne screw, at 5m long and 3m in diameter, it was necessary to bring in a 100-tonne crane (fig 2) from Hall Bros, located

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

PUMPS in Bridlington some 40 miles away, with a reach from crane to lift of 20m for the removal and re-installation tasks,” says Redgrove. “We also had to bring in a diving team and smaller 50-tonne crane for installing the dam board, which performs the same job as stop logs in allowing the bottom bearing area to be pumped out.”

The various engineering jobs

undertaken by AxFlow were part of a rolling programme of refurbishment to the pumping station. Removing the screw started in January 2016 and it was returned to site, re-installed, and commissioned in May (fig 3).

AxFlow, headquartered in Stockholm, Sweden, specialises in the marketing, distribution, and provision of a complete sales engineering service for high quality

fluid handling equipment. The AxFlow Group is active in 27 countries, has approximately 570 employees, and an annual turnover of €175 million. AxFlow is part of Axel Johnson International. z For more information:

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

Fig 3: The screw reinstalled and ready for service

Fig 2: Specialist lifting services were required to lift the screw back into position

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

Schubert & Salzer UK Limited P ho ne: +4 4 / 1 9 5 2 /4 6 2 0 2 1 Fax: + 4 4 / 1 9 5 2 /4 6 3 2 7 5 E ma i l : i nf o @ s c hub er t - s a l z er.c o .uk

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

11.01.2016 09:29:01

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 23

PUMPS

Efficient solutions preferred Successful pump replacement for tough operating conditions

A malfunctioning pump can cause massive damage, and hence high costs – even just in terms of downtime and loss of production. On top of this come the costs of repair work and the time requirements, all of which impact the total cost of ownership (TCO). Up to 90% of damage to pump systems is the result of deficiencies in the design of the pump or operating errors. When selecting the optimal pump – whether for a new purchase or sourcing a replacement – the operator generally provides a precise description of the parameters, such as the medium and operating conditions. In a specific case where mineral oil concentrate was to be pumped, however, this was not done. Here the pump used was selected by the plant manufacturer, and quickly became a “permanent construction site”.

Südöl, a German oil processing company, has been successfully recycling used oils since 1935. The plant of Südöl Mineralöl Raffinerie in Eislingen, Germany, uses an emulsion evaporator to treat cooling lubricants, washing liquids, and other oil/water emulsions. For the pump installed by the plant manufacturer, this task proved too demanding from the outset. The special properties of the oil concentrate, which include abrasive characteristics, and the fluctuating quality of the process medium, were too much for the centrifugal pump with its double mechanical seal.

this process is approx. 25m and the process temperature approx. 90°C. The pump must thus cope with up to 200m3/h of oil concentrate.

Graduate engineer Henrik Dorn, responsible for the emulsion evaporator plant, which is operated independently of the remainder of the refinery process, knows this pump’s struggle with the solids

Up to 90% of damage to pump systems is the result of deficiencies in the design of the pump or operating errors content of the medium all too well.

He describes his painful experiences as follows: “As a result of mechanical wear, the centrifugal pump installed by the plant manufacturer suffered severe leakage at the double mechanical seal,

Custom-made for the application In the second vacuum evaporator stage of the plant, the aqueous components of the emulsion are concentrated at an absolute pressure of approx. 300 mbar. A heated circulation evaporator continuously circulates the medium consisting of mineral oil with crystalline components. The delivery head during 24

The emulsion evaporator plant at Südöl Mineralöl Raffinerie, Eislingen

sometimes within four to six weeks. This resulted in significant product leakage and the loss of vacuum in the process”.

In addition to extended and unpredictable operating downtime, the company also had to shoulder considerable repair costs. Despite all the efforts of the pump and seal manufacturer, no improvement was achieved, either in the short or the long term. Ultimately, the result was a total loss of the mechanical seal. The cost of replacement parts alone came to almost €2,000. The expense of the work for the disassembly and reinstallation would have been added on top of that.

“Since stable and economical operation was not possible, a suitable alternative needed to be found,” explains Dorn, who as operations engineer is responsible for all process plants at Südöl Mineralöl Raffinerie.

Custom-made for the application Any pump installed at the Südöl application needs to overcome the specific difficulties of the medium.

The question posed onsite was: are there pumps that can cope with the extremely problematic situation caused by the emulsion while being cooled? Because the properties of the process medium fluctuate, material deposits and hard encrustations can form during the cooling process.

Through an article in the specialist press, Dorn became aware of Bungartz, a manufacturer of special centrifugal pumps. Together, the two companies comprehensively analysed and discussed the problems and questions on the process and the pump application. The economic side of the pump replacement process was also examined. The best possible solution was found in the form of

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

PUMPS

The Südöl engineering team and employees support the customer through the entire process

the MPCH Dry Run, a robust centrifugal pump designed appropriately for the extreme conditions, with specific properties. This durable, low-wear and low-vibration pump has been tried and tested over many years. Its further advantages include low installation and maintenance costs, and efficient and low energy consumption.

The specific properties of the hermetically sealed MPCH DryRun centrifugal pump include the permanently dry-running and depressurised magnetic coupling. The roller bearing and magnetic coupling operate under a sealing gas atmosphere and have no contact whatsoever with the pumping medium. For this application, it was sufficient to use dry air as the sealing gas. As a custom-made solution for the Südöl application, the impeller was fitted with closed blades. Between the back of the impeller and the shaft bearing, there is a product-free labyrinth area through which sealing gas flows. This sealing system and the structural design ensure a high temperature gradient and hence a lower bearing temperature.

“The MPCH DryRun was commissioned on 30 August, 2012, in cooperation with an employee from the pump manufacturer.

Thanks to the excellent communication, and the employees’ understanding of the difficult process, the pump was optimally designed, including the sealing gas system,” says Dorn, who today is still glad to be rid of the old pump and with it a

permanent nuisance and cost driver.

After the poor experience with the previous pump, a control system was used to monitor the bearing temperature of the magnetic coupling, and the minimum flow rate in the sealing gas system. The values have been in the green range from the start to the present day. The bearing vibrations were analysed after commissioning as a reference measurement. The measurements

are repeated at yearly intervals, in order to identify potential bearing damage at an early stage.

“The following year, it was found that even the impeller of the pump still corresponded to its original condition.

Our excellent experience is therefore confirmed,” states the operations engineer. “Since the new pump was installed, there have been no further problems, faults or leakages. The DryRun functions absolutely smoothly and inconspicuously, and it does so 24 hours a day, 7 days a week,” Dorn concludes.

Retrofitting with many saving effects

be extended slightly because of the length of the magnetic coupling. The economy with which the MPCH DryRun is operated can already be seen through the use of the roller bearings and a ceramic containment cup – no heating of the medium, and neither hydraulic nor eddy current losses occur in either the coupling or the bearing.

The special centrifugal pump from Bungartz also provides energy efficiency.

More recent calculations show that it saves an average of one euro per operating hour – at 10kW/h x 8,000h/ year = 80kW/h x €0.1/kW/h = € 8,000 savings per year. In addition to the low energy consumption, Dorn was also convinced by the maintenance interval of the DryRun, describing the period of three years as exceptionally convenient. The service life of the bearing is also high, with users reporting a service life of more than 32,000 hours.

Despite the investment, the retrofitting turns out to represent a profit. If the previous cost of replacement parts were factored in, the purchase would have amortised itself within 18 to 24 months at the latest. And if the previous production downtime and repair costs are taken into consideration, this period would be significantly shorter, a great departure from the annoyance and expenditure of time in the past. If the typical cost ratio of 30:70 is taken into account – purchase and installation (30%) to operating costs such as energy and maintenance (70%) – chemical and petrochemical industries, environmental protection, and power plant technology companies might prefer to utilise this pump solution. z

The originally dreaded retrofitting process For more information: turned out to be unproblematic, because This article was written by Annette van Dorp for Bungartz. Visit: www.bungartz.de the performance data of the motor at 45kW/1500rpm, the pump casing of the DryRun (dimensioned in conformity with DIN standard), and the flange design were no different from the pump installed previously. There was not even any major modification work required.

Only the concrete foundation for mounting the horizontal centrifugal The MPCH DryRun can present a solution for tough operating conditions and economical life cycle costs pump needed to

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 25

PUMPS

Lifting the standard A French innovation helps operators bypass traditional potholes associated with lifting stations Lift stations are a key link in the chain of wastewater collection and treatment.

Traditional lift stations use submersible pumps in a wet well, which are activated by float switches when the water reaches a preset level. The pumps then run at full speed to empty the wet well.

A primary issue with submersible pumps in wet wells is clogging with wipes and other flushable materials. The float switches are subject to fouling with fats, oils, and grease and may require frequent cleaning to keep them operable. In addition, wet wells occasionally have to be cleaned out, typically with a vacuum truck. Then there is hydrogen sulphide gas that can corrode electrical components, anything made of steel or iron, and even concrete.

These pump clogging issues experienced in many countries today were addressed and resolved by French innovator Stephane Dumonceaux. His company, S.I.D.E Industrie, patented and installed its first DIP System in 2003 and since then more than 1,500 of these systems have been utilised in locations throughout France – for example in Disneyland Paris – as well as in the US, Canada, Cambodia, Portugal, Ivory Coast, and the Caribbean Islands.

Based on practical expertise in the field, the development of the company’s product range – 56 models with flow rates 26

from 20 to 10.000gpm/unit and heads from 3 to 300ft – is a result of 30 years of research and from listening to the daily concerns of its 1,500 users worldwide.

This has allowed S.I.D.E to develop a modern alternative to wastewater lift stations that saves time and money.

Developing the DIP

living close to the works where the DIP System has been used have appreciated the absence of noise and odours of the bypass system provisory in place, so much so that some regretted the end of works and the removal of the DIP as these nuisances returned when the brand new submersible pump unit was started.

With the DIP System, the wastewater remains inside the piping and the pump, creating a clean and dry environment.

As the DIP system pumps are directly connected to the lift station inlet and outlet, a wet well is not necessary. The

In 2002, the DIP System was patented and found its first application and use at a bypass on an existing pumping station that needed to be renovated and recovered.

Several “big names” in French regional water agencies, such as Veolia, Suez, and Saur, have since then adopted the system to bypass lift stations of various size in the context of major works during several weeks, and later several months between 2002 and 2005.

The DIP System works without the operator having to set up a provisional station, which was the only solution its introduction. Residents Sidinox prefabricated lift station fitted with the DIP System

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

PUMPS

The DIP System’s reversing impeller shreds material caught in it

pumps operate continuously and are controlled by a variable frequency drive, which ensures that they run at the speed necessary to handle the flow.

By lifting gravity effluent directly from effluent downstream without water charging or a collecting tank, the DIP System eliminates all the main problems of retained volumes of effluent, such as dangerous gases (hydrogen sulphide), odours, sand and grease accumulation, equipment corrosion, clogged floaters, and offers access safety.

Applications worldwide The DIP System is a suitable solution for communities that want to modernise or extend their wastewater collection networks, as it makes it possible to design durable and economical pumping stations with no wet well. The absence of a collection tank eliminates costly cleaning operations of traditional units and eliminates at the same time both the complaints from residents living close to an installation producing unpleasant odours and the risks for maintenance technicians.

The DIP System has many applications and is particularly suitable for treatment plants, sanitation, and public works, but also for pumping washing water, industrial effluent, wastewater, and sea water with the stainless steel version 1.4404. For example, in the beginning of 2015, S.I.D.E’s distributor Robert Brown Associates Pumps won a deal to supply a DIP11-4VVIX-1.5kW system to Merck Pharma to pump its industrial wastewater with a high pH at high temperature.

Indeed, Merck Pharma was looking for a solution able to handle its industrial wastewater for injection with chemicals from washdown, and required the system to be a non-submersible duplex pumping

A DIP System installed in Portugal

system. It had to be small enough to be hidden in a small bucket, fully made of stainless steel 316 to handle high pH due to chemicals at a high temperature of 82°C, and equipped with a special “anti-fibrous materials” impeller. The DIP11/4VVXI, manufactured from stainless steel 316 and featuring the DIPCut impeller was the suitable solution.

The DIP pump is also self-cleaning and uses a special impeller design. When the torque increases, the pump senses that it is becoming clogged. It then automatically slows down, stops, and reverses direction. When this happens, knives on the impeller pop up and slice up any caught rubbish. When the pump senses that it is running free again, it slows down once more, stops, and returns to the normal pumping direction. All this happens without operator intervention.

also check and update the system via OmniDIP, as well as automatically handle preventive alerts sent by the DIP System.

Some automatic process checks of the DIP System, such as automatic clearing, automatic cleaning, or inspecting the level set-point can be performed through OmniDIP. This allows operators to know the state of the sensor and the motor and test the automatic reversal. If anything out of the ordinary is detected, a summary report is sent to the operator and in the event a physical intervention is required, a S.I.D.E technician will contact and guide the user. The Customer Access feature allows displaying the current condition of the DIP System and to edit summary reports delivered over a chosen period of time.

This allows operators to directly check the average consumption, pumped volumes, runtime, and optimisation measures taken by the self-monitoring system. z

An eye on itself For more information: The self-cleaning pumps are connected This article was written by Valerie Joguet, to and can be monitored and managed marketing manager at S.I.D.E Industrie. with a smart phone, tablet, or a desktop Visit: www.side-industrie.com computer from anywhere in the world with the help of the OmniDIP web assistant.

OmniDIP is a self-monitoring system designed to be used alongside the DIP System. It checks automatically and continuously all the processes through 230 parameters per pump in order to guarantee optimal operation and to avoid any unnecessary interventions. The analysis it provides is so precise that it allows forecasting and optimising instead of only informing when there is a technical fault. Plant staff can The DIP System can be monitored through online tools

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 27

PUMPS

Cost with Someflu 90000

Cost before Someflu

80000 70000 60000

A French zinc manufacturer found stainless steel pumps unreliable for pumping sulphuric acid and sought an alternative from thermoplastics 50000 40000 30000 20000

To extract zinc from ore, such as zinc 10000 • To choose a thermoplastic sulphite, the ore has to be heat-treated material, of which the company 0 2007 2008 2009 2010 2011 2012 2013 first to obtain calcine (Zno). Then, the had no previous experience Year calcine is leached with sulphuric acid Finally, the manufacturer chose the to solubilise the zinc, which is later second solution and contacted electrolysed to deposit on a cathode.

Someflu, a French pump manufacturer, Afterwards, the zinc is melted and casted to solve the problem. In November to obtain ingots. Zinc is mainly used for 2010, an HV vortex pump made of the manufacturing of different kinds Somedur was installed at the facility. of stainless steel. This manufacturing Abrasion Corrosion process is a challenging one, and requires the use of pumps that can SOMEDUR resist both corrosion and abrasion.

CARBON One such manufacturer is operating out 316L of France. At its facility, the manufacturer utilises several pumps, but one in particular Abrasion and corrosion resistance of various pump materials was proving problematic while pumping sulfuric acid. The process fluid and the pump had the following characteristics: The uses of stainless steel 316L with H2SO4 Fluid Fluid and concentration: Sulphuric acid 200g/L (11%) Particles: 400g/l (15%): ZnS, Fe, Mn, or Mg Particle size: From 100μm to 2mm Fluid temperature: 75°C Pump Flow rate: 35m3 Total differential head: 25m Running time: 24/7 Choosing the material While the abrasion issues were happening, the zinc manufacturer used Duplex stainless steel metal pumps. Because of abrasion, the impeller had to be changed every month and the entire pump every two months. This resulted in a massive increase in both maintenance and production costs. To cut back on the piling expenses, the manufacturer began to look for another solution after two years of using metal pumps.

Its R&D department proposed two solutions: • To choose a high quality metal alloy such as Hastelloy F, which could be even more expensive and with no proven abrasion resistance 28

(sulphuric acid) are limited, and with acid concentrations between 20% and 70%, it simply cannot be used. One of the solutions is to go for expensive stainless steel alloys such as Hastelloy or Uranus, but even there the process has to be very well controlled, because even small changes in concentration or temperature will result in material corrosion. The other solution is to choose Somedur or PP, which are suitable for most H2SO4 concentrations and about 40% less expensive than Hastelloy.

Somedur is a PE-UHMW thermoplastic material developed and registered by Someflu. It has a very high molecular weight of 6Mg/mol, whereas standard PE-UHMW starts at 1Mg/mol. This special feature makes the material highly resistant to abrasion, which ultimately results in lower maintenance costs and a longer life time service.

Somedur is currently one of the most abrasion and corrosion resistant raw materials

available, making it a good fit for most abrasive applications. It presents a suitable alternative to 316L and Duplex stainless steel pumps.

What of the results?

Contrary to standard ISO 2858 process pumps where the front clearance between the impeller and the volute casing is less than 1mm, the Someflu HV vortex pump gets a clearance of 65mm. This feature creates a vortex where most of the particles will remain, without being in contact neither with the impeller nor the casing. Moreover, the discharge is not in the axis but on the side. This allows for an easier discharge of the fluid because there is no change in the fluid direction at the cutwater.

The cost of the Someflu pump is about 30% lower than that of a comparable stainless steel pump. After installation, the steel manufacturer monitored the HV pump’s performance for three months to ensure it was working as intended. After this period, the control checks were dropped as the pump was deemed to be working well. Now, after more than two years of service, the pump finally had to be changed and replaced by a new Someflu HV pump.

With the selection of Somedur, the service life of the sulphuric acid pump

Someflu HV vortex pump

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

I N D U ST R I A L VA LV E S M A N U FA C T U R E R Cost with Someflu Cost before Someflu

90000 80000 70000 60000 50000 40000 30000 20000 10000 0

2007

2008

2009

2010

2011

2012

2013

Year

Cost savings at a French steel manufacturer with a Somedur pump

was increased eight-fold with a 40% lower purchase cost. This resulted in savings of more than €160,000 in two years, without including downtime cost. Due to this experience, the French steel manufacturer decided to use Somedur pumps in other processes Abrasion to replace stainless Corrosion as well and has started steel pumps in all applications featuring abrasive fluids.

SOMEDUR

A word on the company

CARBON

For over 50 years, Someflu has specialised in the 316L manufacture of anti-corrosive and abrasion resistant centrifugal pumps. Horizontal or vertical, they are designed for the most difficult applications in many different sectors, such as chemical, mining, fertiliser, water treatment, sea water, or steel industries. Due to the company’s ability to process high performance thermoplastics, Someflu pumps are available in PP, Somedur, UHMW-PE, PVDF, PFA, and PEEK. Someflu pumps, with a capacity up to 2,000m³/h and a head up to 130m, are manufactured and engineered as per specific requirements. The ISO 9001 certified pumps follow a very strict quality channel to ensure high product quality. The company’s custommade product range is composed of ISO 2858, close-coupled, and vortex pumps. Depending on applications, they can be equipped with mechanical seals in different configurations, such as flushing, standstill flushing, grease filling, or double seal.

Someflu is also able to provide complete products for explosive atmospheres. The company’s pumps are made from of a raw block of electro-conductive thermoplastic and equipped with ATEX motors (IECex equivalent). Only these electro-conductive thermoplastics provide complete protection against explosion by conducting static electricity. They can be used in zone 1 or 2 and categories IIB or IIC. z

Dual Expanding PLUG VALVE

ARFLU Dual Expanding Plug valves represent the “single valve solution”, they are easy to operate, require very little maintenance and offer verifiable double block & bleed service with an extraordinary long lifetime.

PETROCHEMICAL DIVISION For more information:

This article was written by Adrian Hourlier, international sales manager at Someflu. Visit: www.someflu.com

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

Visit us in Valve World Expo Stand 3D73

EVENT PREVIEW

Valve World Expo will draw the best and brightest of the valve and flow management industries to Düsseldorf in Germany on 29 November – 1 December. In this preview we give a small sample of all the things to see

Hurry along to Düsseldorf AS-Schneider Industrial valves specialist AS-Schneider recommends its compact VariASBlock series for pressure measurement applications in chemical and oil and gas industries. The VariAS-Blocks are designed to replace conventional, multiple-valve installations and are close coupled to the process piping flange, for connecting process to instruments.

With their sophisticated and compact design, VariAS-Blocks offer numerous advantages over traditional process measurement installations. They combine

AS-Schneider’s metal seated VariAS-Blocks are especially suitable for use under extreme conditions

30

primary isolation (process side) and secondary isolation (instrumentation side) valves in one single valve body – saving weight and space and simplifying the installation. Potential leakage points are also reduced to a minimum in order to increase safety. Measuring instruments like pressure gauges or transmitters are usually directly mounted on the VariAS-Blocks. This compact, space-saving mounting minimises the disturbing influence of vibrations, reduces installation and maintenance costs, and ensures accurate measurement result.

The VariAS-Blocks are now also available with a metal seated ball valve design.

This not only allows for reliable pressure measurements, but also protects people and the environment from dangerous and harmful process media. Even large temperature fluctuations, pressures up to 420 bar, high contamination levels, and aggressive process media are no problem for the metal seats. The new version is also fire safe tested and certified according to ISO 10497 and API 607.

With these features, the metal seated VariAS-Blocks are particularly suitable for use under extreme conditions. n Visit AS-Scheiner in Hall 3, booth F85 Badger Meter Badger Meter will be showcasing its range of control valves at Valve World. The company’s control valves are specifically

designed for controlling small to medium flow rates of liquid or vapour in pipe sizes from 1/4” to 2”. They cover a Cv range from 0.0000018 to 54 in different inner valve sizes.

Theoretically, there are Badger Meter’s control millions valves are available in a of possible wide variety of materials combinations of valves that can be configured to suit a wide variety of applications or specific requirements.

The choices range from process valves (standard bronze valves, flanged stainless steel, or other exotic material), to hygienic valves (barstock or cast, tube, or clamp ends), to special valves (three-way, angle, high-pressure, high-temperature, and cryogenic).

The valves can be made in most flange types and sizes, weld connections, female threads, or tube fittings. Although the standard material is stainless steel, many other materials are available for corrosive applications, including solid

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

EVENT PREVIEW titanium and Tantalum. The valves are available with a wide variety of inner valves, many individually made by hand, standard and special bonnets, conventional and low-emission seals, pneumatic, electric or manual actuation, along with many accessories to meet almost any application requirement. n Visit Badger Meter in Hall 5, booth M05 Bürkert Bürkert will showcase its new Ex product range for solenoid valves. All products in the range were developed and reviewed according to the newest regulations. The outcome is a modular coil and valve concept that fulfils all current requirements of the explosion protection standard EN 60079 and also offers additional customer benefits.

The combination of familiar Bürkert know-how, established electrical connection technology, and the current requirements of ATEX and IEC Ex were the challenges overcome by the new product range. The use of the new cable plug Type 2513 enables a versatile installation of the connection line. The cable plug with a moulded cable, certified after ATEX Cat. 3 GD EN 60079, withstands high pull-out forces and therefore offers a safe connection, with which a “fixed installation” all the way to the end device in the conduit or cable duct is not necessary.

The new explosion-proof junction box combines modern explosion protection with features that allow convenient installation with minimal

and Test-Tel tool on stand, highlighting advantageous benefits of how using these accessories in situ can save overall downtime and long-term investment.

Elfab invites all members and delegates to attend its process safety presentation to learn about the latest pressure relief technological advancements to date including burst detection and wireless technology. n Visit Elfab in Hall 5, booth D30 Elfab’s WirelessHART rupture disc burst detection system

Elfab Pressure relief safety expert Elfab will exhibit its latest showcase of products at Valve World 2016. Elfab is a primary provider of rupture discs, explosion panels, buckling pins, and associated detection systems. With over 80 years’ experience, Elfab specialises in providing high-quality pressure relief products and services to its global customer base on the fastest lead times in the industry.

Elfab’s technical specialists will be on the stand to share its expertise in relation to individual safety critical applications. Various products will be demonstrated, including the industry’s first WirelessHART rupture disc burst detection system, eliminating the need for re-wiring and saving 50% of the cost and 90% of the time required to install a conventional wired system.

Manufacturing technically advanced goods suitable for use in a wide variety of industries and applications, Elfab will advise on the most appropriate solution to fulfil application needs. Enhancing process safety while eliminating ongoing hazards, Elfab will be showcasing its System Loc+ Festo’s VZQA pinch valves can be actuated with low operating pressures

Bürkert’s explosion-proof junction box

cable requirements. The high-quality cast aluminium body with a resistant polyester resin coating withstands strong mechanical impact, a broad ambient temperature range from -40°C to 60°C and can be sealed by only one screw. n Visit Bürkert in Hall 5, booth H20

Festo German valve maker Festo will be exhibiting its new VZQA product series, which offers modularity, flexibility, durability, ease of cleaning, and straightforward servicing. The pinch valve will be launched in two versions, an N/O version for media pressures from 0 to 4 bar and an N/C version for media pressures from 0 to 6 bar. A tubular elastomer pinch valve sleeve opens or shuts off the flow by decreasing or increasing operating pressure without any additional actuators and with no risk of blockage.

The VZQA valves come with different connection caps, housing materials, and sealing components for a variety of configuration options. This makes them useful in optimising pneumatic delivery and metering systems, powder coating systems as well as suction and compressed air control units. The free passage minimises flow resistance, continuously preventing the valve becoming blocked or clogged.

The sealing cartridge can be changed in just a few simple steps and without special tools. The high-performance valves can be cleaned quickly and easily by machine thanks to their full passage and design with very little dead space.

Made from aluminium or stainless steel, the valves are suitable for the most challenging environments. Whether abrasive, corrosive, highly viscous or neutral influences, the VZQA can withstand very high stresses in daily operation thanks to its special sealing cartridge. n Visit Festo in Hall 5, booth 5K05 Goodwin International British engineering company Goodwin International, with a track record of supply of some 35 years, is a global brand for the

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 31

EVENT PREVIEW design, manufacture and supply of dual plate and axial flow check valves to all aspects of the hydrocarbon, energy and process industries. In the past 10 years, the company has enjoyed sales of over $750 million (€680m).

Goodwin is introducing to the valve user market its brand new range of axial isolation and axial control valves.

Founded on the same design and quality principles as its check valve products, the new isolation and control valve ranges have been developed to meet or exceed today’s stringent end-user specifications. Designed around the same platform to ensure as much similarity and compatibility across components without any compromise on performance, both designs employ several innovative features for some of which Goodwin has international patents lodged.

The valve features a three-piece split body design which allows simpler manufacturing processes to be adopted, reducing defect rates and difficult weld repairs whilst also permitting a higher level of access for non-destructive examination techniques. The body also permits the use of forged or cast base material for the pressure envelope components, which can be adapted according to the end use application. n Visit Goodwin International in Hall 4, booth B39 Högfors Högfors opened a new valve factory in 2009. By using the latest technologies, Högfors raised the production of butterfly valves to an entirely new level. The company’s factory is among the world’s most advanced, and it specialises in valve technologies used in the process industry and energy production. Högfors has been supplying valves for demanding

A Högfors valve in DN1400 size

32

power plant projects since the 1980s, carrying out maintenance and renovation tasks, as well as project deliveries for new plants. Exports make up for more than 80 % of the company’s turnover, with more than 50 destination countries.

Högfor’s core competence serves the energy industry. All the company’s products meet its own and customer specific requirements. Quality control covers the entire production from raw materials to final testing. Power plants and district heating valves are customised according to the detailed needs of Högfors’ customers. The exceptional quality and durability of Högfors’ valves is quaranteed throughout the products’ life cycle. n Visit Högfors in Hall 3, booth A09 Inox Mecc Inox Mecc is an Italian manufacturer of valve components for the oil and gas industry. For 50 years, the company has been producing stems from ½“ to 70“ and up to 8m in length. The company is able to also manufacture any other valve components according to customer specifications, such us bodies, closures, bonnets, discs, seats, and flanges up to maximum Ø of 900mm.

IM can manufacture its entire product range in any material, such as standard steels, Duplex, Super Duplex, titanium, nickel alloys, and Hastelloy. The complete traceability during production conforms to ISO and API certification. Additional services are available, including special coatings and surface treatments, welding, standard NDT, and 3.2 certifications.

Inox Mecc’s facility area is equipped with high-tech machinery for lathing, lapping, drilling, threading, milling, cutting, broaching, and welding. The company aims to offer the highest quality standards, from single items to full batches, from small to big dimensions, through an internal manufacturing process and qualified subsuppliers with the latest equipment and knowledge, relying on highly qualified, flexible, and skilled staff.

Inox Mecc

Schroeder will be exhibiting its new SmartLine recirculation valves

quality system is certified according to UNI- EN-ISO 9001 and API Q1. In 2016, the company expects to be certified with the EU Export Compliance License and Quality, Environmental and Safety Integrated Management System according to UNI EN ISO 9001; OHSAS 8001; UNI EN ISO 14001. n Visit Inox Mecc in Hall 5, booth K22 Schroeder Valves Schroeder Valves is a Germanybased global specialist in designing and manufacturing pump protection valves. For more than 60 years the company has been producing high quality valves for refineries and power plants, for the chemical industry and the offshore sector, and more recently for the production of renewable energies.

Schroeder Valves’ portfolio ranges from throttles and automatic recirculation valves to high-pressure control valves.

Each product is unique, designed specifically for the respective pump and system data of the customer.

Schroeder exclusively uses highquality materials, making its products also suitable for use under extreme conditions. This year Schroeder Valves expanded its portfolio by a serial version of its automatic recirculation valve. The range, named SmartLine, is available in five bypass flow-rate steps (five Cvvalue stages) for each frame size. All of them are low pressure valves, suitable for

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

EVENT PREVIEW to prevent serious injury should the chainwheel separate from the valve.

Attached to a valve stem, floorstand or actuator, Trumbull position indicators clearly show the position of the valve, so operators do not over-open or overclose and break the valve stem. The position indicators are constructed of non-corrosive, UV resistant and high strength Delrin plastic. They are available in three models of 57, 275, and 870 turns. n Visit Trumbull Industries in Hall 3, booth B39

Termovent’s valve range will be exhibited at Valve World Expo 2016

various media and for admissible average temperatures between -50°C and 200°C. With the SmartLine, Schroeder Valves meets its customers’ requirements, as they often not only demand pump protection valves for higher pressures or pressure levels respectively and adapted flow volumes, but also valves for applications which do not require an exact design for a tightly tolerated area of minimum quantity. At Valve World, Schroeder Valves will present the valves from the new series for the first time n Visit Schroeder Valves in Hall 5, booth J21 Termovent SC Serbia Since its founding in 1963, Termovent SC Serbia has focused on development, manufacture, and distribution of industrial valves. Termovent SC valves are installed and functioning reliably in more than 40 countries worldwide, in power plants, pipelines, refineries, and industrial plants.

All product components are manufactured in Termovent’s own manufacturing plant with highly developed infrastructure and a modern work environment. All casting components are made at the Termovent SC Steel Foundry in Backa Topola, Serbia. The company’s long-standing casting supplier, Steel Foundry, became part of the company in 2002.

Design, process planning, casting, machining, assembly, testing, surface treatment, logistic and quality management integrated into Termovent’s plants is crucial for ensuring the high quality of its products. Termovent’s ongoing investments into the latest machines and process technology is the key factor for continuously

Trumbull’s chainwheels are available in several materials

increasing productivity, ensuring accurate, efficient, and high quality production of valve components.

Quality assurance accompanies the complete production process. Final inspection tests, as well as functional testing, are performed for every single product. The unique identification number on each Termovent SC product provides full traceability through all processes during production and final inspection. n Visit Termovent in Hall 4, booth B38 Trumbull Trumbull Industries will be bringing its chainwheels and position indicators to Düsseldorf. Trumbull chainwheels are offered in ductile iron, aluminium, carbon steel, and stainless steel, which are ideal for corrosive environments.

Universal design allows the chainwheel to be clamped to handwheel or pinned directly to valve stem. Secondary safety restraint systems are available

Z-Tide Z-Tide UL listed pressure reducing valve in sizes 3”, 4”, 6”, and 8” is new in the valve market and suitable for firefighting systems. It is approved by Kuwait Fire Department and delivered more than 220 pieces to the Middle East area in 2016.

In addition, Z-Tide multi-function autocontrol valves have block-mounted pilots without external tubing that makes the valves easy to install and tamperproof.

Compact light cylinder design and straight flow path inside the body give the valves 20% more capacity than competitive products. The large flow can reduce malfunctions caused by impure water and effectively decrease turbulence. Pressure drop capability of Z-Tide valves is 6 to 1 ratio without cavitation, which is unique in the industry.

The company’s diaphragm-type water hammer arrester is another featured patented Z-Tide product. Unlike traditional piston-type water hammer arresters, Z-Tide’s arrester has an airbag with a ball pressing-type design, which absorbs the water hammer effect directly and quickly.

Less friction and function progresses enable a longer life for the arrester. n Visit Z-Tide in Hall 3, booth E43 z

Z-Tide’s new pressure reducing valve

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 33

METERS

A portable monitoring system using Flow Pulse

A finger on the pulse A non-intrusive flow measurement solution helps wastewater stations avoid costly shutdowns There are many situations where reliable flow monitoring is required. Beyond simply measuring flow rate, further monitoring may be needed from measuring the flow throughout a process network, identifying flow movement or valve failure, and initiating pig deployment to clean pipework to confirming the efficient operation of pumps.

The traditional solution is a magnetic flowmeter installation, but this can be time consuming, costly, and interrupt the process. A more suitable solution would be a non-invasive device, capable of being installed on the outside of the

Flow Pulse installed at Thames Water pump station

34

pipe. One such device is Pulsar Process Measurement’s Flow Pulse, a device that is non-invasive, can be retro-fitted to an existing pipe, will work over a wide range of pipe diameters, and requires no special positioning or alignment to work. Flow Pulse measures through a wide range of pipe materials, on both new and existing pipe installations Flow Pulse is a compact and costeffective non-invasive pipe flow monitor that delivers high repeatability and simple installation with no downtime – it simply clamps onto the outside of a pipe. It is suitable for monitoring

flow rates in fluid distribution systems, checking pump efficiency in process plants or sewage pumping stations, and has been proven in thousands of applications around the world.

The device is able to both interface with existing plant control infrastructure and also operate as a portable, handheld monitoring and troubleshooting unit.

The pipe material can be rigid plastic, stainless steel, mild steel, or cast iron, and even light corrosion on the pipe does not prevent Flow Pulse from reaching good results. Typically, flow rates from 0.3m/s through to 10m/s can be measured,

Monitoring flow close to a bend in Wales

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

METERS ranging from a slurry at the “thick” end down to particle sizes as small as 100 micron and concentrations as low as 200ppm (the equivalent of hard water).

Operating principle Flow Pulse uses a novel spread spectrum analysis technique never before used in flow monitoring. It introduces a new digital signal processing approach for exceptional repeatability. Ultrasound is fired through the pipe wall at 90° to the flow via a tangentially mounted high-output ceramic, then refracted at angles across the axis of the flow, and subsequently reflected from bubbles, particles, and vortices in all directions and at a wide range of frequencies.

The wide, refracted, ultrasonic beam maximises the ultrasound energy that could be captured from flowing particles.

These multiple reflections are received back into the unit via a second crystal.

The mass of data generated is analysed using Flow Pulse’s refracted spread spectrum analysis (RSSA) digital signal processing platform to derive flow information. RSSA analyses and integrates the received signals over a wide frequency range, then slices them for real-time analysis and flow rate calculation. Flow Pulse can provide a direct signal back to the SCADA system or telemetry, can provide a local display with the optional flow monitor wall mounted unit, or can be supplied as a compact portable flow monitor system with the Flow Pulse Handheld battery powered controller.

Water in Wales Many Flow Pulse applications have been developed around the wastewater industries. Flow Pulse has aided compliance and asset management throughout the Dwr Cyrmu Welsh Water’s (DWCC) region by monitoring flow rates within critical sewage pumping stations (SPS) under both normal and storm conditions, showing huge savings when compared with magnetic flowmeter installation costs. The estimated savings come to £1.5 million (€1.66m).

Measurement of flow within an SPS provides vital information for both management and regulators.

Total throughput can be monitored, but more importantly flow can be compared with other data from the SPS control system to determine the relative performance of the pumps so

maintenance can be planned and efficiencies maximised. Pumped volumes also warn of upstream or downstream emergencies, such as a blocked or burst main. In addition, important information can be provided to regulators such as the Environment Agency (UK) or Environmental Protection Agency (USA) to confirm that pumps were performing during extreme storm conditions.

DCWW identified the requirement for around 250 monitoring points across their network of SPS. That many magflow meters would have been prohibitively expensive to implement, taking into consideration the cost of the instruments, the tankering and logistics during the process interruption involved, and the direct cost of installation.

No disruption for Thames In a two-pump station, Thames Water Three sensors measuring the efficiency of three was interested in monitoring pump station pumps performance along with checking the individual condition and efficiency of involved, as just clamping a small sensor each pump. While much can be inferred to the outside of a pipe is enough to get a from derived flow calculations, direct flow reliable, repeatable flow measurement. z monitoring is much more informative about pump station operation. The usual way For more information: This article was written by Alistair MacKinnon, to achieve that would be by installing a director of sales and marketing at Pulsar Process magflow type meter, requiring groundwork Measurement. Visit: www.pulsar-pm.com including the building of a separate chamber adjacent to the existing pumping station.

Cost saving was of course important but, by using Flow Designed to reliably Pulse, Thames Water monitor flowrates of liquids did not affect station and slurries in pipes to flow, so there was no 1250mm dia and 20mm wall thickness. Non invasive. disruption to local Clamps onto the outside of traffic or neighbouring the pipe. DSP technology properties, and ensures reliability. no need to tanker ● Fixed or portable sewage away. versions The Flow Pulse ● Simple pipe strap fixing was installed with ● 4-20mA output/ Pulsar’s optional Modbus and relay alarm Flow Monitor wall mounted controller Contact us today for to power the unit and information to provide a local display of flow rate.

Flow Pulse is a leap forward in flow measurement and in ease of installation.

Malvern, Worcs WR14 1JJ, UK Tel: +44 (0) 1684 891 371 There is no need to info@pulsar-pm.com break into a pipe or to get any engineering

Flow Pulse Flow Monitor

www.pulsar-pm.com

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 35

METERS

Save your production A petrochemical company reduced the risk of lost production by using Coriolis flowmeters with meter verification Ethylene is used as a critical feedstock for many petrochemical products, including polyethylene, ethylene oxide, and polyvinyl chloride. Ethylene is typically transferred in mass flow units (lbs, kg, etc.) and it has a critical temperature of 9.5°C, which is lower than many fluids. Above the critical temperature of a fluid, no matter how high the pressure goes, the fluid does not pass from a gas to liquid phase. There is essentially no phase difference and the fluid acts as a supercritical fluid.

Supercritical fluids behave similarly to gas (fill all available space in a container), yet have much higher densities than typical gases, more similar to liquid densities. Another property of supercritical fluids just above the critical temperature is that with small changes in pressure and temperature, there can be large changes in density. As a result, ethylene can be very difficult to measure with traditional volumetric meters.

A large petrochemical company in the Gulf Coast was purchasing 9-12 million lbs/ year of ethylene as a critical feedstock for its process through a pipeline from an ethylene supplier. The supplier was using a 1” differential pressure meter (orifice) that had limited turndown in the application. The ethylene supply contract was written in such a way that when the ethylene usage went below a minimum value or the measurement fell below a specific dP, the supply would be shut off until more ethylene could be used.

While this was not typically an issue during production, during start-up the flow rates varied significantly and were occasionally low enough to trigger an interruption in supply. The risk of lost production was enough to cause the petrochemical company to seek out a new supplier and a different measurement technology for the custody transfer of ethylene. The company established certain criteria for the new measurement technology, including: 36

Ethylene skid with Micro Motion CMF050 Coriolis meter installed

1. Custody transfer accuracy – measurement that is accepted for gas and has accuracy that would be suitable for billing.

2. Wide rangeability – no loss of measurement during startup or production even under varying flow conditions.

3. Diagnostic capabilities – immediate notification to critical personnel if health of the meter is compromised.

4. Verification of performance – verify measurement accuracy in line on a monthly basis and pull meter out of the line during scheduled turnarounds to prevent loss of measurement or downtime due to proving.

Solution After evaluating multiple measurement technologies, the company partnered with a new ethylene supplier and both parties agreed to install a ½” Micro Motion Elite sensor. Coriolis meters measure mass flow directly, so pressure and temperature compensation due to fluid density changes is unnecessary. The American

Gas Association (AGA) Report Number 11 Measurement of Natural Gas by Coriolis Meter, written in 2003, further validated Coriolis meters for use in gas custody transfer applications. The incumbent dP technology specified a lab accuracy of around ±0.75%, whereas the Elite meter was able to perform at ±0.35%, representing over 50% improvement in measurement accuracy. In addition, the Elite meter has a much wider turndown than a traditional orifice measurement, virtually eliminating the low flow shutoff risk.

In order to monitor the health of the sensor after it was installed in the line, the petrochemical company chose to retrieve the Modbus status/ health information from the transmitter and bring it directly into its SCADA system. The health register would notify operators of any of the following errors: • EEPROM checksum failure • RAM diagnostic failure • Sensor failure • Temperature sensor failure • Input over-range • Frequency/pulse output saturated • Transmitter not configured

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

METERS • Real-time interrupt failure • Primary/secondary mA output saturated or fixed • Density over-range • Flowmeter zeroing failure • Zero value too low or too high • Transmitter electronics failure • Flowmeter zeroing in progress • Slug flow • Power reset occurred • Transmitter configuration changed • Transmitter initialisation/warming up Consequently, any of these errors would also send an e-mail or text to the appropriate technician(s). In addition to continuously monitoring these health registers, the ethylene supplier and enduser chose to order the Micro Motion sensor with Smart Meter Verification.

Meter verification A Coriolis mass flowmeter generally has one or two tubes (straight or bent) that are vibrated at their natural frequency by using a drive coil and magnet to move the tubes at a specific amplitude. When there is no fluid flowing through them, the inlet and the outlet of the tubes are moving at the same time. Sensing coils located on the inlet and outlet sections of the tubes oscillate and produce a sinusoidal electrical wave as the coil passes through a magnetic field. When there is flow through the tubes, because of the Coriolis effect, the gas causes the tube to twist.

The inlet of the tube and the outlet of the tube will no longer be moving at the same time. The time difference between the inlet and the outlet of the tube is proportional to the mass flow of the gas. This is true for compressible and non-compressible fluids.

Coriolis flowmeters are well known for their long-term stability. There is no timedependent shift in the calibration factor due to the lack of moving or wearing parts. However, if meters are misapplied to applications and are subject to erosion or corrosion or over-pressurisation of the tubes, the stiffness of the tubes can change and result in a change in the flow calibration factor (FCF) and consequently result in incorrect mass flow measurement.

Smart Meter Verification measures the stiffness of the tubes and compares that measurement to the stiffness of the tubes when they left the factory. Each meter with the Smart Meter Verification option is given a unique fingerprint or baseline of stiffness results prior to leaving the factory. That information is stored within the electronics of the sensor. Smart Meter Verification

Micro Motion CMF050 with Smart Meter Verification measuring ethylene

uses the stiffness of the flow tubes as a secondary variable to verify the validity of the FCF. The FCF is used to relate the measured time delay to the mass flow rate.

All of this is done without taking the meter out of line or losing measurement from the meter. There is no flow interruption and the entire verification can be completed in less than two minutes.

Results The petrochemical company and the ethylene supplier purchased and installed a Micro Motion Elite Model CMF050 ½” sensor equipped with Smart Meter Verification and began measuring the ethylene immediately. Due to concern over risk of lost production, the petrochemical company asked the supplier not to remove the sensor from the line except during plant turnarounds for calibration checks. They mutually decided to run Smart Meter Verification on a monthly basis to flag any potential change in the FCF. After running the sensor with no issues for two years, the petrochemical company had a plant turnaround. During this time, they removed the sensor from the line and sent it to a third-party lab to be proved. The result of the proving was that the sensor was with -0.06% of the prover, well within the specifications of the meter and the uncertainty of the prover.

Based on the consistent results from Smart Meter Verification and the lack of FCF shift when compared to a lab prover, the customer has decided to extend

its Smart Meter Verification interval to quarterly instead of monthly. The company has also decided to continue with the practice of only proving the meter during plant turnarounds unless they see an issue with Smart Meter Verification results.

The petrochemical company has also seen an improvement in its measurement performance versus the former measurement technique. Based on the spot prices for ethylene and their usage, the improved accuracy of the system provided payback of the meter in approximately four months, not including the cost savings of removing the meter for periodic proving.

Smart Meter Verification is a robust option for in-situ verification of a Coriolis flowmeter and can improve measurement confidence. With no moving parts, gas mass flow accuracies as good as ±0.35% of rate, no need for gas calibration (manufacturer dependent), and no flow conditioning needed, Coriolis meters make an excellent choice for many applications including those requiring custody transfer performance. z For more information:

This article was written by Tonya Wyatt, chemical and process gas industry marketing manager at Micro Motion, and Brian Reagan, area growth director at Rosemount Measurement.

Visit: www.emersonprocess.com

References

1. Allow Coriolis Meter Verification to Reduce Your Proving and Proof-Test Costs, Cunningham T., O’Banion T., 8th International Symposium of Fluid Flow Measurement, June 2012 2. Using Structural Integrity Meter Verification, Cunningham T., Stack C., Connor C., Micro Motion White Paper WP=00948, www. micromotion.com, 2007 3. An In Situ Verification Technology for Coriolis Flowmeters, Cunningham T., 7th International Symposium of Fluid Flow Measurement, August 2009

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 37

METERS

2017: The year of oil How the oil price crash affected the global flowmeter market

Flowmeters play a vitally important role in the oil and gas industry. Oil and gas are both measured many times as they move from the wellhead to a gas processing plant or refinery. The output of a gas processing plant includes gases such as nitrogen, oxygen, helium, and carbon dioxide, while major products output from a refinery includes petrol, jet fuel, and heating oil. All these products are measured on multiple occasions as they travel downstream to their ultimate point of use. The movement of hydrocarbons from wellhead to point of distribution can be referred to as the process stream.

Many flowmeter types play a significant role in flow measurement in refineries and gas processing plants. Coriolis, ultrasonic, vortex, and turbine meters measure both gas and liquid flow in in-plant measurement, and flowmeters are also used in blending operations for liquid hydrocarbons. Also, oil and gas are typically measured both as they enter and leave the processing plant.

Even though in-plant measurement is not usually custody transfer, highly accurate measurements are required.

Different flowmeter types are used at different points along the way.

Three streams Flow measurement during the process stream is often divided into the three main phases of upstream, midstream, and downstream. Petroleum fluid is drilled and separated into its components in the upstream phase, and sent to a gathering station. From the gathering station, oil and gas are sent to a refinery or gas processing plant, which makes for the midstream phase. After the oil or gas leaves the processing plant, it is sent downstream to its ultimate point of destination.

Upstream Oil and gas typically lie thousands of feet below the Earth’s surface. Most scientists agree that oil was formed from the fossil remains of plants and animals over a period of tens or even hundreds of millions of years. To reach this oil, most companies use an oil rig that has 38

a drill to penetrate the ground down to the location of the oil or gas. This drill is in many cases equipped with three sets of steel or diamond-tipped teeth. Such a drill can penetrate through thousands of feet of rocks per day. Once the drill reaches the oil and gas deposit, the process of bringing them to the surface can begin.

The oil well is prepared to bring up the petroleum fluid by lining the wellbore with casing. The wellbore is the vertical hole in the ground created by the drilling bit, while casing is a long metal tube inserted into the wellbore at the depth the drilling company believes that oil can be found.

Tubing is placed inside the wellbore to enable the petroleum liquids to come to the surface. Petroleum liquids are usually a combination of crude oil, gas, and water. They are typically brought to the surface due to pressure that is created in the well as a result of drilling fluids that are pumped into the well.

Once the petroleum liquid reaches the surface, it typically goes through a test separator to physically separate the oil, gas, and water. The purpose of a test separator is to separate the fluid into its constituent components for metering and analysing. A flowmeter measures each fluid as it leaves the separator. In many cases, the fluids then passes through a production separator, which separates them for processing purposes. After the production separator, the petroleum liquid may pass through a heater treater. The heater treater breaks oil-water emulsions so that the oil can be accepted by a pipeline or a transporting vehicle.

This could be a truck, railcar, or ship.

During the past 20 years, multiphase flowmeters have been developed that can replace the separators that are placed near the top of the well.

Instead of having to physically separate the components of petroleum liquids into their component parts for analysis, multiphase meters analyse the content and the flow of oil, water, and gas as it the leaves the well on a real-time basis. This enables operators to better analyse the contents of the reservoir, and to tell when a well is beginning to

decline. While multiphase technology is quite expensive, and is still in the development phase, multiphase meters are playing an increasingly important role in the upstream environment.

Midstream In the midstream segment, crude oil or natural gas is carried from the production field to a gas processing plant or to a refinery. Lease automatic custody transfer (LACT) units play a major role in the midstream phase. They receive petroleum liquids from the production separator or heater treater and measure and control the flow of crude oil onto trucks and into pipelines. LACT units measure and track the temperature, American Petroleum Institute (API) gravity, and base sediment and water (BS&W) of the crude oil. BS&W is measured to determine if oil contains too much water.

If it does, the custody transfer operation is either adjusted or brought to a halt.

A typical LACT unit contains multiple instruments and devices. These include a flowmeter, a motor and pump, an air eliminator, a sampler system, valves and sealings, and a control panel. An LACT unit is an integrated system of devices that measure and control the delivery of oil to pipelines and trucks. They are generally divided into pipeline LACTs, truck loading LACTs, and truck unloading LACTs. The flowmeter is one of the most important components of an LACT unit. Positive displacement (PD) meters have traditionally dominated the market for flowmeters on LACT units, but more recently, Coriolis meters are being specified in place of PD meters.

Coriolis meters are highly accurate, and do not place an obstruction in the flowstream. FMC Technologies is a dominant supplier of PD meters for LACT units, while Emerson Micro Motion, Endress+Hauser, and ABB are companies that are widely used for Coriolis meters.

Once oil or gas enters a pipeline or is carried by truck, rail, or ship, there are often a number of custody transfer points along the way. For natural gas, the amount of gas is measured as it enters the pipeline, and it may be measured

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

METERS at multiple points in transit. Natural gas is also measured as it enters a gas processing plant. The market for custody transfer of natural gas is dominated

by Elster, Emerson Daniel, and Sick.

The path of crude oil in the midstream segment is parallel to that of natural gas.

Crude oil is measured as it enters pipelines or is loaded onto rail cars or trucks. In some case, it is taken to storage locations, while in others the final destination will be a refinery. PD and turbine flowmeters are widely used in these measurements, though Coriolis flowmeters are beginning to have an impact as well. Crude oil is also measured as it enters a refinery.

Flowmeters also play an important role in leak detection in pipelines. Though there are multiple methods of leak detection, some not involving flowmeters, ultrasonic flowmeters are widely used for these applications. In some locations, companies lose oil not just from leaks but also by theft. Leak detection is extremely important, since companies may face stiff penalties if they are found to be responsible for pipeline leaks.

Downstream gas Once natural gas leaves a gas processing plant, it enters the downstream phase where it is typically again measured multiple times before reaching its point of use. Natural gas is measured as it leaves the processing plant and usually goes to a utility company in charge of gas distribution. Large pipelines, often from 20” to 42” in diameter, carry the natural gas, sometimes for hundreds or thousands of miles. The gas is measured each time it changes ownership.

Ultrasonic, turbine, and DP flowmeters are the most commonly used devices for these custody transfer measurements.

Once natural gas reaches its point of use, a local utility company delivers it to commercial and industrial buildings, and to individual homes. This is often called fiscal or utility measurement, although it is somewhat like custody transfer measurement. While much natural gas is transported downstream by pipeline, some is distributed in the form of compressed natural gas (CNG) or liquefied natural gas (LNG). Natural gas is transformed into LNG when it has to be transported over long distances and no pipelines are available.

LNG is typically transported by ship from the Middle East and Europe to Australia, India, China, Japan, and other Asian countries, many of which have relatively small amounts of oil and gas,

Rendering of a Graylon LACT unit

though some such as China are very rich in coal. Some Asian countries cannot receive natural gas by pipeline because they are islands. Flowmeters measure the natural gas as it is liquefied, and measure it again as it is regasified at the point of delivery and transferred into pipelines.

have traditionally dominated this market.

However, more recently Coriolis meters have begun displacing PD meters in fuel dispensing systems. In the US, the market is dominated by Liquid Controls (IDEX).

Downstream oil Crude oil is refined into a variety of petroleum products, including petrol, heating oil, diesel fuel, kerosene, and others. These products are carried by pipeline, barge, truck, tanker, and railcar to a storage area or to their point of use. This may involve multiple flow measurement points, although the volume of oil in storage tanks is sometimes determined by level measurement rather than by flowmeters.

Petroleum liquids are measured as they leave the refinery, and they then are often transported via pipeline to a terminal that contains storage tanks where they remain until they are ready for the next step in the distribution process.

Once refined products are ready for delivery, they are usually delivered by truck, rail, or pipeline. Trucks carry petrol to stations and heating oil to businesses and to individual homes, where flowmeters are used to measure the amount of oil delivered. This is measured by a fuel dispensing system that typically contains a flowmeter, a pump, a control system, and usually a printer so that the results of the transaction can be recorded. PD meters

From 2011 to 2014, oil prices stayed generally within the $80 to $100 per barrel range (€73-€91). Then oil prices began declining in August 2014, and continued the downward spiral until they bottomed out at just above $26 per barrel in February 2016. Many analysts attribute this decline to the additional supply brought online by the technology of hydraulic fracturing, or fracking. Most of this technology has been used in the US, although it is also now being employed in other countries.

In the past, the Organization of Petroleum Exporting Countries (OPEC) has controlled prices by cutting production to keep prices high. However, this time, in a November 2014 meeting, OPEC declined to act. As a result, prices continued their decline from that time until February 2016. Since then, oil prices have recovered to the range of $40 to $50 per barrel. On 28 September, 2016, the OPEC ministers met in Algiers, Algeria, and agreed to a framework of an oil price freeze. The details are to be worked out at its regular meeting on 30 November, 2016. This agreement

Impacts of oil price downturn

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 39

METERS products such as petrol was not affected by the price decline – if anything, it was enhanced. Refineries continued to be supplied with crude oil, whether it was domestic or imported, newly drilled, or from storage. Even though new supply was being reduced, there was plenty of supply available from storage or from imported oil to satisfy refinery needs.

After two years of the oil downturn, there are signs that oil and gas companies are beginning to spend money on new projects again. This is good news for anyone in the oil business, and it is good news for flowmeter companies that supply into the oil and gas process stream. Many signs point to a strong year for oil in 2017, a year that may get dubbed the Year of Oil. z An oil field with storage tanks near Houston, Texas. Photo © Flow Research

had the effect of stabilising prices.

The downturn in oil prices had a significant effect on flowmeter companies that supply into the upstream and midstream phases of the oil and gas industry. Many large exploration and

For more information:

production projects were cancelled or postponed, especially subsea projects.

However, companies selling into the downstream phase of the business were less affected. The main reason is that the demand for refined petroleum

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

T Ge ank rm St 16 an or -1 7 y ag No Ex e ve St m po an be d r2 B 8

40

01 6

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

Engineering safety TANKER LOADING

Working at height filling road and rail tankers is a risky business and selecting the right equipment is key to preventing falls A question asked often in the liquid handling business is “What is new?” In many cases it is an enquiry made in the hope that someone, somewhere, has devised a new and ingenious method for providing complete safety of operators on tanker tops, with an installed cost of practically zero.

So what has changed? Gravity remains the primary issue. Concrete comes a close second. However, tanker heights have increased over the last 20 years from an average of 3.2m to a maximum 4.2m. Legislation and awareness of the dangers has increased globally and now variations of the UK’s Work at Height Regulations 2005 (WAHR) are implemented in most countries around the world. With these four factors as a starting point, let us try to provide some guidance on how to develop a strategy for selecting the right equipment to make tanker top operations safer.

A number of companies have devised and written their own standards for tanker loading/unloading and access, which have been developed in close consultation with leading suppliers of bespoke fall prevention and tanker loading systems. This ensures that they have the widest range of options available to them, which can be applied appropriately to suit the varying conditions encountered at site. These standards are applied to every one of the company’s operations globally so that local engineers can apply investigative tools, allowing them to select a preapproved methodology for solving a particular problem. This also helps to eliminate the “homemade” solutions that can be found at some sites.

The homemade market is a serious problem. Very often these devices supplied are copies of established brands and have not been tested to the same rigours as the original. They possess no certification and lack the necessary insurance cover that manufacturers of this type of equipment need to carry.

Of course there are many end-user

Gravity remains the number one foe of those working at heights to fill tankers

companies who do not have their own standards and their engineers will seek to develop solutions locally, using the internet as the main route for investigation. Internet searches will produce a wide range of suppliers, eager to secure their equipment onto a project.

In many cases the suppliers are offering broadly similar equipment manufactured in a wide range of locations.

Supplier selection So how does the engineer differentiate between one supplier and the other? The easiest filter to apply at an early stage is whether the equipment being offered meets legislative criteria. For instance, in Europe, does it carry the necessary CE compliance certification? Finding out that it does not when the equipment is delivered is not a pleasant surprise.

Suppliers with the necessary compliance certification will be able to demonstrate readily that their equipment meets the minimum standards applicable in the region the equipment is deployed.

Another way of filtering suppliers would be to request references of past installations where similar access problems have been resolved with the proposed equipment. Again, post-delivery is not a good time to find out that you are now the owner of serial number 0001.

An important factor when developing a tanker access solution is to know what the equipment is going to be used for.

Here are some possible scenarios: • Tanker top loading with arms, hoses, or “chandeliers” of valves • Tanker unloading and venting • Application of venting or purge connection • Incoming or outgoing load sampling • Checking tanker security This then leads us to the third supplier filter.

If the project requires close interaction of fall prevention systems with tanker loading/unloading arms, then it is critical that the supplier understands this and can design both sets of equipment to work together. So often an engineer will buy the two items separately and then have endless issues with clashing

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 41

TANKER LOADING and inconvenient handling, which could so easily have been avoided.

What is new?

Going back to the “what is new?” issue, it rather depends on how much an operator has been keeping up-to-date.

In approximately 90% of current tanker access positions, the gap between the tanker and the platform is bridged by a drop-down ramp with little or no counterbalance to cushion the impact on the tanker top. In an age when tankers were around 3.2m high and the platforms were approximately the same, this worked adequately at best and variably at worst. But tankers have grown and the majority of these platforms have not. This leads to the access ramp resting against the tanker almost vertically and negating any notion of providing safe access.

If this sounds familiar, then the world of fall prevention in 2016 will not fail to astound. If, however, an operator already has a folding stair/gangway with a safety cage and wants to access a greater range on the tanker top, then there are a number of choices: • Track-mounted folding stairs allow the unit to traverse the face of the platform and extend the working range. This is almost unlimited depending on the platform.

• Large safety cages can extend to 12m and allow the tanker top to be accessed with a cage surrounding the working area.

These solutions are relatively low-cost

Tanker heights have increased over the last 20 years

and can be retrofitted to existing suitable platforms. However, there remains a variable that is one of the main causes of falls from height. They both rely on the quality and availability of the grating fitted to the tanker top. This can vary from tanker to tanker and in some cases the only option is to walk on the barrel surface, which can be wet and slippery.

The solution to this is a vertically elevating cage that has integral flooring.

This allows the operator to walk anywhere within the cage in complete safety and select the working area by lifting a number of hinged floor panels. The system is widely recognised as being the safest method of fall prevention for tanker top operations. The fact that it is vertically

elevating means that it can provide suitable protection as low as 3.2m and as high as 4.2m while having the parking position at 4.7m above the ground and well clear of passing traffic. Also, because it does not operate through an arc, the tanker centreline is always the same, which is important if using loading arms.

The system is ideally suited to users who want to access the full length of the tanker top and use loading arms to fill compartments of the tanker without having to move the vehicle.

The operator can easily walk the (appropriately designed) loading arm to any manhole on a flat and grippy walk surface in any weather without having to take care of obstructions.

On the rails

Vertically elevating floor cages provide ultimate safety in tanker loading

42

In the UK, the Health and Safety Executive document Prevention of falls from road tankers and tank containers enforcement standards makes the point that if the road tanker is equipped with elevating handrails, it should have these on all open sides. A number of tanker manufacturers have developed ingenious and easily operated systems that provide this feature. The document also points out that these are “unlikely” to be found on tank (IS/sea) containers, which represent an increasing percentage of bulk liquid transfer.

Whilst these measures are considered satisfactory, the document does say that they should only be used where fixed gantries are not “reasonably practicable”.

What does that mean? The general consensus is that it should be read from a FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

TANKER LOADING opportunity for all industries engaged in liquid transfer. No two customers have identical problems, there are always factors that make each application different. Fortunately, there is a wide range of solutions available to meet all budgets and applications. Choosing the application that meets an operation’s logistical and financial criteria is something that must be done with an expert supplier who can select and, if necessary, adapt their design to meet the application’s needs. Having a large stock of folding stairs “on the shelf” and ready to ship is not necessarily the solution to a problem that requires thought about the operator, the tankers, and the future.

So, what is new? Well, not a lot really.

There are many companies, driven by safety and operator welfare, who are pushing the industry to develop increasingly fool-proof and secure systems. Then there are companies

A road tanker being loaded

logistics or engineering viewpoint, rather than a lack of desire to spend money.

The UK’s Road Haulage Association document Prevention of falls from road tankers has some interesting and disturbing statistics. Between 2001 and 2005 in the UK, there were five deaths and ten serious injuries as a result of falls from tankers. Three of those deaths occurred because handrails were not properly raised and one was because there were only handrails on one side. One death was due to inadequate gantries and the other due to a handrail that gave way.

This brings into consideration the human element. The fall prevention system should be designed so that the operator’s task is enhanced, while doing away with shortcuts or avoidance of procedure. The inclusion of built-in safety cages goes a long way to guaranteeing this ethos. Assume a folding stair/ gangway is installed without an integral safety cage, and a fitted harness and safety wire mitigates falls while on the tanker top. The very real risk is that the operator, whether distracted or deliberate, will access the tanker without going through the labour-intensive action of putting on the harness. All the procedures, instructions, and threats of termination cannot guarantee that a “moment of madness” will not happen.

prevention. If the task is to fill or empty a number of compartments, then providing a single-position tanker access system, which means endless tanker shunting, often results in damage or accident or both. The operator will be frustrated and seek ways to shorten the task. If the range of tanker heights and shapes means that the existing platform is too low, then the operator will take shortcuts to lessen his efforts.

Fall prevention from tanker tops is a constantly evolving, feature-laden

who are in denial about the effects of gravity and concrete. The good news is the former are definitely outweighing the latter and long may that trend continue, for everyone’s sake. z

For more information:

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

Value So the age-old saying of “you get what you pay for” holds true in fall

Two elevating vertical cages

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 43

MAINTENANCE

A hot food line

Regular maintenance is essential for keeping food production lines using heat transfer fluid in operation Britain is a nation that loves its food. A staggering 1.5 million cans of Heinz baked beans are sold every day in the UK. Food production is a very important part of the country’s culture and economy, so when it comes to the processes responsible for food manufacturing, maintenance and regulation are of the upmost importance.

It is reported that there are around 4,000 companies operating thermal fluid systems in the UK and Ireland alone, and roughly one in five of these systems is used in the manufacture of food products.

Heat transfer fluid maintenance and analysis are essential operations that need to be conducted on a regular basis.

Unfortunately, some plant managers do not realise there is a problem until it is too late. A food manufacturer should source food grade fluids that are suitable for use in food processing. Food grade thermal fluids are highly refined mineral oils or speciality synthetic fluids designed specifically to be used in the processing of food. They are non-toxic, non-irritating, and have no odour to ensure consumer safety in the event of a leak or spillage.

This is an essential health and safety measure in the food processing industry.

Food grade fluids carry a HT-1 certificate issued by governing bodies such as NSF International and the US Food and Drug Association (FDA).Furthermore, food grade thermal fluid is a requirement for manufacturers that want to supply the top supermarkets and fast food chains in the UK, in compliance with the British Retail Consortium’s (BRC) global standards.

44

Any manufacturer who wants to sell into the UK, US, or European food market must abide by the correct standards.

With all these compliance and control standards in place, lack of commercial awareness is truly surprising. It is all too common to find food manufacturers who are keen to sell to the UK, European, and US markets, but are not entirely aware of what mandatory requirements exist for heat transfer fluids. The current framework of self-governance and external audits means there is a potential for companies to knowingly and unknowingly use thermal fluids not suitable for incidental contact with food. Assuming the leak is known, a company can simply choose to dispose of any food stuffs that come into contact with non-food grade oil, which is a highly wasteful process.

Baking a carbon cake A heat transfer fluid’s thermodynamic attributes vary according to operating conditions. At high temperatures, a thermal fluid will experience chemical degradation. The freezing point of thermal fluid must be lower than ambient conditions. Alternatively, the temperature of the thermal fluid needs to be kept above ambient temperature to keep it from freezing. For example, some products freeze at 12°C, which is higher than might be expected.

To keep heat transfer systems in tiptop shape, regular monitoring needs to be undertaken so as to establish the

condition of the fluid. The best way to get the most out of the fluid and the system is to test them thoroughly and regularly.

Regular representative fluid analysis and planned preventative maintenance ensure a healthy system, while reducing downtime and decreasing the amount of costly thermal fluid changes needed.

Problems in heat transfer systems occur when fluids are left for prolonged periods of time without correct supervision and preventative maintenance. Due to their chemical structure, thermal fluids degrade with age. Thermal cracking and oxidation cause molecules in the oil or fluid to break down, which produces solid carbon. If left alone, this carbon builds up and clogs pipes, making the entire system inefficient and more expensive to heat. At this stage, maintenance activities are relatively easy to conduct, as the carbon is still soft and can be flushed by using thermal cleaning products.

However, if the fluid is left to degrade further, food manufacturing companies run the risk of solid carbon becoming baked onto the inside of the heat transfer system, causing dangerous hot spots. Carbon is an excellent insulator and if hot spots form near the heating element of a system, there is a severe fire risk. Blocked pipes and hot spots eventually lead to breakdowns and costly repairs or replacements, not to mention the added expenses associated with flushing the system and refilling.

In addition, disposal of old fluids has to be carried out by qualified professionals in accordance with

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

MAINTENANCE environmental regulations. This can be extremely expensive if unplanned, hence the need to have a comprehensive maintenance contract in place.

Light at the end Light ends are another aspect of heat transfer fluid degradation that food manufacturers need to be aware of. The formation of short-chained hydrocarbons – or light ends – are denoted by a decrease in flash temperature, which represents a potential fire risk. This is due to light ends having lower boiling and ignition temperatures. Flash temperature represents the proportion of flammable decomposition products in a thermal oil.

The development of light ends needs to be monitored by routine laboratory testing of open and closed flash temperatures, as poorly maintained heat transfer systems pose a danger to staff and infrastructure.

By monitoring heat transfer fluids on a regular basis, it is possible to detect problems and to take preventative actions that minimise degradation and oxidation, keeping food-based heat transfer applications efficient and cost-effective.

By monitoring heat transfer fluids on a regular basis, preventative action can be taken to correct problems

Ideally, any plant using heat transfer fluids should create a robust maintenance plan that contains regular system analysis, fluid top-up, and careful flashpoint and fouling management. For plant managers in the food manufacturing industry, correct thermal fluid maintenance is a twopronged approach. Not only is a proactive maintenance plan crucial for looking after heat transfer applications, but ensuring that a food grade fluid is used is essential.

By using thermal fluids specifically designed for food manufacturing, operators have the peace of mind that should the unavoidable happen and there is a spill, entire batches of product will not be wasted. This way, we can all continue to enjoy our beans on toast in the morning. z For more information:

This article was written by Clive Jones, managing director at Global Heat Transfer.

Visit: www.globalheattransfer.co.uk

Adding value to butterfly valves

Making quality work World-Valve incorporates well over 50 years of knowhow and experience in developing and manufacturing butterfly valves for industrial applications.

World-Valve solutions are applied all over the world by leading companies in various segments of operation, including the power, oil & gas, marine, and (petro)chemical industries. Our ongoing efforts to optimize customer satisfaction have recently resulted in extending our product range by adding World-Valve Approved products. The World-Valve Approved Logo is your guarantee for uncompromising quality.

For more information visit our website: www.worldvalve.com

MEMBER OF THE AVK GROUP.

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 45

ADHESIVE HANDLING

Adhesive bonding technologies and applications

Applying adhesive manually

High-quality measuring, mixing, and dispensing equipment is essential for industries dealing with adhesives Virtually every product assembled requires bonding or sealing at some stage of the process. Manual and automated technologies for singlecomponent and two-component bonding and sealing are available for a broad array of applications.

Adhesive bonding is the process of joining two work pieces securely by using a liquid or semi-liquid material to create a long-lasting bond. In a high-volume manufacturing environment, adhesive is usually applied using specialised application equipment. Adhesives can be dispensed in a continuous bead or dots using automation equipment, or applied manually using a hose-fed handgun system.

valve, and finally equipping the system for automation or a manual process.

Typically selected because of their fastcuring nature, two-component materials require metering, mixing, and dispensing machines. Most suppliers provide both manually operated adhesive dispensing

Urethane foam for insulated piping

Single- and two-component bonding Single-component adhesives and sealants, such as silicone sealants, UV curable acrylates, urethanes, and epoxies are used widely in the assembly of component parts ranging from small surface-mounted electrical components to large appliances and automobiles. Single-component materials are chosen primarily for their ease of use, but they have a long curing process unless energy is used.

The keys to the successful application of these materials are understanding the chemistry, transferring the materials out of the shipping containers, creating repeatable flow rates or shot size, actuation and design of the dispense 46

machines with hand-held guns, as well as fully automated dispensing machines that are integrated into production lines or robots. The key success factors for applying reactive two-component adhesives or sealants are knowing the chemistry, accurately metering the individual components, and finally mixing the two components as they are applied to a part. Systems are available that dispense small amounts of adhesive up to very large-scale meter-mix machines custom built for robotic processes.

Graco MD2 dispense valve

Rovanco Piping Systems manufactures urethane pre-insulated piping systems made from materials such as steel, PVC, and stainless steel. The pipes transfer materials such as drinking water, wastewater, gas, and chemicals.

Rovanco wanted to improve heat control, obtain a more robust pump line, and have a more user-friendly interface.

A Gusmer H-2000 proportioner and Graco Reactor H-20/35 Pro with AR-C guns were being used for small pipe sections, while a Cannon RIM system was used for larger sections. Manufacturing of pipes required pour shots lasting up to three minutes, with 10 to 20 shots per day on small pipe sections.

The Graco HFR metering system produced very rigid foam with good cell structure. Rovanco Piping Systems felt the foam looked and acted like what they were accustomed to, with a

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

ADHESIVE HANDLING cream time of roughly 13 seconds, and liked the foam mix produced by the Graco EP pour gun. They also reported good uptime since they were spending much less time rebuilding the gun. This was eliminated with the new system.

Filter applications Filtration plays a critical role in several key applications and industries. In motor vehicle and internal combustion engine manufacturing, air, oil and fuel filters require adhesives to mould, bond, and seal end caps. In the production of high efficiency particulate air (HEPA) filters used in hospitals and clean rooms, adhesives are used to bond filter elements to frames. In liquid purification applications, the spiral-wound and hollow-fibre membrane filters that separate wastewaters and purify blood supplies are potted using adhesives for applications such as industrial water purification, residential water purification, and medical blood purification.

Regardless of the application, filter manufacturers are faced with challenges when working with adhesives. First, plural component materials bring added complexity to the production process, as achieving ratio accuracy and repeatability are crucial to the material curing properly. If off-ratio conditions occur and go undetected during

Graco HFR metering system

Automated adhesive dispensing in filter manufacture

production cycles, the cost to scrap product and rework can be significant.

Second, filter manufacturers often produce multiple sizes or configurations that require different volumes of adhesive material. They need dispensing equipment that allows for quick, simple calibration and changeover between pre-programmed shot volumes to control labour costs and maintain quality control. Inaccurate shot volumes lead to manual rework to trim excess adhesive.

The third major challenge is the difficulty posed by the multitude of variables in process control and monitoring.

Many existing dispensing systems lack the capability to monitor the process and capture data, denying critical insight to managers and operators.

Finally, because some materials used in these applications are abrasive, processing equipment must be able to withstand

Many existing dispensing systems lack the capability to monitor the process and capture data the wear or risk premature failure and high repair costs.

An increase in demand for topquality filtration products has driven the evolution of metering, mixing, and dispensing equipment for plural component adhesives. For the twocomponent polyurethanes and epoxies used most frequently in modern filtration manufacturing, the consistent, repeatable, on-ratio mixing of these materials is crucial for success. By delivering advanced metering, mixing, and dispensing of these materials to filter manufacturing processes, modern equipment reduces the costly waste and time-consuming rework that occur when materials fail to cure. Additionally, this equipment – such as the Graco HFR metering system and the Graco PR70 Series of metering, mixing, and dispensing systems – ensures consistent success, low costs, and improved uptime and throughput for filtration manufacturers. z

For more information:

This article was written by Greg Van Gansen, product marketing specialist AFD at Graco. Visit: www.graco.com

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 47

EVENTS

Fluid Handling International will be distributed at the following events 2-3 November 2016

WWEM 2016

7-10 November 2016

ADIPEC

16 - 17 November 2016

Telford, UK

Abu Dhabi, UAE

Tank Storage Germany

29 November-1 December 2016

Valve World Expo

28-30 March 2017

StocExpo 2017

26-27 April 2017

StocExpo Middle East Africa

11-14 September 2017

Hamburg, Germany

Dusseldorf, Germany

Rotterdam, The Netherlands

Dubai, UAE

46th Turbomachinery & 33rd Pump Symposia (TPS)

Houston, USA

Don’t miss your chance to appear in the January/February 2017 issue of Fluid Handling International For editorial suggestions contact: Ilari Kauppila, ilari@woodcotemedia.com, +44 (0) 208 687 4146 For advertising information and prices contact: Russell Priestley, russell@fluidhandlingmag.com, +44 (0) 208 648 7092 Next issue features include: Industry feature: Oil & gas Fluid focus: Transfer systems, actuators Regional feature: Middle East & Asia Regular features: Pumps, valves, meters

Advertising deadline: 20 January, 2016 48

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016

PAGE HEADER

A New Series of Studies from Flow Research

The World Market for Ultrasonic Flowmeters, 5th Edition

CORE STUDY The World Market for Ultrasonic Flowmeters MODULE A

The World Market for Inline Ultrasonic Flowmeters

MODULE B

The World Market for Clamp�on and Insertion Ultrasonic Flowmeters

Special focus on: Custody transfer applications Multipath flowmeters for liquid and gas Clamp-on and insertion data independently analyzed Growth factors for oil & gas and other process markets Order the entire set and receive a major discount, plus additional benefits!

For more information, contact:

Flow Research, Inc. 27 Water Street, Wakefield, MA 01880 USA (781) 245-3200; Fax: (781) 224-7552

We create change in flow

www.flowresearch.com www.flowultrasonic.com info@flowresearch.com

FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016 49

PAGE HEADER

Breathe, it’s a DiP! Direct in-line, Innovative and Performant sewer pumping

www.side-industrie.com 50

www.dipsysteme.com FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2016