HELPING TO KEEP YOUR BUSINESS FLOWING
JULY/AUGUST 2017
Issue 4 Volume 5
Measuring natural gas flow
As the industry grows, what are the options for gas flowmeters?
Cryogenic applications
Specifying top entry buttweld triple offset valve design in LNG
Rock Solid Pumps Huskyâ„¢ - Durability when you need it most. Long Life and Low Overall Cost of Ownership High Flow Rates for Increased Productivity Fast and Easy Maintenance
DISCOVER ALL ADVANTAGES
WWW.GRACO.COM/HUSKY
COMMENT & CONTENTS
Contents July/August 2017 ISSUE 4 • VOLUME 5
Woodcote Media Ltd Marshall House 124 Middleton Road, Morden, Surrey SM4 6RW, UK www.fluidhandlingmag.com MANAGING DIRECTOR Peter Patterson Tel: +44(0)20 8648 7082 peter@woodcotemedia.com EDITOR Daryl Worthington Tel: +44 (0)20 8687 4146 daryl@woodcotemedia.com DEPUTY EDITOR Liz Gyekye Tel: +44 (0)20 8687 4183 liz@woodcotemedia.com ADVERTISING SALES MANAGER Fraser Owen Tel: +44 (0)20 8648 7092 fraser@fluidhandlingmag.com PRODUCTION Alison Balmer Tel: +44 (0)1673 876143 alisonbalmer@btconnect.com
2
Latest news
25
11
Options for measuring natural gas flow The use and measurement of natural gas is growing as environmental concerns increase
14
Gas flow measurement as a cash register The impact of flow measurement on business performance and profitability
27 Getting it right with AODD pumps Air-operated double diaphragm pumps are reliable and cost-effective, but only if they’re configured correctly
16
The case for top-entry in cryogenic LNG Specifying top entry buttweld triple offset valve design in LNG cryogenic applications
18
Gland packing vs. mechanical seals When it comes to choosing between gland packing or mechanical seals, Aesseal says it’s important to look at the long rather than the short-term costs
29
Is peristaltic the answer? When it comes to fluids that difficult to pump, peristaltic pumping could be the answer
A seal for life An easy-to-install, reliable above ground fill point solution for a new build filling station
31
What will the pump of the future look like? How digitalisation, software and simplified analysis are revolutionising pump design and use
22
23 Analyse this (fluid flow) Through effective data analysis, both a university and an LNG plant have seen huge benefits
Interview: trends and challenges in automation and instrumentation A Q & A with Ryan Spooner, Automation and Instrumentation Engineering manager at Singer Valve
HELPING TO KEEP YOUR BUSINESS FLOWING
Issue 4 Volume 5
JULY/AUGUST 2017
Measuring natural gas flow
As the industry grows, what are the options for gas flowmeters?
Cryogenic applications
Specifying top entry buttweld triple offset valve design in LNG
Don’t miss out on future editions. Head to www.fluidhandlingmag.com to subscribe to Fluid Handling International, and read a free copy online
Gas storage tanks. ©leungchopan. Picture from bigstockphoto.com
Comment Dear reader,
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.
In his article on page 12 of this edition of Fluid Handling International, Jesse Yoder from Flow Research notes the growing importance of natural gas, a fuel source increasingly seen as a viable, more environmentally-friendly alternative to oil and coal. Environmentalists continue to debate whether natural gas is really the way forward for reducing the world’s emission problems, in particular questioning the environmental impact of some of the more extreme methods of its extraction, but it is undeniable that gas handling is a growing industry, one which presents unique challenges, and pioneering solutions. As well as Yoder’s piece, articles from experts at Emerson and Honeywell Process Solutions discuss technical developments in the gas sector, and how these developments are bringing financial, safety and efficiency benefits. Gas also appears in our analysis feature from Applied Flow Technology, which includes a case study on how an LNG plant used fluid dynamic simulation tools to validate an improvement in flow rate, and in an article from Verder on peristaltic pumps which presents a case study on anaerobic digestion. Gas may be the industry focus of this issue, but a key theme running throughout is how technical solutions can provide reliability and performance improvements, and dramatic cost savings across a range of fluid handling industries. Aesseal describe the long-term savings that can be gained through a switch to mechanical seals, while an interview with Singer Valves’ Ryan Spooner gives a run-down of developments in the world of automation and instrumentation. If there are any topics you’d like to see covered in future issues of Fluid Handling, or any industries or innovations you feel we need to pay attention to, please feel free to contact me at daryl@woodcotemedia.com.
Best wishes,
Daryl ISSN 2399-5602 1
PUMP NEWS
Atlas Copco adds ‘plug and play’ to its pump range US-based Atlas Copco Portable Energy has added to its medium and large submersible dewatering pumps with the launch of the WEDA+ plug and play range. Five models are in the WEDA+ range: the WEDA 50, with normal and high head variants, and the WEDA 60+ available in normal head, high head and super high head configuration. According to Atlas Copco, the super
high head WEDA 60+ is 15% smaller and 20% lighter than other pumps in its class. The new range of pumps offer flow rate capabilities of 1020 to 2425 l/min (61 to146 m3/h) and a maximum head of up to 69 metres. To prevent the risk of the impeller rotating in the wrong direction, all WEDA+ pumps have rotational control and phase failure protection. All models
are constructed with an aluminium alloy that provides high corrosion resistance in tough environments. “The new WEDA+ pumps are easy-to-move and install in a wide range of dewatering applications,” explained Wim Moors, vice-president Pumps, Atlas Copco Portable Energy. “We have taken our portable and powerful electric submersible offering to the next level by focussing
KSB launches a compact, high-pressure pump for horizontal installation KSB Aktiengesellschaft has launched a new compact high-pressure pump for horizontal installation in plant engineering applications. H(S)I is the latest addition to KSB’s compact high-pressure Movitec pumps range. Unusually for a compact high-pressure pump, the suction nozzle and discharge nozzle are arranged at a 90-degree angle more typical for process centrifugal pumps. The discharge nozzle can be arranged on the left, on the right, or at the bottom, a configuration which offers OEMs and plant engineering contractors more options for using these versatile, highly efficient pumps. According to KSB, the new pumps are ideally suited to applications such as water distribution, water treatment, cooling water supply, boiler feed and pressure boosting.
All wetted parts are made of ‘high-grade’ stainless steel. Like other members of the Movitec series, H(S)I pumps are characterised by ‘hydraulically optimised’ stage casings and impellers, which KSB claims makes them more economical and also reduces energy costs. To enable operators to select the most appropriate mechanical seal for a specific application, the seals are available in a range of material combinations and are easy to replace. H(S)I series pumps are available in five sizes with different numbers of stages. The maximum flow rate is 26 m3/h and the maximum discharge head is 195 metres. The fluid temperature lies between -20°C and +140˚C. Ultra premium efficiency IE5 motors can be supplied on request. z
Fully equipped Movitec H(S)I with KSB SuPremE IE5 motor, PumpDrive 2 variable speed system and PumpMeter monitoring unit. (© KSB Aktiengesellschaft, Frankenthal, Germany)
2
on efficiency and new features that will simplify the customer experience and enhance their productivity.” For practicality, the WEDA+ pumps have a modular construction allowing easy simple separation of the principal components, while all stainless-steel fastenings are the same size, meaning one tool can be used to change all seals, impellers and other parts. z
Verder launches Vantage 5000
Verderflex, a member of Verder Group, has launched a next generation peristaltic pump with touch screen technology and an intuitive operating system. The Verderflex Vantage 5000 is designed to offer precision dosing through an extremely user-friendly operations menu structure, and includes colour-coded on-screen status alerts and alarm indicators. A gentle, low shear pumping action makes the Vantage 5000 well suited to pumping fragile biotech cultures and particle size sensitive water industry flocculants. It is able to pump off-gassing liquids including hyperchlorites, eliminating vapour locking dosing failures without the need for additional degassing valves and other ancillary equipment. Vantage 5000 has enough internal memory to store up to 30 dosing and batching programs, while also allowing users to back up job files. z
Watson-Marlow positive displacement pump achieves rare aseptic certification
Watson-Marlow Fluid Technology Group’s (WMFTG) MasoSine Certa pump has become only the second pump on the market to achieve EHEDG Type EL Class I Aseptic certification, meaning it meets the demands for aseptic applications specified by the certificate. For users of the Certa pump, benefits of the certification include the fact the pump is self-draining, has a reduced CIP cycle time and requires lower volumes of cleaning agents. WMFTG has also added four new models to the Certa range, covering flow rates as high as up to 99,000 litres per hour and as low as 100 l/h. z FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
PUMP NEWS
Framo signs pumping system contract with Höegh LNG Framo has signed a contract agreeing to supply Höegh LNG with a pumping system for its new Floating Storage Regasification Unit (FSRU). The contract is for one unit, but includes the option for three more units which are currently being built at Samsung Heavy Industries in South Korea. FSRU is a floating processing and terminal facility used when it is not profitable or practical to develop onshore terminals. By using an on-board regasification unit, the liquid gas handled by the LNG tanker is converted to gas prior to being brought ashore. This is only possible by heating the gas, and this is only possible by pumping large amounts of seawater. Framo is set to install four pumps into each of the vessels which are due to be delivered over the period 2019 to 2021. “Global demand for energy is on the rise, but in many areas the necessary infrastructure is not in place. FSRU is a highly versatile alternative as a vessel can be moored at any quay and operate as a terminal. Furthermore, the investment costs are significantly lower than for onshore developments.” says Thorbjørn Vågenes, Director, Oil & Gas Pumping Systems at Framo. The system Framo will deliver to Höegh LNG is built around technology which has been extensively tried and tested in offshore operations. A similar solution was delivered to Shell’s floating LNG facility, Prelude FLNG. In a statement, Framo says the pump systems have “improved operating reliability, are lighter, and have fewer components to maintain compared with the conventional pumps most commonly used on board FSRU vessels.” The company also claims that the Framo system will eliminate the need for a separate pump on vessels where space is often limited. “We are using recognised and well-proven Framo technology in a new market where there has been a significant rise in demand the past few years,” says Vågenes. z
Award Winning Pump! High Pressure Low Volume Dosing
The Ultimate in Secondary Containment Reliable dosing of off-gassing liquids Gently meters shear sensitive products Excellent for pumping abrasive, very viscous or high density fluids Robust industrial design
AxFlow launches new twin-screw rotary positive displacement pump Pump specialist AxFlow has added a new rotary positive displacement pump to its portfolio, the ‘twin-screw’ Waukesha Universal TS. The new pump uses Waukesha Alloy 88 non-galling material twin screws to pump various media containing large particulates, in turn lowering damage to the pump and reducing the need for maintenance. According to a statement from AxFlow, the new pump also offers a high suction capability and wide range of operating speeds, meaning that only one pump is required to transfer product and undertake CIP. By reducing the number of pumps, valves and control instrumentation required, the Waukesha is designed to contribute towards reduced costs, and facilitate simpler, more compact systems. The rotating geometry of the twin screws creates a pulse free flow, making the pump suitable for a range of applications such as feeding homogenisers. The Universal TS is available in four models each with three screw pitch options, and delivers flows of up to 4,618lt/min and has a pressure range up to 25bar. z FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
Verderflex Dura 5 and 7 Series
info@verderflex.com - www.verderflex.com
The Green Peristaltic Pump
3
VALVE NEWS
Arca Flow Controls provides anti-surge valves for natural gas pipelines in Mexico Arca Flow Controls, the US subsidiary of German based Arca Regler GmbH Germany, has delivered five anti-surge valves to Mexico. The valves have been designed for use in several compressor lines that are scheduled to go online in winter 2017 or the beginning of 2018. The anti-surge globe-type control valves come from the Ecotrol modular parts system, and will be installed to prevent the compressors from pumping during stressful situations in the plant. In addition, they prevent airflow disruption at the compressor blades in order to prevent damage to the compressor. Each of the compressor lines consists of one single-screw
compressor and are driven by a gas turbine. Two lines will be installed in a pipeline station in La Laguna in the state of Coahuila. The other three lines will be set aside for a pipeline compressor station in Villa de Reyes in the state of San Luis Potosi. When operational, the pipelines will deliver natural gas to CFE (Comisión Federal de Electricidad) power stations as well as industry plants. The compressor stations output serves a pipeline of about 1,500 kilometres length that transports the natural gas from the North into the country’s inland. The Ecotrol modular parts system undergoes continuous development, with the goal of being able to satisfy the
Weir Flow Control announces new safety valve for steam boiler applications Weir Flow Control France has announced a new addition to its Sarasin-RSBD range of safety valves, the new Starflow V design for steam boiler applications. The Starflow V has been designed to complement Weir’s existing Starflow P and Starsteam options. According to the company, the new product will allow boiler manufacturers and plant operators to deal with a single supplier for multiple sizes and pressure conditions ranging from 1” to 8” (1 bar to 370 bar). Andrew Clarke, product marketing manager for Pressure Relief Valves, commented: “Quality assurance and lifetime maintenance costs are vital issues for the power generation customers. Safety Valves are crucial to optimal operation and performance of plants, so we have invested in the Sarasin-RSBD ASME 1 range for customers who are focused on that essential performance, longevity, and low operational costs without compromising on engineering standards. The result is a safe and versatile valve portfolio which makes life easier for customers.” z
4
Anti-surge Ventile Arca Comp
growing demands of the compressor manufacturers market. Arca claims that high flow rate, low noise level, a
fast reaction time and high control accuracy are some of the benefits offered by the modular parts system. z
Blacoh releases ‘world’s first’ combination pulsation dampener and back pressure valve Blacoh Fluid Control has announced the release of the ‘world’s first’ combination pulsation dampener and back pressure valve, which it has named the Hybrid Valve. The new valve is intended to combine the steady flow control of a pulsation dampener and the regulation of a back pressure valve to deliver the performance and functionality of both in a single piece of equipment. Blacoh president Andrew Yeghnazar said: “Blacoh Industries as an organisation has explored many new ideas to solve existing problems in the industry as well as fuel growth for our organisation and those we serve. As a result, we are pleased to launch another new and innovative product to improve pumping systems and reduce costs.” The new Hybrid Valve has been designed to maximise efficiency and flow. Placing a back pressure valve in series with a pulsation dampeners improves flow significantly in a metering pump system. However, Blacoh claims that its own performance tests show these combinations can’t match the performance of the single construction Hybrid Valve. When installing pulsation dampeners and back pressure valves in any pumping system, location and proximity are key. A back pressure valve installed in series with a dampener can negate the dampening effect if the valve is opening and closing before the dampener is able to capture a full pulse. This quick-opening effect can also create too much gain within the back pressure valve resulting in inefficiency and chatter. “By combining the dampener and back pressure valve into a single harmonious unit,” said Yeghnazar, “we’ve eliminated the most common issues with installation for a more efficient, simplified system.” z FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
VALVE NEWS
Petrobras looks to the sky for deep well safety Brazilian company Petrobras is applying knowledge and experience from the aeronautic industry to boost safety standards in undersea oil and gas wells. At the recent Offshore Technology Conference in Houston, Texas, Petrobras presented the gains made in improving submarine safety through its collaboration with Brazilian Aerospace company Embraer. Among the innovations that have been developed is the review and improvement of the SPM-type valve design, made by a BOP (Blow-Out Preventer) manufacturer. The new valve, which is already available on the market, leads to increased reliability, ensuring fewer BOP failures, increasing operating safety and reducing the likelihood of project delays.
Other project results include improvements in safety index calculations (likelihood of completing the well phase without a BOP failure) and system reliability in drilling and completion activities; identifying the most critical component to increase BOP system reliability, and pinpointing opportunities and conceptual design developments for a new regulating valve with a focus on reliability. At the conference, Petrobras also presented new initiatives related to subsurface safety valves to guest offshore operators. These initiatives take advantage of the lessons learnt in the project with Embraer to work towards increasing the critical system reliability and safety in the construction and operation of submarine wells. z
AR Controls acquires well-known valve manufacturer South African valve and actuator technology manufacturer and supplier AR Controls of Vanderbijlpark has announced that it has acquired IncoValve and Controls. Under the terms of the buy, IncoValve and Controls will now be established as a leading producer for a range of industries. IncoValve and Controls has worked closely with AR Controls to combine the latest design and manufacturing technologies with decades of field experience, said AR
The right pump for every application
Positive Displacement Pumps by NETZSCH For each application there is an optimum pump principle: that is why we offer you as a leading manufacturer of three different pump technologies the right kind of pump for your individual application.
Controls director Julien van Niekerk. He added: “The philosophy behind the acquisition is to offer the industry highly-engineered premium products at affordable prices. “AR Controls, already wellestablished in the marketplace, will use its global leverage to position IncoValve and Controls on an international platform. Initially we will expand into the African market and thereafter into South America, North America, Europe and Australia.” z
Velan unveils new cast metal-seated ball valve At the Valve World Expo in Houston, Texas, Canadian company Velan unveiled its Securaseal R-series cast metal-seated ball valve. Incorporating Velan’s severe service technology, the R-series valves are designed to be a package suitable for most processes with fluid slurries and high temperatures. Speaking at the expo in Houston, Yves Ludec, Velan’s CEO, said: “Velan has a great history of innovation in
metal-seated ball valves, but a lot of that innovation has happened on a project-to-project basis. The R-series is the result of an extensive R&D program built to optimize Velan’s technology into a product that addresses the most common requirements—both from an application and commercial point of view. We believe the result is a platform that underpins the best metal-seated ball valve product line in the market.” z
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
NOTOS® multi screw pump, NEMO® progressing cavity pump and TORNADO® T2 rotary lobe pump
NETZSCH Pumpen & Systeme GmbH Tel.: +49 8638 63-0 info.nps@netzsch.com www.netzsch.com 5
FLOWMETER NEWS
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 6
www.flowresearch.com www.flowultrasonic.com info@flowresearch.com FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
FLOWMETER NEWS
Badger Meter announces new mass flowmeter Badger Meter has announced the addition of a new product to its portfolio, the RCT1000 Coriolis mass flowmeter. According to a statement from the company, the RCT1000 is ‘especially suited’ to the precise measurement of high viscosity fluids, aggressive media and contaminated fluids, as well as high density gases. Badger Meter states that these measurements can be obtained while maintaining a wide turndown ratio. Possible applications for the new mass flowmeters include filling or dosing oils, solvents and chemicals, as well as measuring adhesives or binding materials, coatings
and hardeners, dyes, vitamins and other additives. A lack of internal moving parts means the RCT1000 experiences little to no mechanical wear, lengthening its operational life expectancy. Boasting flexible integration options, the new mass flowmeters are capable of controlling equipment such as valves and pumps with PID and batch control signals. The transmitter includes a userlock feature which prevents accidental activation, while a local LCD display has optical buttons which allow the operator to navigate the display without opening the enclosure. z
Hydrotechnik UK unveils £100,000+ flow test rig
Hydrotechnik have unveiled a significant extension to their calibration department, a £100,000+ flow test rig enabling them to provide full in house flowmeter recalibrations traceable to National Standards. The new rig runs on oil, a major advantage for its hydraulic, lube and diesel use customers. The oil’s viscosity is adjusted from 15 to 100cst with 32cst being the norm. A 5 point calibration is standard although 10 or more points throughout the measuring range can be performed on request. The rig has a flow range of 0.05L/min up to 700L/min and has 2 master flow meters giving a maximum uncertainty of +/-0.5% Hydrotechnik have created a dedicated inhouse laboratory room which caters for Flow, Pressure, Temperature and Oil Particulate sensors as well as instrumentation calibrations, recalibrations and repairs. Pressure sensor calibration is from 0 – 1,200 Bar and Temperature from -50 to 200°C, all traceable to UKAS standards. z
Hydraulic Test Facility for your fluid & process equipment Pumps, turbines, valves, pressure safety valves, specific components or systems A high capacity, independent laboratory for the qualification of your products: P P P
P
4 500 m² of test facilities Various test fluid (water, gas, oil, multi-phase fluid...) High capacities (flowrate up to 36 000 m³/h, several closed loop, pumping station, high temperature, test bench, air test bench up to 12 kg/s @ 40 bar and 3 kg/s @ 180 bar….) 4,5 MW electric power available
1705-002 ©Cetim
ISO 17025 accreditation: Cofrac accredited laboratory n°1-0037 for pumps, valves and PSVs
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
Fabienne Picot Tel.: + 33(0)3 44 67 36 82 sqr @ cetim.fr
7
OTHER NEWS
Bank of Scotland reports cautious optimism in oil and gas industry
A new report from the Bank of Scotland paints a picture of cautious optimism for the oil and gas industry, with signs that many companies are ‘gearing up’ for growth. Key findings of the new report include the revelation that more than half of oil and gas firms are planning for growth, and that there are signs job cuts are starting to slow. The sixth annual Bank of Scotland Oil and Gas Report gathers views from across the industry and its supply chain. It sets out to analyse the state of the sector, and the challenges it is facing. As well as finding that business confidence had grown in the last year, the report also picked up on a dramatic swing in the net balance of firms feeling optimistic, from just 2% in 2016 to 39% in 2017. Even though oil prices remain low, 58% of companies are still planning for growth. Those 58% of firms said they expect, on average, growth of 26% of their current annual turnover in the next twelve months, up from the 49% who expected an average of 17% growth in the 2016 survey. Job cuts in the industry are set to start slowing. The number of firms expecting to make cuts within the next year is down from a third to a fifth. More than half of companies said they expect to increase their overall headcount within the next year. z
8
Robot leak detection could be a revolution for water and gas Researchers at MIT (Massachusetts Institute of Technology) have developed a new leak detection system, one which uses a robot to inspect pipes from the inside to find leaks before they have time to become catastrophic. The new leak detection system can inspect gas and water pipes. Significantly, it works “no matter what the pipe is made of”. Many other leak detection systems, on the other hand, don’t work well in systems that use wood, clay or plastic pipes – materials used in the majority of pipes in the developing world, according to an MIT statement. MIT professor of mechanical engineering Kamal Youcef-Toumi and graduate student You Wu have been developing and testing the new system for nine years. This summer, further tests will be carried out on the 12” concrete water-distribution pipes under the city of Monterrey, Mexico. In September, Youcef-Toumi, Wu, and two colleagues will describe the system in detail at the IEEE/ RSJ International Conference on Intelligent Robots and Systems (IROS) in September. PipeGuard, the MIT team behind the project,
now intends to commercialise the robotic detection system to help alleviate the huge amounts of water lost each year due to leaks. With sponsorship from King Fahd University, the system has been tested in Saudi Arabia, where some 33% of drinking water produced at the desalination plants is lost through leakage. The tests, in pipes with many bends, T-joints, and connections, involved creating an artificial leak for the robot to find. The robot did remarkably well, distinguishing the characteristics of the leak from false alarms caused by pressure variations or changes in pipe size, roughness, or orientation. “We put the robot in from one joint, and took it out from the other. We tried it 14 times over three days, and it completed the inspection every time,” Wu said in the MIT release. “What’s more, it found a leak that was about one gallon per minute, which is one-tenth the minimum size that conventional detection methods can find on average, and a third as large as those systems can find under even the best of conditions.” Watch MIT’s video on robot leak detection at www.fluidhandlingmag.com/videos/ z
Titan Enterprises goes online with flow measurement resources Flowmeter technology specialist Titan Enterprises has added an innovative customer resources section to its website ((www.flowmeters.co.uk). The new online service has been specifically designed for use by engineers and scientists responsible for making flow measurements in a variety of applications, with the intention of facilitating easier selection of the optimum flowmeter and instrumentation. The new area of the site,
available in the ‘Customer Resources’ section, contains a series of flowmeter selection charts providing guidance on parameters such as technology, accuracy, flow rate, maximum temperature, maximum pressure, fluid type and cost. In addition, the new section on Titan’s website provides access to a bibliography of articles produced by Titan, as well as an archive of the company’s fLowdown newsletters dating back to 2013. z
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
OTHER NEWS
COG makes FKM seal material breakthrough Germany-based manufacturer C. Otto Gehrckens (COG) has announced a special new compound for seal manufacture, which it claims could present a breakthrough for the valve and gas industry. “One of the central demands from the valve sector and gas industry has been for a seal material that has suitable low temperature flexibility, and which conforms to the DIN EN 14141 standard,” COG writes in a statement. “Up until now, there simply hasn’t been a suitable FKM seal material available. But now, the independent seal manufacturer COG has developed a special FKM compound which fulfils the requirements of the valve and gas industry.”
The new FKM compound has been successfully tested according to DVGW DIN 682 (type GBL). In addition, the material has low temperature flexibility to under -40°C, allowing it to meet the DIN EN 14141 standard. With a TR-10 value of -40.1°C, the compound is suitable for use at temperatures as low as -46°C, fulfilling API 6A and 6D standards. The compound’s resistance has also been demonstrated and proven to the DIN EN 13787 standard. COG claims that this combination of properties is unprecedented in an FKM seal, representing a major advance in seal technology for valves and the gas industry. z
Spanish company agrees €500 million pipe deal with Iran Spanish company Tubacex has signed a contract to supply Iran’s oil industry with corrosion resistant alloy pipes. The deal is worth over €550 million ($615 million), according to Reuters. The agreement will ultimately result in the construction of 600km of pipe. Tubacex signed the contract with Iran’s Foolad Isfahan company which will take over production of the pipes in three years. Sanctions placed on Iran had made CRA pipes incredibly difficult to obtain for the country. According to Bijan Zanganeh, who was speaking to SHANA Agency, if an agreement hadn’t been reached between Iran and the west in 2016, which saw
sanctions lifted in exchange for Iran cutting back its nuclear programme, the contract with Tubacex would have been impossible. The agreement is a major contributor to Tubacex reaching a €700 million backlog on its premium products, a company record. According to a press release from the company, Tubacex has boosted sales of high value products and diversified into new markets. The backlog includes a large number of projects in the Middle East, including the Iranian deal. In Europe, much of Tubacex’s business is in Norway and Russia, including a large order with Russian oil company Lukoil. The company has also won significant contracts further afield. z
Velan wins $55 million contract at Hinkley C nuclear powerplant Canadian company Velan has won contracts worth $55 million (€64 million) to supply safety related valves for third generation nuclear reactors at Hinkley Point C in the UK. Velan will provide NNB Generation, a subsidiary of French-British power utility EDF, and Areva NP, nuclear valves to equip the primary and safety auxiliary systems of the two new generation EPR reactors at the Hinkley C nuclear power plant. Given the go ahead in 2016, Hinkely Point C is a new nuclear power plant being built next to two existing facilities (Hinkley A and B). Set to begin generating
electricity in 2025, the ten year construction project is a joint venture between EDF and the Chinese CGN group. According to EDF, Hinkley Point C will be the biggest construction site in Europe. Velan will supply valves critical to the project, including high pressure gate valves and globe valves, manually or electrically operated, as well as check valves. They’ll contribute to the safe operation of the reactor by isolating or controlling all primary fluids within the plant’s nuclear island. These valves would help in shutting down or controlling the reactor in accidental or post-accidental conditions. z
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
Many options, fast choice. ELAFLEX Hose assemblies, rubber expansion joints and couplings reflect the decision for premium quality. They ensure safe operation and long-term optimisation of the total cost of ownership. Due to the large number of product options we have complemented our catalogue with online configurators. These configurators offer a fast and efficient overview or can be used for your enquiries.
hoseconfigura
tor.elafle x .de
ervconfigurato manntekconfi
r.elafle x .de
gurator.elafle
x .de
ELAFLEX - Gummi Ehlers GmbH Schnackenburgallee 121 · 22525 Hamburg, Germany Tel. + 49 40 540 005-0 · info@elaflex.de 9 www.elafl ex.de/en
GAS
The leading event for the Asian tank storage industry
REGISTER FREE TODAY Over 1,600 visitors
suppliers
New technology
2 day
& product launches
80+ global
conference
IPPF-logo-(Horizontal)
Show supporters
Show sponsor IPPF-logo-event
Serving the tank storage community globally MIDDLE EAST AFRICA 25 & 26 NOVEMBER 2015 - HAMBURG MESSE, HAMBURG
REGISTER FREE TODAY qq www.tankstorageasia.com FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
xx
GAS
Options for measuring natural gas flow The use and measurement of natural gas is growing as environmental concerns increase Global warming and the world’s emission of fossil fuels has become such a critical issue worldwide that most countries are trying to reduce their greenhouse gas emissions and also search for renewable sources of energy. For many years coal and oil have been the dominant sources of energy in many countries. While Asia, including China, does not have nearly the amount of oil and gas compared to the Americas, Europe, and the Middle East, it does have vast amounts of coal. Though coal is a relatively inexpensive source of energy, it is also one of the worst sources of pollution. Coal is made mainly of carbon, and burning it produces carbon dioxide. Burning oil also produces carbon
dioxide and other greenhouse gases. This has led to government restrictions in the US and other countries, especially on the emission of carbon dioxide, methane, nitrous oxide, and ozone. The Paris Accord represents a worldwide attempt on the part of 197 countries to keep the global rise of temperature this century to less than two degrees Celsius below pre-industrial levels. While the United States initially joined the Paris Accord, President Donald Trump has announced his intention to withdraw the United States from this international agreement. Coal, oil, natural gas, nuclear, and renewable energy sources are all sources of energy to power industrialised societies. They are all used as sources of energy for
power plants, and most vehicles run on gasoline, which is a refined fuel. The harm caused by the collective burning of fossil fuels worldwide was not understood for many years and by the time it came to be understood, much of the damage to the earth’s ozone layer had already been done. This is somewhat like smoking in the 1950s and 1960s. By the time medical science fully appreciated smoking as a cause of lung cancer, many people had already practiced this habit for years. The effects of global warming are all around us. The polar icecaps are melting, the average temperature of the oceans is rising, and abnormally violent weather has become commonplace. Global warming is viewed by many as the most
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 11
vast amounts of coal. Though coal is a relatively inexpensive source of energy, it is also one of the worst sources of pollution. Coal is made mainly of carbon, and burning it produces carbon GAS dioxide.
United States
Coriolis and ultrasonic flowmeters. The growth in both these markets is tied closely to custody transfer applications.
25,890
Russia
21,225
Iran
6,162
Qatar
5,650
Canada
5,349
China
4,360 0
5,000
10,000
15,000
20,000
25,000
30,000
Top natural gas producers by country in 2014 in billions of cubic feet Source: US Energy Information Administration (EIA)
Top natural gas producers by country in 2014 in billions of cubic feet Source: US Energy Information Administration (EIA) serious security threat to many countries. investments in renewable energy. Unless someone figures out a way to
Inadequate amounts of research
Coriolis meters are benefiting from the market for custody transfer of natural gas Coriolis flowmeters rely on the momentum of a moving fluid to cause a twisting motion in one or more vibrating tubes that serve as the meter body. The amount of twisting motion is proportional to mass flow. This motion is monitored by the flowmeter, which uses it along with other variables to compute mass flow. Because Coriolis meters rely on fluid momentum to compute flowrate, they perform better on liquids than gases. This is because liquids are denser than gases. However, a significant percentage of Coriolis flowmeters are used to measure gas flow, and this use is growing. One main use is for custody transfer of natural gas.
Burning oil also produces carbon dioxide and other greenhouse gases. This has led to reverse this trend, the best hope is to funding in areas such as wind power Custody transfer of natural gas is a reduce the impact of global warming by and solar energy has meant that these fast-growing market, especially with government restrictions in the US and other countries, especially on the emission of carbon slowing down the emissions of fossil fuels. technologies have often not been the increased popularity of natural dioxide, methane, nitrous oxide, and ozone. The Paris Accords represent a worldwide attempt competitive with fossil fuels. Renewable gas as an energy source. Natural gas Renewable energy a promising solution energy in most cases is more expensive changes hands, or ownership, at a on the part of 197 countries to keep the global rise of temperature this century to less than two As the world moves away from coal and than traditional forms of energy like number of points between the producer degrees Celsius below pre-industrial levels. While the United States initially joined the Paris oil as sources of energy, it is naturally coal and crude oil. When economies and the end-user. These transfers occur Accord, President Donald Trump has announced his intention to withdraw the United States turning towards renewable energy. like that of China and even the United at custody transfer points, and are This includes wind power, solar energy, States are pushing for faster economic tightly regulated by standards groups from this international agreement. biofuels, geothermal power, hydropower, biomass, and others. Each of these types of renewable energy has its advantages and disadvantages, and each has its own set of suitable applications. When the wind is not blowing and the sun is not shining, the value of wind and solar power is limited. This makes the capability of storing energy especially important. On the other hand, there are areas in deserts and in the Middle East where the sun shines relentlessly. These areas are ideal for the deployment of solar power resources. A similar example is true for high-wind areas. Renewable energy is widely deployed in many areas throughout the world, and is a rapidly growing industry. It is already making a significant contribution to CO2 and other greenhouse gas emissions throughout the world. The chief problems with the deployment of renewable energy resources are lack of political will and a lack of research funding. The lack of political will has in part to do with the fact that some people have been slow to accept the now overwhelming evidence that human activity affects the ozone layer and the environment. These people are likely to try to block significant 12
growth, it is often tempting to take short term but less expensive energy solutions instead of more expensive but environmentally-favourable sources of energy. This is a dilemma faced by almost every country on earth. Natural gas: a cleaner alternative Natural gas is often seen as a cleaner and more environmentally-friendly alternative to both coal and oil. Burning natural gas emits 50% less CO2 than coal into the atmosphere. It also emits 20-30% less CO2 than oil and gas. This makes natural gas the cleanest burning fossil fuel, though it is not as clean as renewable energy sources. Because natural gas is so versatile, and can be used many places where refined derivatives of crude oil are used, it is widely viewed as a kind of “bridge fuel� to renewable energy. Another plus for natural gas is that it is very plentiful, especially in the United States, Russia, and the Middle East. Natural gas as a bridge fuel could last 20 years or more. Measuring natural gas flow While many flowmeters can measure gas flow, two of the main types include
such as the American Gas Association (AGA). Other geographic regions have their own regulatory bodies. The AGA approved a report on the use of Coriolis flowmeters for custody transfer of natural gas in 2003. The report is called AGA-11. This report helps account for the positive growth rate of Coriolis flowmeters, as they become more widely used for natural gas custody transfer applications.
Emerson Daniel 3416 gas dual transmitter inline ultrasonic flowmeter
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
GAS
Gas flow measurement occurs during upstream production, in midstream transportation, within gas processing plants, and during downstream distribution all the way to the point of use Even though it often takes some time for end-users to adopt a new technology, this report provided a significant boost to the use of Coriolis flowmeters for natural gas flow measurement. The American Petroleum Institute (API) has issued a draft standard titled Measurement of Single-Phase, Intermediate, and Finished Hydrocarbon Fluids by Coriolis Meters. This document was added to the API Library in July 2012. A second draft standard called Measurement of Crude Oil by Coriolis Meters has also been approved by the API. Just as the AGA has been active in approving standards for the use of Coriolis flowmeters for gas applications, the API has actively approved standards for using Coriolis meters in petroleum liquid applications. The chief barrier to the widespread use of Coriolis meters for natural gas applications is line size. The largest Coriolis flowmeter made today can accommodate a line size of 16 inches (406mm). However, Coriolis meters become expensive and unwieldy when built for line sizes above four inches, and those built for line sizes from 8 to 16 inches are very large, unwieldy, and expensive. Even so, their use is growing as end-users are willing to live with these disadvantages in order to achieve the accuracy and reliability of Coriolis meters. Multipath ultrasonic flowmeters used for custody transfer Unlike Coriolis meters, which rely on fluid momentum to compute flowrate, ultrasonic flowmeters send a signal across the pipe in both directions. When the ultrasonic signal travels with the flow, it travels more quickly than when it goes against the flow. The flowmeter monitors the “transit time” of the signals travelling with and against the flow, and uses this difference to compute flowrate. The development of multipath transit time flowmeters, which use more than one ultrasonic signal or “path” in calculating flowrate, has been an important technological development for ultrasonic flowmeters. Each path requires a pair of sending and receiving transducers. By using more than one path, the flowmeter measures flow at multiple locations in the
flowstream, leading to greater accuracy. Multipath flowmeters have been especially important in the use of transit time meters to measure natural gas flow. Suppliers such as Emerson Daniel, Honeywell Elster, and TechnipFMC have introduced four-path, fivepath, and six-path transit time meters, respectively, to measure natural gas flow. The American Gas Association approved the use of multipath ultrasonic flowmeters for custody transfer natural gas applications in June 1998. Since that time, there has been a substantial increase in the use of these meters for natural gas measurement, especially for custody transfer applications.
Endress+Hauser Promass 83X/84X Coriolis flowmeter
A company that has entered the ultrasonic market on the liquid side is Schlumberger/Cameron, which purchased Caldon in 2006. Caldon manufactures an eight-path meter that for many years was marketed mainly to the nuclear industry. In the past ten years, the company has been selling its eightpath meter into the petroleum market. Another company selling its ultrasonic meter into the liquid petroleum market is Faure Herman, a division of IDEX. Faure Herman manufactures an 18-path meter. Other types of flow measurement Turbine and differential pressure flowmeters are also used for gas flow measurement. One especially interesting area is measuring the flow of stack gas and exhaust gases in power plants, refineries, and other manufacturing plants. In the early 1990s, the US Environmental Protection Association (EPA) put in strict requirements regarding continuous emissions monitoring (CEM). This spawned a great deal of flow measurement activity, chiefly among thermal, ultrasonic, and averaging Pitot tube manufacturers.
Beginning in 2008, the EPA’s attention turned more towards monitoring greenhouse gas emissions. Thermal, ultrasonic, and averaging Pitot tube manufacturers have also been active in pursuing this market, although other technologies such as sonar also play a role. The importance of this monitoring activity is likely to increase as greater attention is paid to minimising greenhouse gas emissions into the environment. Flow measurement occurs all along the process stream Gas flow measurement occurs during upstream production, in midstream transportation, within gas processing plants, and during downstream distribution all the way to point of use. In addition, it occurs as the byproducts of burning gas are emitted in stack gas, exhaust, and flue gas systems. Considering that natural gas is becoming more a fuel of choice for a wider variety of applications, the prospects for both the use of natural gas and gas flow measurement have never been brighter. z
For more information: Jesse Yoder, PhD, is president of Flow Research, Inc. in Wakefield, Massachusetts (www. flowresearch.com), a company he founded in 1998. He has 30 years of experience as an analyst and writer in process control. He has authored more than 250 market research studies in industrial automation and process control, and has written more than 280 published journal articles on instrumentation topics. He has published in Flow Control, Processing, Pipeline & Gas Journal, InTech, Control, Fluid Handling, and other instrumentation publications. Study topics include Coriolis, magnetic, ultrasonic, vortex, thermal, differential pressure, positive displacement, and turbine flowmeters. He has authored two separate six-volume series of studies on gas flow and oil flow. Dr. Yoder is a regular speaker at flowmeter conferences, both in the United States and abroad. He has most recently written a book with Dick Morley called The Tao of Measurement, which was published by ISA in March 2015. Flow Research has recently published a study on ultrasonic flowmeters, which is described at www.flowultrasonic.com.
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 13
GAS
Gas flow measurement as a cash register The impact of flow measurement on business performance and profitability
The flow measurement of multipath transit time ultrasonic meters (USMs) is a vital function because USMs ultimately act as cash registers, measuring gas volume as it moves between businesses within a natural gas supply chain. It’s a high-risk process: the smallest measurement inaccuracy can lead to a substantial financial loss because of the high volume of gas flowing through a pipeline at any given time. However, if measurement is undertaken effectively, it offers the lowest possible uncertainty for the most demanding operations, and can produce substantial savings. For measurement engineers and transport grid operators, the pressure is on. These professionals are responsible for measuring an ever-growing mix of
Honeywell Meascon software
Five characteristics of effective flow measurement Here are five critical characteristics operators should look for when choosing their flow measurement technology solution: 1 The highest standards of accuracy to minimise uncertainty 1. 2 Real-world performance, rather than claims based on laboratory tests 2. 3. 3 Reliability to cut maintenance costs and avoid undetected errors 4. 4 Connectivity to share data in real-time with stakeholders who need it, and realise the potential of the Industrial Internet of Things 5. 5 Choice and value, providing the right performance at the right price for the task at hand
14
Honeywell Q.Sonicmax
hydrocarbons and ever-higher number of metering assets. Their specific responsibilities include undertaking correct and accurate measurement, as well as traceability to primary standards by the (re-)calibration of primary and secondary measurements. At the same time, the workforce around them is shrinking because long-time metering professionals are retiring, often leaving them without the support they require. However, their responsibilities remain as weighty as ever, and their output has a direct, immediate impact on a company’s profitability. Measurement engineers, not surprisingly, are relying more than ever on the accuracy of their tools to help them succeed. The challenge is that flow measurement can be notoriously difficult. There are frequent profile disturbances within gas flows caused by anything from short inlets, extenders and reducers, to manifolds, elbows and a range of other piping elements common in natural gas plants. Additional obstructions can include dirt build-up or particles blocking the flow conditioner. Metering tools must be able to quickly and effectively detect and correct any of these disturbances. Key to the success of any measurement device? High accuracy and reliability, giving engineers consistent, precise measurements they can rely on. This requires an accuracy class of 0.5 (based on the International Organisation of Legal Metrology, or OIML, R137-1 2012
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
GAS
Honeywell’s solutions: The Q.Sonicmax and Meascon Honeywell has channelled decades of flow measurement experience into its new Q.Sonicmax solution, an ultrasonic gas flow meter delivering the highest available level of accuracy in custody transfer processes. The solution’s patented design incorporates an eight-path ultrasonic meter to combine both reflective and direct paths. This enables Q.Sonicmax to detect and correct disturbances in the gas flow. Meeting OIML accuracy class 0.5 requirements, the meter is available with Sonic Explorer software which can cut maintenance costs by up to 75% by giving engineers and technicians the ability to configure, diagnose or monitor a meter locally or remotely. Another new member of Honeywell’s ultrasonic metering family is its Industrial Internet of Things-ready Meascon software, which provides 24/7 monitoring for realtime visibility and control of gas metering stations. With Meascon, engineers can easily and securely share real-time and historic data across a site or enterprise. Additionally, the solution’s built-in Ethernet connection allows customers to outsource their entire meter monitoring operation to Honeywell Technical Support if they so choose.
standard), which is the highest standard of accuracy to minimise uncertainty. Other standards that should be adhered to include ISO 17089-1:2010 and AGA 9. Having a small metering skid footprint, as well as the capability to share data in real-time with key stakeholders and integrate with larger connected plant initiatives, are also important. Measurement engineers are also calling for stress-reducing features such as
intuitive, easy-to-use software for health monitoring; diagnostics for conditionbased monitoring; remote operation capabilities; and an event and alarm log to provide an audit trail for compliance. Thankfully, a new generation of flow measurement solutions have arrived that meet these requirements and reduce day-to-day pressures. The best of these deliver accurate, reliable measurement that gives resource-
constrained engineers the confidence they need to thrive in their positions, build trust with others in the supply chain, and contribute to the profitability and success of their operations. z
For more information:
This article was written by Eric Bras, product manager, Ultrasonic Flow Meters, Honeywell Process Solutions. Visit: www.hwll.co/USM
Level Measurement ■ Visual Level Indicators VLI ■ Tank Level Instruments TLI ■ Meets the design standards of the oil & gas, ■ ■ ■ ■ ■
petrochemical, hydrocarbon and LPG/LNG industries Pressures from vacuum to 500 bar Densities down to 0,27 g/cm³ No maintenance (fit and forget) More than 50 years of experience Certified according CE, EAC, Pattern Approval, ABS, BV, DNV-GL, LR, RINA, RMRS ...
Oil & Gas Industry Petrochemical Industry Chemical & Pharmaceutical Industry Power Industry Shipbuilding & Marine Industry Water Management
sit us Please vi te: si at our web .ch a-ag www.wek
WEKA AG · Schürlistrasse 8 CH-8344 Bäretswil · Switzerland Phone +41 43 833 43 43 Fax +41 43 833 43 49 info@weka-ag.ch · www.weka-ag.ch
ARCA Flow Group worldwide: Competence in valves, pumps & cryogenics
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 15
GAS
The case for top-entry in cryogenic LNG Specifying top entry buttweld triple offset valve design in LNG cryogenic applications
The requirement for a port entry in buttweld valves in the LNG industry has become extremely common. The end user’s key objective is to align with regulatory requirements such as EN 1473 or NFPA 59A and comply with local regulation (especially for LNG terminals). For this reason, specifying valves with a lower amount of flange connections is critical and welding valve bodies to the pipe appears to be an obvious solution. However, what happens when things go wrong? How can operators gain access to the key components and carry out maintenance? Even today, the typical journey for triple offset valve (TOV) specification goes from double flanged to buttweld to top entry buttweld body design during the different stages of a project to strike a balance between lowering the risk of fugitive emissions and making maintenance and repairs feasible tasks. Consensus needs to be reached within the valve engineering and manufacturing industry about how to define a “top entry” valve, how the top flange should be designed, and how it will benefit end users in carrying out repair/ maintenance tasks. This article explores these issues as a means of providing a level of understanding about what to consider when specifying TOV valves in cryogenic applications based on Emerson’s leadership in developing a top entry solution for the LNG industry.
offset, also known as high performance, and triple offset) ensure longer lifecycles, require lower maintenance, and provide an improved leakage performance compared to concentric types. Nonetheless, the differences in terms of capability and functionality between double offset valves and triple offset valves (TOVs) are still somewhat confused. The concept of a top entry design is here applied to a TOV, a valve that provides closing with no rubbing across the 90° rotation (differently from double offset valves) in view of a single, instantaneous point of contact between sealing elements only when closed position is reached. TOVs can handle bidirectional flow and are tight in both sealing directions up to extreme pressures due to torque seating and non-rubbing rotation achieved with three “offsets” (fig. 1):
Figure 2: Exploded view of a Vanessa disc
A cryogenic TOV is a valve with an extended bonnet and a solid seal ring, available across a wide range of body styles. The Vanessa seal ring is always a one-piece solid ring in Neutronic 50, a material highly resistant to corrosion able to preserve important mechanical features at low temperatures. 1. The shaft is placed behind the plane of the sealing surface;
Analysis
2. The shaft is placed to one side of the pipe/ valve centerline;
Significant technological developments have been made in the butterfly valve segment over the past 40 years - the reduction or complete elimination of rubbing during rotation being part of the evolution of this type of valve. These relatively new designs (namely double
3. The seat and seal cone centerlines are inclined in respect to the pipe/valve centerline.
16
component as it represents the key flexible element necessary to perform sealing against a seat typically overlaid with Stellite grade 21. A dynamic spiral wound gasket ensures an adequate expansion and contraction of the seal ring during opening and closing (fig. 2).
Figure 1 triple offset design
Based on these premises, the seal ring (and not the disc itself as in the case of concentric butterfly valves) is the critical
Available solutions: Side entry Buttweld design Side entry buttweld TOVs are designed to be maintainable from an access on the body (located to one side of the trim) and they always feature a removable seat (necessary to uninstall the seal ring). Paradoxically, the seats, which are often in 316 Stainless Steel with no
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
GAS Whenever inline access is mandatory, similarly to a top entry ball valve, the top entry buttweld TOV allows for all possible extraordinary repairs via complete removal of internal components. It is safe to claim that on a clean LNG service maintenance requirements are unnecessary thanks to the 100% metal seating and only extraordinary repairs may become necessary to fix tightness and operability-related issues. Emerson’s Vanessa triple offset valve experience shows that in such a compact body, the top flange is also minimally affected by pipe loads. The trim can be completely removed from the body and every component can be repaired or replaced (fig. 3). This means the valve is safe to repair, there is no exposure of service personnel to safety risks and there is also the possibility of addressing operability problems linked to the bearing areas. Figure 3 Vanessa top entry buttweld TOV: Offline Reparability in total safety
Stellite overlays, and the graphite multilayered (or “laminated”) seals of side entry TOVs are typically made of materials with a shorter life expectancy. Graphite exposed to cryogenic temperatures becomes brittle over time. Furthermore, the number of bolts exposed to the flow is doubled compared with integral seat TOVs and there is no effective prevention against bolt loosening. Overall, this design makes trim components prone to deterioration; therefore, regular maintenance becomes necessary. In side entry valves, the trim cannot be extracted and maintenance must be performed with direct exposure of service personnel to safety risks. Other issues include the ability to carry out maintenance operations only on limited valve sizes/pressure classes. It is very difficult – if not impossible – to access valve internals for sizes lower than 12” and dangerous/difficult to replace sealing components for large
sizes and high-pressure classes. In the latter case, a service person is required to enter the line, with direct exposure to pockets of residual gas (gas masks, extra ordinary safety measures and constant monitoring of oxygen may be necessary), accidental pressurisation, accidental strokes of the valve and risky removal of heavy components without a safe way to stably lift them up.
Maintenance issues: Side entry small diameters Irrespective of the size of a valve, before removing the top flange of a side entry valve and accessing the trim components, the actuator should always be removed for safety reasons. Although an operator may be able to use a single hand inside the open port, they may not be able to insert the appropriate tools to disassemble the components. Even if two hands can be used, it is still extremely
Available solutions: Top entry Buttweld design On clean liquid/gaseous cryogenic applications, some TOVs are virtually maintenance free and do not require any specific maintenance programs. To do so, cryogenic TOVs must be able to guarantee the same performance irrespective of body style designs. Typically, this is linked to the valve trim components operating at temperatures down to -254 °C (-425 °F).
Figure 4 Maintenance of small-sized side entry buttweld TOVs: An unfeasible task
Choosing between an oval shaped vs. rectangular flange Overall, rectangular ducts and joint construction are not typically used in the oil and gas industry. However, some manufacturers may opt to use this specific shape to design the top flange in view of practical and cost considerations, though unbalanced stress distribution, gasket
and bolting failure may ultimately result in critical fugitive emissions. These types of ducts are normally allowed in heating venting and air conditioning systems typically designed for extremely low pressures generated by a fan. However, even in these systems recent guidelines to minimise air
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
leakage to increase system efficiency now recommend the use of round/ oval duct and joints. For example, the SMACNA (Sheet Metal and Air Conditioning Contractors’ National Association) recommends the use of round ducts having the lowest possible duct friction loss for a given perimeter.
17
GAS difficult to disengage components and take them outside the port. In addition, this operation is completely unfeasible if the valve is installed at a height/difficult location to reach (fig. 4). Overall, these critical issues may jeopardise the very reason for a side entry body specification (maintenance operation), as only a visual inspection can be carried out.
operations following the drying of the lines after being flushed with water. Conclusion
Maintenance issues: Side entry large diameters A crane must always be used to remove the side entry flange, seat, seal ring and seat and seal retaining flanges. A 72” Class 150 side entry flange, for example, will weigh more than 1,000 kg. (over 2,200 pounds) and seal ring, seat ring, seal ring retaining flange and seat ring retaining flange will all weigh hundreds of kilograms (several hundred pounds). Even for medium-sided entry sizes in accordance with ISO 11228 and NIOSH equation, lifting and moving of equipment with weight more than 25 kg. (55 pounds) should never be done manually. Once the top flange is removed, a service representative should be let inside the conduit at extremely high safety risks including exposure to residue gas, pressurised equipment, and other factors (fig. 5). Another serious risk that may remain unaccounted for during valve specification is the potential of crushing the operator during the removal of key components since lifting aids cannot be safely applied after removing bolting (fig. 6). A less evident aspect to consider is the fact that any components to be installed on the seat/disc are offset in comparison to the side entry port where they enter the body and it is impossible to put them in/out of place by using the crane alone. The higher the diameter/
Figure 5 Maintenance of large-sized side entry Buttweld TOVs: A risky task
pressure class, the longer the distance between the port and the seat. Ultimately, the operator will not be able to dry up valve cavities or to address operability problems which are common during LNG plant/terminal start-up
Cryogenic TOVs are installed worldwide in double flanged, lug, buttweld and buttweld top entry executions with double flanged being the most commonly adopted body style. Whenever inline access is required, the arguments in support of a top entry design are predominant. Furthermore, the use of one piece (solid) seal rings and Stellite grade 21 seat overlays is believed to guarantee the highest level of reliability and longterm excellent performance as graphite becomes brittle at low temperature over time and the seal ring will “delaminate”, creating operability and tightness problems extremely difficult to solve. Ultimately, it appears critical that if a high-quality torque seat, metalto-metal non-rubbing TOV is being selected, the top entry access will be used for extraordinary repairs (and not for ordinary maintenance) on clean cryogenic services. z Stellite is a registered trademark of Deloro Nitronic is a registered trademark of AK Steel
References:
EN 1473 (2007) – Installation and Equipment for Liquefied Natural Gas – Design of Onshore Installations ISO 11228-1 (2003) – Ergonomics – Manual Handling – Part 1: Lifting and Carrying NFPA 59A (2013) – Standard for The Production, Storage, and Handling of Liquefied Natural Gas (LNG) SMACNA (2006) – HVAC Systems Duct Design 4th ed.
For more information:
Figure 6 Risk of operator crushing during maintenance of large side entry buttweld TOVs
This article was written by Alberto Bertamoni, Marco Ferrara, and Sergio Casaroli, who are Vanessa Triple Offset Valve subject matter experts with Emerson Automation Solutions. Visit www.vanessavalves.emerson.com for more information.
Repairing a top entry: A case study A set of four identical Vanessa 24” Class 300 TOVs in cryogenic configuration top entry buttweld body were subject to extraordinary maintenance. All valves were with pneumatic, double acting actuators and had suddenly experienced operability issues (locked at 50% open). Once the valve trim had been removed from the pipeline, a significant presence of water and unidentified solid particles were detected in
18
the bottom bearing area. After cleaning up and drying the bottom bearing area, all valve parts were reinstalled on the pipeline and an operability test was successfully performed. The entire maintenance cycle carried out by two technicians took 4 hours and involved the following activities: – Removal of actuator – Removal of trim – Clean-up and drying of
bottom bearing area – Installation of the valve trim – Installation of the actuator After the installation was completed, a pneumatic test was also performed with no measurable leakage. Should this valve have been a buttweld side entry, this issue would have been impossible to address directly on the pipe – the only solution would have been to cut off the valve from the line.
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
Gland packing vs. mechanical seals
SEALS
When it comes to choosing between gland packing or mechanical seals, Aesseal say it’s important to look at the long rather than short term costs Why would you choose to use mechanical seals over gland packing? Why would you choose the more expensive option if you’re already coping with your current method? Is it really any better? Naturally there are advantages to both sealing methods but firstly let’s understand why gland packing is still popular. What is gland packing? Quite simply gland/pump packing is a tried, tested and relatively inexpensive method of sealing pumps and is the most widely used technique. In fact, it is the earliest form of pump sealing dating back hundreds of years. Originally, gland packing was made from old ropes and natural fibre products and packed around the shaft to physically stuff the gap to reduce any leaks. This is where the familiar term ‘stuffing box’ was derived from. Modern packing now comprises sophisticated braiding and materials designed to wear less, reduce friction and withstand heat better than ever before, but regardless of all this innovation, it will still leak. Gland packing is a method however, which most maintenance personnel will be familiar with and know the process on how to maintain. Continuous operation means an increased amount of leaked product, Gland packing and mechanical seal
A $30,000 (€26,000) yearly saving for Australian copper mine An Australian copper mine was having unacceptable failure rates on a filter press feed pump that was used to dewater the copper ore slurry. The current gland packing sealing solution was causing excessive wear on the shaft sleeves, leading to a loss of product and gland water as well as damaging the bearing barrels. Aesseal installed heavy duty slurry seals that are designed especially for the mining industry, and are built to withstand high levels of pump vibration and cavitation. The installation of the SW2 water management system removes water wastage and provides more cost efficient cooling than the once-through flushed gland system previously used. The solution installed by Aesseal not only increased the mean time between failure rate by 300%, but also stopped water ingress into the product, significantly reducing filtering costs. The SW2 water management system has contributed to saving over 10,000,000 litres of water per year, saving the mine $30,000 a year. and is a regular occurence with this type of sealing. To rectify, it can be simply readjusted and tightened even without having to shut down or dismantle a pump. In terms of price, initial outlay of gland/pump packing is relatively low when compared to mechanical seals. With the right kind of materials of construction, an ‘acceptable’ leakage rate of as low as 1 drop per minute of sealed product per inch/25mm of outside diameter of shaft can be achieved. These numbers are based on an ideal scenario but, as experience tells us, the leakage rates can be considerably higher than this. It is worth considering that a gland leakage of just 1
drop per second is a loss of around 9,500 litres/2,375 US gal per month or 114,000 litres/28,000 US gal per year for every pump. Why use mechanical seals? • Gland packing leaks more than mechanical seals It’s a fact that all seals leak - they have to in order to keep them cool, clean and therefore working properly, but the leakage from a mechaical seal is so minute, you can’t even see it, in fact it’s such a tiny amount it just vapourises. If there are no visible leaks, there are no clean up costs. Greater volumes of water, product or other flush medium are often used to lubricate packaging in order to prevent shaft damage but this also leads to substantial leaks. On the figures used to describe the leakage through use of gland packing, if the product cost 10p/lt, reduction in leakage alone would pay for even an advanced mechanical seal in less than six months. • Gland packing results in more waste disposal costs than mechanical seals Leakage is becoming less and less
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 19
SEALS of the gland packing to address the fact that it will wear the shaft. If not fitted, the shaft would need to be replaced or rebuilt in the worn area. If a sleeve is fitted, the shaft diameter may have to be reduced to allow for fitting, which can lead to bending. Broken shafts are not uncommon and are generally caused by fatigue due to the constant stress during operation. There are many reasons for this happening, like running the pump away from its best efficiency point, against throttled or closed discharge valves, over its designed capacity; long shaft overhang and stop-starting all of which create massive forces within the volute. Typically, the longer and thinner the shaft is, the more likely it is to break. Shaft sleeves can also be notoriously difficult and time consuming to remove and may even lead to damage of the shaft itself. Regardless of whether a sleeve is used or not, having to hold a stock of either shafts or sleeves can be expensive, along with the costs of downtime while shafts and sleeves are repaired.
Engineer maintains seal support system
acceptable and conservation of resources is increasingly important. Correctly fitted mechanical seals have no visible leakage and can significantly reduce effluent disposal costs, and so provide substantial benefits to emission reduction. Depending on what the process product is, waste disposal costs can be significantly higher than the initial cost of manufacture. Just looking at a domestic water bills illustrates this. Even when only dealing with water, sewage charges are significantly higher than the initial cost of the product. Companies are also under extreme pressure and constant observation on environmental issues. Governments are continuously under national and global scrutiny to ensure that manufacturers accept the responsibility for the effects their products and processes have on the environment. Businesses themselves often also have environmental targets to meet. • Gland packing uses more power than mechanical seals Gland/pump packing can consume up to six times more power than a balanced mechanical seal. This is because the gland packing is in direct contact with the rotating shaft, essentially increasing friction, making it work harder and therefore greatly increasing power costs. By comparison, mechanical seals are non-contact and will reduce power consumption considerably over gland packing. • Gland packing impacts bearing life whereas a mechanical seal won’t If you need more reason to consider using mechanical seals, let’s go 20
FIDC mechanical seal
back to leakage because did you know that the single major cause of bearing failure in rotating equipment is contamination of the lubrication? In a study conducted by Mobil Oil it was discovered that water contamination of 0.002% reduces the rated bearing life by almost 50%. This is the equivalent of just 2 drops of water in a litre of oil. Packing leaks by design and is in close proximity with the bearings. This subjects the bearings to a constant stream of leakage and contamination. Any reduction in contamination will greatly increase the Mean Time Between Failure (MTBF), and in turn reduce maintenance costs. Minimal leakage equates to longer bearing life resulting in less interruption and associated costs with a failure. • Good gland packing will wear expensive shafts and sleeves, good mechanical seals will not Most rotating equipment is fitted with repairable wear sleeves in the region
• Gland packing flushing will dilute your product, mechanical seals will not Gland packing often requires the supply of a clean flushing medium to prevent air entering the system if under vacuum and to remove the excess heat generated by friction against the shaft that would otherwise damage the packing. The costs accumulated in this method are with the supply of the flush water, the leakage of the flush to atmosphere and the leakage in the product (product dilution). This dilution may be acceptable to the process but if not, additional costs may be incurred for its removal at a later stage. Choosing the right mechanical seal can eliminate product dilution resulting in a better quality, purer product with no additional removal costs. If flush liquid is added to a hot process, this will also mean re-heat costs and can significantly increase a process operating cost due to the tens of thousands of kW hours or millions of BTUs required. • Gland packing is expensive to maintain, mechanical seals are not To ensure that packing operates as efficiently as it should, it requires constant attention. Too loose and leakage rates are high, too tight and
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
SEALS Increasing MTBF from 6 months to 6 years and saving over £137,000 (€155,000) A pulp and paper manufacturer was having regular reliability issues with their hard wood pulper that was gland packed. The regular leakage was causing maintenance issues and seeing large amounts of product being lost onto the factory floor. The pulper was originally fitted with Kevlar packing and was being repacked every 6 months. With the pulper being vertically mounted, all leakage from the packing washed out any grease in the bearings, leading to new bearings and new shafts being fitted every time the shaft was re-packed. The leakage was also causing large amounts of stock to be lost and was making the drive belts slip, increasing power usage to operate the machine. Aesseal replaced the gland packing with a CURC single mechanical seal, which comes with environmental control options allowing a flush line to be connected to the seal to ensure the seal faces stay as cool and clean as possible. The CURC increased the MTBF from 6 months to over 6 years and helped save over £137,000 in this period, without including the cost of lost product.
the packing can burn out immediately on start up, increasing leakage, wear on the shaft or sleeve and increasing power consumption. Maintenance must be constant and conscientious throughout the life of the packing to ensure acceptable operation. Mechanical seals require no routine maintenance. By eliminating leakage, secondary maintenance is minimised by reducing corrosion, cleaning and painting. By using a mechanical
seal, these secondary maintenance costs are also greatly reduced. • Gland packing doesn’t offer containment, a dual mechanical seal can Packing leaks, as all seals are designed to, but it leaks the “sealed” product to the atmosphere. Understandably this is unacceptable for environmental reasons and particularly in cases where the product is corrosive, toxic or even
explosive. In these scenarios, packing simply cannot be used. All products classified as fugitive emissions or hazard should always be double sealed to mitigate the risk of leakage. Airborne pollution is eliminated with double seals achieving zero product emissions. Summary So yes, people are frugal these days - they have to be in order to survive financially, but there is a habit of taking things at face value and when presented with two costs, people are programmed to take the cheapest option. Instead of looking at that initial cost, look deeper at the reasons why something is cheaper. It’s not always the case but very often lower prices can mean higher life-cycle costs. So consider using a mechanical seal and you will soon reap the cost benefits of lower running and maintenance costs with no leakage, meaning that your clean-up costs are reduced and your bearings are likely to survive longer. It really is the most cost effective solution to sealing your pump. z
For more information:
This article was written by Chris Dean, Group Technical Training Manager at Aesseal Visit: www.aesseal.co.uk
Have you done your homework?
Research gives you a clear advantage over your competitors. You can get the very latest information on new plants, projects, innovations and legislative updates all from one source… www.biofuels-news.com Get an A* and get online today.
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 21
A seal for life
SEALS
A major Romanian oil company approached OPW to provide an easy to install, reliable above ground fill point solution for a new build filling station including associated internal equipment (pipework and fill caps) that would perform for the life of the site The oil retailer required an above ground remote fill sump which would allow safe and fast access to fuelling points for tanker drivers while protecting against unauthorised access or water ingress from above or below ground. Four fill points and one vapour recovery were specified, with fill caps and an easy-install piping solution to run to fuel tanks. For safety, all items needed to be conductive to prevent static electricity build-up. Consideration was also given as to the accidental yet inevitable fuel drips and spills that occur when fuelling.
Installer friendly KPS piping used to connect fill points to tanks
A non-steel solution Industry first Fibrelite GRP above ground remote fill sumps provided a great alternative to traditional galvanised steel. This system was designed in 2014 through collaboration with a major global oil company as a retrofit system to replace existing concrete sumps and connect to existing underground pipework. The composite material is impervious to corrosion from exposure to water and fuel, meaning it will remain liquid tight for the life of the site, vacuum testable like all Fibrelite sumps. Designed with a secondary contained spill tray to catch fuel spills and drips, the sump system includes an earth cable kit to ground the pipework. The two-leaf watertight hinged door provides lockable easy access to the fill points for the tanker driver. On this site, the door was padlocked for security instead of each individual fill cap, allowing for faster fuel delivery. Models are available in three sizes to accommodate from three to seven fill and vapour recovery lines. Systems are designed to contain either single or double wall pipework and are available with or without a drain back to the tank or interceptor. The above ground remote fill’s simple single piece design provides a large working space to install pipework inside the sump before the spill container is installed. 22
OPW heavy duty corrosion resistant seal caps
All Fibrelite products are regularly subjected to rigorous independent testing to comply with stringent standards for safety, product performance, quality and reliability. In addition, they are ISO 9001:2008 quality accredited meaning that the quality systems of the factory where Fibrelite products are made are systematically assessed. To ensure a watertight seal for the life of the site, this system was supplied with high quality Fibrelite Viton pipe and cable entry seal kits. Fibrelite seal kits/entry boots are designed to be easy to install. Only one hole is drilled through the chamber wall, reducing the number of leak points often associated with additional screw holes. Components screw together to create a watertight seal. Once installed, systems can be vacuum tested using the Sherlock system to check workmanship of installation and ensure watertightness. Fibrelite supply the highest grade of materials which have been extensively tested against hydrocarbons including ethanol blends to E85 and biodiesel to B20.
KPS piping was selected to connect the fill points and remote fill. Compact KPS fittings minimise the number of welds required by welding both pipes simultaneously wherever connections are required, reducing installation time. To complete the containment, the OPW tight-fill top-seal caps were installed on top-seal adaptors which prevent gasoline vapours from escaping and water dust and debris from entering the tank. The OPW 634TT seal cap is heavy duty and corrosion resistant, with a body made of Duratuff to help eliminate rust and oxidation for a long, maintenance-free life. The toggle lever distributes downward pressure to compress its Buna-N gasket evenly, assuring a positive, water and vapour-tight seal. The 634TT can be locked with a padlock or wire seal. Together, the Fibrelite sump, KPS piping and OPW fill caps form a contained and conductive system, preventing leaks or static electricity build up. OPW successfully provided a maintenance-free solution which will endure for the life of the site, and shortened installation time by supplying all products from a single source and reducing the number of welds required with easy-install KPS piping. The fuel retailer is now specifying Fibrelite above ground remote fills for a series of new sites. z For more information:
This article was written by David Holmes, technical director. Visit: www.opwglobal.com
Vacuum testable Fibrelite GRP above ground remote fill
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
ANALYSIS
Analyse this (fluid flow)
Through effective data analysis, both a university and an LNG plant have seen huge benefits The collection, retention and analysis of data is everywhere, from supermarkets to election campaigns. The insights that can be gained from big data collections are hugely valuable to a multitude of industries, and that includes a host of fluid handling applications. Developments in technology and software mean more data than ever before is available to plant engineers and operators, providing a massive quantity of information on the most minute of details. Taking advantage of this data can deliver enormous benefits in performance, in sustainability, and in saving money. Founded in 1993, Applied Flow Technology specialises in developing pipe flow modelling software, with a particular focus on fluid flow analysis. The Colorado Springs, US, based company has developed a range of software designed to help in the design and development of piping and ducting systems for a range of applications in a range of industries. The two case studies presented here give practical examples of how AFT’s modelling software has been used to benefit two substantially different industries, providing a valuable insight into how data analysis can be used to deliver tangible benefits. University optimises chilled water system, boosts sustainability, and saves $60,000 a year University of Alabama in Birmingham obtained annual energy savings of $60,000 after awarding a project to Bernhard TME Engineering (TME) to optimise the university’s district chilled water system.
The university’s pumping station modeled in AFT Fathom
Three existing chilled water plants pumps to that building. Due to the very with 38,100 tonnes (34,600 metriclarge and multi-branched piping layout of tonnes) of cooling capacity serve the campus, the most hydraulically remote 48 existing buildings on the campus, building was not able to be guessed covering just over one square mile (2.5 at based on building size or location. square kilometers). The chilled water With AFT Fathom, Smith and Guo were system provides cooling for the air able to determine the most hydraulically conditioning systems in this hot and remote building based on which humid southeastern US location. building’s control valve was most open. The university had two AFT Fathom’s Valve Summary feature requirements from TME: specifies the open percentages of each (1) Model new piping plans and two valve in the system. Knowing which additional 8,000-ton (7,300 metric-ton) buildings were most critical allowed TME chilled water plants to support the to add booster pumps and run several university’s expected 20-year growth different scenarios to determine the (2) Provide strategies for optimising best operating condition for the plant. their current plant operation to “We ran dozens upon dozens of be more energy efficient. scenarios in order to meet the project Brandon Smith, commissioning technician, requirements for this model,” says and Wei Guo, energy engineer, at TME, Smith. “We were very impressed by used AFT’s pipe flow modeling software, how quickly AFT Fathom is able to AFT Fathom, to create a hydraulic model process and calculate solutions for of the existing district chilled water such a large piping network. When set system. AFT Fathom is fluid dynamic up properly, our chilled water model simulation software for engineers, used converges in less than 10 seconds.” to calculate pressure drop and flow After running the analysis, Smith distribution in liquid and low velocity and Guo determined one building gas piping and ducting systems. was causing all of the plants to run at The university’s chilled water plant differential pressures much higher than operates off of a fixed differential pressure necessary. By adding a booster pump set point based on the combination to that building, the campus is able of dry bulb and wet bulb outside air to obtain annual savings of $60,000 temperature. The differential pressure a year with minimal upfront costs. set point had been proven to satisfy the “Without the speed of AFT Fathom, chilled water demand of the campus this type of modeling project would not buildings after years of experience, but was not necessarily the most efficient way to do so. Smith and Guo were able to run simulations of the chilled water plants’ pumps in several different arrangements in order to determine the most efficient way to run the plants. A major step to reduce the plant differential pressure set points and reduce overall energy cost was to determine the most hydraulically remote AFT Fathom model built of chilled water system laid over the univerbuilding and add booster sity’s campus map
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 23
ANALYSIS have been economically feasible for the university to invest in,” explains Smith. Smith and Guo also utilised AFT Fathom to assist with designing the proper pipe sizes for the university’s future growth. Additionally, the model is now set up to help make future design decisions concerning issues such as chilled water plant locations and building booster pump locations. The model will also assist in determining the best sequence of operations for the plant’s optimal savings. Though the chilled water system optimisation required an initial investment from the university, the payback period is well under one year. In addition, other departments at the university can benefit from the annual energy savings in a number of ways. “Every dollar that the university can save in energy costs can be reinvested into the education programmes and healthcare provided by several of the hospitals on the campus,” says Smith.
to the pipeline. The flow rate needed to be increased by almost 60%, going from 64,800 ft3/ hr (1,800 m3/hr) to 102,600 ft3/ hr (2,900 m3/ hr). One of the customer’s main concerns was the send-out line to the boil-off gas Figure 2: Max predicted surge pressures after LNG system flow expansion (BOG) condensers remain below maximum allowable and the possibility of pressure with the send-out coming from Tank surges, as the level control valves A using three in-tank pumps all rated close within three seconds. for 24,200ft3/hr (690 m3/hr) at 535ft (160 Denis Escobar, process engineer at m) of head and 76.5% efficiency. CB&I, used AFT Impulse to model and The expansion scenario included a analyse the expansion. AFT Impulse is flow of 102,600 ft3/hr (2,900 m3/hr), with AFT’s fluid dynamic simulation tool used the send-out coming from Tank A and to calculate pressure transients in piping Tank B using six in-tank pumps also all systems caused rated for 24,200 ft3/hr (690 m3/hr) at 535 ft (160 m) of head and 76.5% efficiency. by waterhammer. Using AFT Impulse, Escobar determined Given CB&I had that with the increased flow, the pressure designed the in the system would remain below design original facility, pressure of 15.5 barG (225 psig) (see Figure piping isometrics 2). This reduced the concern of pressure and a 3D model Valve summary in AFT Fathom indicating which building’s control valve surges resulting from valve closures. of the plant were was most open Since there was no benchmark for readily available. the pre-expansion flow rate, the project Smith and Guo submitted the University The AFT Impulse workspace was created team requested additional information of Alabama project to AFT’s Platinum with the 3D model in mind. Escobar says regarding the stress to which the system Pipe Award Contest and received this approach, including the use of the would be subjected. Using the two the 2016 award for the Operational Visual Report tool in AFT Impulse, helped scenarios and the force capabilities Benefits and Sustainability category. provide a visual of the plant space and of AFT Impulse, different points in the “The application of AFT’s system the location of equipment (see Figure 1). systems were analysed and the changes modeling software at the University of Without a benchmark for the in subjected forces were determined. Alabama continues to demonstrate original design, Escobar had to create The data was provided to a different the value of system modeling and the two scenarios for the plant model group to perform a stress analysis of power and versatility of our software – one for the pre-expansion and a the system. The group determined the products,” says AFT President Trey Walters, second for the desired expansion. forces would increase using the new P.E. “There is much work to be done to The pre-expansion scenario included surge conditions but would remain improve the energy efficiency of installed a flow of 64,800 ft3/hr (1,800 m3/hr), within the design parameters. pumping systems and to change the Escobar says one of the advantages paradigm of how pumping systems of using AFT Impulse to model the LNG are initially designed to reduce their plant had been its ease of use. “By environmental footprint. This application using the 3D modeling views with the is an important step in that direction.” Visual Reports tools and capabilities the software has, it helps in presenting the AFT Impulse validates flow rate increase results in a well-summarised approach.” z at liquefied natural gas plant CB&I, a leading provider of technology and infrastructure for the energy industry, was tasked with performing a hydraulic analysis of a liquefied natural gas (LNG) plant expansion. The plant was built by CB&I in 1999, and the owner recently requested an increase in the send-out rate 24
For more information: Figure 1: AFT Impulse model of LNG pipe system delivery flow to boil-off condensers
This article was written by Chelsea Woodward, public relations and social media manager at Applied Flow Technology (AFT) Visit: www.aft.com
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
VALVES
Interview: trends and challenges in automation and instrumentation Ryan Spooner, Singer Valve
A Q&A with Ryan Spooner, Automation & Instrumentation Engineering manager for Singer Valve Tell us a little bit about Singer Valve? Singer Valve is a global manufacturer of hydraulic operated water control valves. These control valves operate in applications such as upstream/ downstream pressure control, flow control, altitude control and surge/ pump control in the municipal, industrial and fire industry. Singer Valve offers these with both mechanical and electrical control options. We also have a UL certified panel building facility and produce all our own custom engineered control solutions right here in North America. What are the areas of greatest growth in your product offering right now? The boom right now is in automation and instrumentation, where end users want to have better monitoring and automated response to changes in a system. Usually the process starts with them acquiring and adding instrumentation to their system which assists them to understand what’s happening. Then the addition of
automation enables them to control their system based on the feedback and see the live results in the operations room or on a mobile device. Automation and instrumentation not only give a better understanding of a system, but help streamline personnel efficiencies and reduce cost in maintenance by having higher control productivity. This also helps reduce the number of emergency situations as well as the response time to deal with emergency situations. What are the biggest challenges that need to be overcome to meet this growth?
single solenoid operated/override control valve and 4-20mA level sensor or high/ low level switches. This combination package is ideal for filling any kind of tank with water that requires filling to a level setpoint and then drawing down the level of the tank to a secondary setpoint before activating the fill cycle again, thus ensuring tank turnover. The LCP-TP is quick and easy to configure to read and compare the level 4-20 mA signal to the desired setpoint. The setpoints can be set locally via an interactive button display screen or remotely via either SCADA
The biggest challenge we have is with training and understanding of the automation and instrumentation devices. The benefits of having automation and instrumentation far out way the option to not, which everyone understands, but showing an end user that anyone with a bit of training can understand and operate these devices can sometimes be challenging. Singer Valve puts lots of emphasis on educating by providing seminars and hands-on training events worldwide to help users learn how to operate the products. These events allow users to see the full benefits of automation which often results in the operators finding more innovative ways to streamline processes, as they are the ones who understand the intricacies of their system best. It has become truly a holistic approach to optimising water distributions systems.
Modbus or hardwired 4-20 mA remote set-point signals. If a high/low level switch system is preferred, the LCP-TP can switch configuration to allow for level switch inputs and regulate the control valve accordingly. Data logging is also a useful feature to log sensor feedback and setpoint data with a time stamp, allowing for system analysis. The biggest value of this automated level controller is flexibly and readability of control. For the user who wants to setup a full communication network that has access to all storage tanks and controls them remotely, it’s easy to do with Modbus and remote 4-20mA communication options. For the user that has a remote site, but wants to be able to data log and analyse the tank turn over, the LCP-TP offers the data logging feature. Both options offer lots of feedback and traceability of the system operation.
What are some of your latest products? The Level Control Panel with Touch Panel (LCPTP) interface is designed by Singer Valve to accomplish optimum level control feasibility and flexibility. This level controller is designed to complement a
SPI-MV in the field
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 25
VALVES Based on this information, the tank level setpoints can be adjusted to match the needs/demands of the system with simple interaction to ensure the system can function at its optimum. This ability to take all the information and then easily adjust the tank setpoints is a huge benefit. Singer Valve also has a new option for an existing product, which is the Battery Operated SPI-MV. The SPI-MV was offered in the standard AC or DC powered options but now a battery option is available that allows 3-5 years of operation without having to provide an external source of power, which is great for remote locations. In addition to the standard battery option there is also an external solar panel add on, that can expand the life time of the battery for up to 10-15 years. The battery version maintains the accuracy of the standard unit with 2% of actual reading and only needs 3 pipe diameters of straight pipe upstream for installation. The SPI-MV offers the opportunity to have both the flow measuring and the hydraulic control valve all in one package. This can significantly reduce the size of the control vault and in turn cut cost on construction as you no longer need the standard full bore meter or inline insertion, plus straight pipe lengths before the control valve. Are there any new trends to watch out for? Pressure management and water loss prevention/leak management are two areas that continue to be on the rise with aging infrastructure and population growth requiring more of this precious shared resource. A great deal of water and profits are lost to non-revenue water (NRW) each year. The water loss happens due to leaks and pipe breaks in a system. The focus has grown to be able to monitor the amount of loss as well as take measures to try and prevent as many of these issues as possible. This is where monitoring devices such as the SPI-MV are important, to be able to map all flows in the system to determine exactly where the leaks are happening. Management and prevention of NRW can often be achieved by reducing pressures in the system when demand is low. This is a very cost effective approach which is an ongoing issue as municipalities are constantly weighing priorities for maintenance vs. new infrastructure needs. Singer has many products such as an electrical option, the 420DC pilot operated motor actuator or 26
SPI-MV battery
control panels paired with dual solenoid control valve, as well as the mechanical options such as the 2PR-630 Pressure Management valve to achieve pressure management and reduce leakage. What is one of the most recent interesting installations you have done? The most recent impactful installation has been with the St Bernard Parish just outside the City of New Orleans. As we all know the area is prone to flooding, and after a few floods kept destroying their electrical control systems for their water tanks, a new system needed to be designed. We designed a system that would allow the electrical pilot system and electrical control panel which included the SPI-MV flow meter, level and flow control, full SCADA communication and much more, to be completely removed from the enclosures. They designed the valve to have the option to be switched completely to mechanical altitude backup. Therefore, if a storm came through, the electrical pilot system and electrical control panel would be completely removed, ensuring they did not get damaged and the valve would maintain in operation ensuring the water supply in the tanks was still under control. Once the storm passed, the electrical pilot system and electrical control panel could be reinstalled and regular operation could be established. This will have a large impact on ensuring that the water supply to and from all the tanks in the Parish is still available and ready for use at any time, especially when
desperately needed, right after the floods. With the wave of retiring baby-boomers exiting the industry, how are you addressing the needs of a younger generation of operators taking their place? The younger generation are all technology and computer savvy and so they fit right in with the evolving trend of the industry towards automation and instrumentation. The new generation of operators are more likely to be found behind a computer in a SCADA control room making pressure changes to a valve than having to go out into the field to make a simple adjustment to a PRV valve. Singer is constantly trying to bring innovative new products to market to meet these demands. It was announced in January that Mueller has acquired Singer Valve, how will this affect Singer’s Future? Singer Valve sees this as a great opportunity to further expand our business, both with market share as well as new product development with the help of Mueller’s extensive resources. There are many product synergies between Mueller and Singer, together we can offer more product options for clients and better service with a greater distribution network. z For more information:
Ryan Spooner is Automation and Instrumentation Engineering manager for Singer Valve. This interview was carried out by Brigitta Shore, Shore Communications. Visit: www.singervalve.com
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
Getting it right with AODD pumps
TROUBLESHOOTING
Air-operated double diaphragm (AODD) pumps are reliable and cost-effective, but only if they are configured correctly
The Husky Family range (stainless steel, polypropylene and aluminum) together with the wide range of material options for diaphragms, balls and seats
In a variety of applications across a number of industries, air-operated double diaphragm (AODD) pumps provide reliable, high performance pumping. They have come to be known as the “work horse” of industry when it comes to handling and transferring fluids at relatively low flows and pressures. Above ground or below ground, on land or on sea, in normal or extreme conditions, the versatility of AODD pumps ensures that processes keep moving. Key to safe and reliable operation of an AODD pump is correct configuration. This involves taking fluid characteristics into consideration, such as pH levels, abrasiveness, temperature and fluid density. It is also important to check chemical compatibility: manufacturers often provide guides on their websites to ensure pump materials are suitable for the fluid being transferred. These same websites often feature online pump selector tools to assist in configuring a pump in a matter of minutes, with a few clicks of the mouse. However, some of these configuration tools can appear overwhelming at first, especially considering the
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
vast number of alternative materials that can be specified for pump components. Making the right choice can significantly reduce the overall cost of the pump – while making the wrong choice can give you a pump that is too expensive for your requirements. This article identifies and recommends popular ball, seat and diaphragm materials (internal pump components) and pump fluid sections (pump bodies) to perform in applications with varying fluid characteristics. These are general guidelines and points to consider when specifying the correct configuration. In parallel with these recommendations, it’s always advisable to check the manufacturer’s specifications and chemical compatibility guides. What temperature? The first guideline is to remember to identify the temperature limits of all components in the pump. The internal pump components may be rated to an extremely low or high temperature, but that does not imply that the pump body material is rated to the same level, and vice versa. When configuring an AODD pump, it’s important to identify temperature ratings of all components by referring closely to the manufacturer’s product specifications. Increasing the working temperature has a significant consequence on material selection. For example, plastic pump bodies are not recommended because cold flow and creep can lead to leaking. As temperatures rise above 80°C, the choice of compatible internal components further decreases. At these elevated temperatures, materials such as ethylene propylene diene monomer rubber (EPDM), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF) and fluoroelastomer (FKM or Viton) are preferred. FKM and EPDM have the highest heat resistance, rated to 27
TROUBLESHOOTING 160°C and 135°C respectively. Next in line are PVDF and PTFE, rated to 107°C and 100°C respectively. At the other end of the thermometer, glycol transfer pumps are required to withstand cold environments down to -20°C, thus requiring aluminum, stainless steel, EPDM, FKM and Santoprene. KEY TAKEAWAYS: • For high temperature applications: Stainless steel or aluminium pumps with FKM, EPDM, PTFE or PVDF wetted materials. • For low temperature applications: Stainless steel or aluminium pumps with EPDM, FKM or Santoprene wetted materials. Corrosive environment? If you want your AODD pump to handle corrosive chemicals or fluids with fluctuating concentrations and/ or pH levels, then it’s vital to make the proper selection of pump bodies and internal pump components to avoid pump corrosion, ensure compatibility, and reduce maintenance requirements. For such applications, plastic pump bodies such as polypropylene, PVDF, Kynar and PTFE are often chosen on account of their chemical inertness. The highest chemical compatibility is offered by PTFE, which can generally be safely used from the most basic chemicals to the most acidic acids. It could be, however, that PTFE is an over-specification. Other materials such as polypropylene or PVDF may suffice. It therefore makes sense to refer to the manufacturer’s chemical compatibility guides for guidance as to which are the optimal pump materials to use for the chemical or fluid you are working with. KEY TAKEAWAYS: • Check manufacturer’s chemical compatibility guide. What’s the fluid density? Surprisingly, when configuring a diaphragm pump the most frequently overlooked specification is fluid density. It’s an important factor to consider because diaphragm pumps utilise ball checks that rise and fall as pressure changes occur within the fluid chambers of the pump. Ball checks come in a whole range of metal and elastomer configurations. Each of these materials has a different 28
weight, or specific gravity. Understanding how this weight relates to the fluid has an influence on the material specified. If a low-viscosity fluid is being transferred, the weight of the ball is not of critical importance because the fluid is not restrictive during the ball seating process. A 30% slurry, on the other hand, has a higher viscosity and therefore requires a heavier ball to move through the slurry so the ball seats properly. If the ball is too light, it will hang up in the slurry and will not seat, leading to poor pump performance that includes priming issues and cavitation. A rule of thumb is the denser the fluid, the heavier the ball check.
KEY TAKEAWAYS: • Neoprene, stainless steel and PTFE ball checks have the highest specific gravity, or weight, allowing ball checks to seat reliably through high-viscosity fluids.
Want to minimise wear? For abrasive fluids, metal pump bodies are generally recommended. The most commonly used materials are aluminium, stainless steel and Hastelloy. Santoprene and Geolast are good for internal pump components as they provide longevity and resistance to destructive abrasives. Applications with petroleum-based fluids, such as waste oil, are best paired with Geolast ball, seat and diaphragm materials. Santoprene, one of the most versatile elastomers, offers good chemical compatibility and excellent abrasive resistance. PTFE offers a high level of chemical inertness and compatibility in hightemperature applications, but it is often incorrectly specified in abrasive applications, such as chemical slurries. Again, it’s important to check chemical compatibility of all these materials.
KEY TAKEAWAYS: • Stainless steel pumps with Santoprene or Geolast wetted materials. Looking to reduce costs? When configuring a cost-effective pump, aluminium, polypropylene, Geolast, TPE and EPDM need to be high on your shopping list. As variables such as temperature or abrasives become more challenging, using an ultra-high molecular weight polyethylene (UHMWPE), neoprene or nitrile may be required, but this is going to increase the pump’s cost. Other materials that will add to the cost of the configured pump are specialty materials intended to handle the most extreme fluids. These materials include PTFE, PVDF, FKM, Hastelloy and stainless steel. A useful tip is to be open to using a different material when your pump has to be repaired. It might not be necessary to reorder exactly the same material. Consulting a chemical compatibility guide might help identify other materials that are perfectly suited for the same fluid but at a lower cost. KEY TAKEAWAYS: • The most cost-effective materials: Polypropylene, Geolast, EPDM, TPE and aluminium. • Midrange materials: UHMWPE, neoprene and nitrile. • Higher price range: PTFE, PVDF, FKM and stainless steel. For more information
This article was written by Walter Leeten, product marketing specialist process, EMEA Graco offers a range of air operated diaphragm pumps, which can be configured with an online selector tool at www.graco.com/husky-selector-tool
Two 3” Aluminum Husky pumps used for dewatering and chemical transfer
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
Is peristaltic the answer? When it comes to fluids that are difficult to pump, peristaltic pumping could be the answer
A quick internet search of the term peristalsis will swiftly lead to a screen full of images of the human digestive system. More than just being a biology lesson however, this gives an insight into a form of pump design that is popular in a range of applications involving some of the most complicated media. The US National Library of Medicine’s MedlinePlus website defines peristalsis as “a series of wave-like muscle contractions that moves food to different processing stations in the digestive tract”. The same principle is also used in a peristaltic pump. As Dutch pump manufacturer and distributor Verder Group explains on its website: “The fluid is contained within a flexible hose or tube fitted inside the pump casing. The actual pumping principle is based on alternating compression and relaxation of the hose or tube, drawing content in and propelling product away from the pump. “A rotating shoe or roller passes along the length of the hose or tube creates a temporary seal between the suction and discharge sides of the pump. As the pump’s rotor turns this
sealing pressure moves along the tube or hose forcing product to move away from the pump and into the discharge line, where the pressure is released. The hose or tube recovers, creating a vacuum which draws the product into the suction side of the pump This is called the priming mechanism. “Combining these suction and discharge actions results in a powerful self-priming positive displacement action.”
PUMPS
sensitive products such as polymers. There are several advantages to selecting a peristaltic pump. Because the flow of the pump is proportional to speed, they’re well suited to dosing applications. As the pumps are available in both large and small models, they can be used in anything from laboratories to mining, and more. The hose of a peristaltic pump prevents crosscontamination, while in the event of a hose rupture, the fluid is contained safely.
Where can peristaltic pumps be used? Peristaltic pumps are unique in a way as they’re positive displacement pumps without valves and seals, unlike centrifugal or mag-drive pumps. Instead, every peristaltic pump features flexible hoses or tubes to give an open flow path. This gives a high resistance to abrasion and allows the easy flow of solids, high S.G. and viscous media. Peristaltic pumps are capable of pumping some of the world’s most difficult fluids, yet the pumps themselves deliver a gentle pumping action, making them ideally suited to pumping shear
Case study 1: A cost-effective and efficient solution for an anaerobic digestion plant A prestigious brewery based in Norfolk, UK, that produces fine quality real ales, installed an anaerobic digestion (AD) facility for producing biogas to be supplied into the national gas grid. The AD facility is fed with kerbsidecollected food waste, food processing waste, supermarket food waste and brewery waste. The organic matter is entered into a feed inlet at the start of the process where a rotor chopper
Verderflex is a key brand of the Verder Group, producing a peristaltic pump and tube pump range. The company has provided pumping solutions to a wide range of industries, from water treatment to chemical manufacturing and oil and gas, showing the versatility of peristaltic pumps in handling fluids that are “difficult to pump.” Verderflex’s peristaltic pumps are manufactured in the EU within ISO 9001:2008, ISO 14001 and ISO 18001 accredited facilities, and the products have a range of food and similar industry specific certifications.
Verderflex Rapide Green family
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 29
PUMPS breaks down the raw material. Verderflex pumps move the chopped slurry from holding tanks and through a heat exchanger to raise the temperature prior to entering the main AD facility. As the hot organic material enters the main AD facility it is dosed reliably and accurately by a Verderflex Dura pump with an inorganic pH buffer to accelerate and maximise the breakdown of the material. The large mass of organic material is ‘churned’ by Verderflex pumps in a plant room connected through a series of pipes to maximise the surface area and further accelerate the AD process to obtain the greatest yield of heat and biogas. The heat is recycled back into the heat exchanger. Upon completion of the AD process, the digestate and wastewater is pumped from the tank by a Verderflex pump for further use as fertiliser. The final product of biogas is then filtered and processed further ready to be inputted into the national gas grid. In this process the Verderflex Dura efficiently pumps the following with minimal maintenance and losses: • Rotor-chopped cold organic material • Warm organic material • Warm slurry • Digestate • Wastewater liquor • Enzyme and chemical solutions Pumping all stages of the AD process In partnership with Naiad Acquatic Environmental Solutions, Verder offers an innovative dosing system allowing both crystal saturation and liquids to be dosed reducing site costs and carbon footprint. This can be used for the treatment of wastewater from the AD process and for the addition of enzyme
Peristaltic pumps are unique in a way, as they’re positive displacement pumps without valves and seals solutions in the AD process itself. Thus, Verderflex’s unique, versatile range of Dura pumps has been successfully installed to pump slurries and corrosive fluids generated at various stages in the AD process. The Verderflex Dura is a significant advance in hose pump technology, combining the compactness of a close coupled pump with all the benefits of the traditional long coupled pump. The range includes smaller pumps with minimum flow rate of 23l/hr, to industrial pumps with maximum flow rate of 15 m³/hr, and various hose options such as NR, NBR, EPDM, NBRF or CSM and maximum discharge pressure for the range of 16Bar per pump. Case study 2: Making the headlines – pumping ink The Verderflex Rapide is a range of industrial tube pumps that includes a balanced selection of simple to operate peristaltic pumps. The range has been developed to offer reliable and cost effective pumping solutions for industrial applications. Standard designs incorporate rugged aluminium pump heads with “thick-walled” tubing for increased suction lift and IP55 gear motors with both single and three-phase options.
compressed air and require constant maintenance due to the wearable parts like seals and valves. This could result in high repair and maintenance costs, and higher and more frequent downtimes. In addition to this, these pumps are required to deliver shear sensitive inks to the printers without foaming or separation. After assessing the situation, a Verderflex R8 peristaltic hose pump was recommended to the printing company. With a flow rate between 170 l/hr and 470 l/hr at 2Bar, the low maintenance Verderflex R8 was ideal for this application. This pump has enabled the customer to save both cost and time by having high dependability and only one wearing part – the hose. With a simple clamping mechanism enabling hose change, the pumps are easy to maintain on-site, without requiring specialist repairs. There are no seals or valves to replace, nor impellers that can become clogged. Verderflex’s happy customers claim that Verderflex R8 is a “great pump and very reliable”. In addition to the benefits described above, customers were satisfied that the Verderflex pumps also saved money on ink during setup/cleaning between jobs by being reversible. They simply pump any unused ink back into the supply after the print job is finished. z
Verderflex pump in printing process For more information:
In a printing company, where pumps are used to deliver inks to printers, the pumps use a considerable amount of
This article was written by Lekha Bodhe, head of marketing at Verder UK, and Daryl Worthington, editor of Fluid Handling International Visit: www.verderflex.com
Verderflex Dura family of pumps
30
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
TECHNOLOGY
What will the pump of the future look like? By Bryan Orchard
Step 2 – Algorithms are used to interpret vibration characteristics
How digitalisation, software and simplified analysis are revolutionising pump design and use
This analysis now needs to be simplified further. In the future, instead of using wetted sensors, it will be possible to record vibrations and transfer this operating data to the cloud using mobile communication. This has two advantages: First, conventional measurements using wetted sensors are not always straightforward, particularly when the medium being pumped is
Few components in plant and equipment engineering are as steeped in tradition as the pump, but how does this fit in with the age of digitalisation? Is it even possible to design a hydraulic element that is fit for Industry 4.0? KSB has been reconciling these two worlds successfully for some time now. KSB has always focused primarily on the optimisation of pumps – knowing the exact load profile and tuning the pump to the operating point. This is borne out by the sheer number of different pump casings and materials used and the impeller adjustment options available. However, conditions can change during the life of a pump and it often happens that a pump no longer runs at the optimum operating point. This also applies to newly installed pumps. For years now, KSB experts have therefore been investigating how to optimise pumps more easily without using complex analytics or having to replace the pump. Digitalisation offers tremendous potential for this. However, it takes time to develop new approaches and put them into practice. “It’s a matter of transferring decades of experience and expertise into an algorithm and a software solution,” explains Thomas Paulus, head of Programme Office Digitalisation & Startup Projects at KSB. “This cannot be done in a single step, it involves many different components and aspects. By bringing together these component parts, however, you end up with an intelligent and practical concept that provides real added value for the pump operator.”
Figure 1: PumpMeter continuously analyses the pump operating data, establishes a load profile, and makes the operator aware of energy saving potential that could be leveraged by using a variable speed system. ©KSB Aktiengesellschaft, Frankenthal
Step 1 – The digital monitoring unit The KSB “PumpMeter” monitoring unit (Figure 1), which shows in plain language what goes on inside a pump, has already established itself successfully on the market. The monitoring unit comprises pressure sensors as well as an analysing and display unit fitted to the pump. Two sensors in the pump measure the suction and discharge pressures around the clock. The PumpMeter uses this data to calculate the differential pressure and determines the current operating point, which is updated continuously in real time. A typical four-quadrant pump characteristic curve shows the range in which the pump is operating at a point in time. A flashing outer segment on the left or right of the display indicates that action is required – because the flow rate is either extremely low or too high. A flashing third quadrant in the pump curve indicates the optimum operating range. If the segment on the left (the second segment) is flashing, this indicates a long-term need for optimisation. This display allows the operator to evaluate the operating point immediately upon start-up and adjust the pump accordingly. Operators can see at a glance whether the availability of their pumps is at risk and whether they are operating economically. A flashing EFF (energy efficiency) symbol also indicates potential for significant energy savings.
a chemical product. Second, cloud access means that technicians can obtain information about the status of a pump from anywhere in the world without having to be on site. This application is currently being piloted very successfully with 100 selected project partners. “Those involved include some automotive suppliers, who are very open to the project,” says Paulus. Measurements taken in parallel using the PumpMeter are being used to verify the values obtained using the vibration sensor. At the same time, the KSB team is continuing to optimise the underlying algorithms. According to Paulus: “Based on these results, it is already easy to see whether it makes sense to switch to closed-loop control, whether the settings or modes of operation need to be changed, or whether it would be better to buy a new pump.” The operating data is transferred to the cloud via a portal. KSB processes the data and the user receives an automatically generated PDF with clear recommendations and, where applicable, improvement suggestions for the pump (Figure 2). Step 3 – Operating point optimisation with MyFlow But how can these improvement suggestions be put into action? The traditional approach would be to call a KSB service technician. But what if it were possible, based on the information obtained, to adjust the pump using software instead of having
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 31
TECHNOLOGY change in power, substantial savings can also be made,” says Gontermann. Pump optimisation through virtual impeller trimming is fast and convenient by smartphone or tablet via a Bluetooth gateway. “During development, special attention was paid to security. The KSB FlowManager app establishes a pointto-point connection, which ensures that the correct pump is being addressed, and only by the person entitled to do so,” explains Gontermann. “The great thing is that you can now defer the individualisation of the pump to a much later point in the supply chain, which of course means that fewer variants are required.” This is another aspect that is likely to play a major role in pump selection in the future. With individual fixed speed adjustment, fewer pump sizes now cover the entire selection chart – with efficiency and NPSH values remaining practically constant. The variant Figure 2: The operating data is transferred to the cloud via a portal. KSB processes the data and the user receives an automatically generated PDF with clear recommendations and, where applicable, improvement suggestions for the pump. ©KSB Aktiengesellschaft, Frankenthal
to adjust the impeller manually? “This is actually possible with our MyFlow Technology,” (Figure 3) says Daniel Gontermann, head of Product Management – Drives and Mechatronic Solutions, at KSB. This is a combination of the KSB SuPremE IE5 motor and the MyFlow Drive, which is based on the proven PumpDrive speed-control system. The conventional approach for fixed speed pumps is to match the flow rate and head to the calculated operating point by trimming the impeller. Now, the pump can be adjusted by changing the speed. MyFlow Technology already offers many advantages in day-to-day work. Because the operating voltage of the IE5 synchronous reluctance motor is modulated by the minimum frequency inverter mounted on the motor, it can be used in almost any power grid around the world. This is also a huge advantage for global engineering contractors because they no longer need to consider the local mains voltage when selecting pumps. The direction of rotation is now defined at the factory, saving the time and costs usually incurred by conventional direction-of-rotation checks.
Industry 4.0,” acknowledges Gontermann. “Nevertheless, they form the basis for the next crucial step: pump optimisation using virtual impeller trimming.” In the further course of the product life cycle, the pump speed can simply be adjusted to individual requirements by smartphone – pump optimisation with virtual impeller trimming. “A software application can be used to bring the pump closer to its optimum operating point,” says the pump specialist. Unlike with mechanical impeller trimming, the operating process does not need to be interrupted. This is how you can quickly and economically optimise energy efficiency if the actual Q/H point deviates from the design values, or respond to a system-induced change in the operating point. “Because a change in speed is always associated with a Figure 3: MyFlow Drive allows the pump operator to increase or reduce the volume flow rate with just a few simple adjustments. ©KSB Aktiengesellschaft, Frankenthal
complexity for hydraulics is reduced by more than 50%, saving time and money on design and administration. “Simply reducing the complexity by having fewer variants will promote the topic of virtual impeller trimming,” says Gontermann. Outlook Original equipment manufacturers (OEMs) will therefore be the first to benefit from the new opportunities presented by digitalisation, by being able to drastically reduce their stock, for example. Nevertheless, this shows the direction in which pump technology will move. “Digitalisation is not an end in itself,” emphasises Paulus. “Our users will only accept the new technologies if they bring added value to their day-to-day work and, above all, are workable.” This last point is certainly one of the greatest challenges. It is useful that KSB has set out on the road to the digital future at an early stage. “In the same way that we have been getting the most out of pumps in terms of performance and efficiency for decades, we are now also making progress in developing the algorithms and software. Without our many years of pump expertise, it would be simply impossible to make a pump fit for the Industry 4.0 era.” Paulus and Gontermann are sure of this. z
Step 4 – Software-controlled pump adjustment “Although these advantages make the pump operator’s job much easier, they are not enough to make a pump fit for 32
For more information:
This article was written by Bryan Orchard, a freelance journalist. bryan@bryanorchardpr.co.uk . Visit: www.ksb.com
FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017
PAGE HEADER
WHEN WASTING EARTH’S MOST PRECIOUS RESOURCE ISN’T ACCEPTABLE You choose Singer Valve’s leakage management valves. Water conservation products designed for the health of our planet.
™
WEFTEC BOOTH 4451
VISIT US TODAY! SINGERVALVE.COM FLUID HANDLING INTERNATIONAL l JULY/AUGUST 2017 33
AESSEAL Water Management Redu ce en ergy c onsum ption Eliminate excess seal water
bility a li re p m u p e v o r Imp
t n e m n iro v n e e t th c e t o Pr AESSEAL Water Management Systems save in excess of 25 Billion (US) Gallons of water for customers each year Operating Principle
1
1 Water from the plant water line enters the system
2
2 The pressure of the barrier fluid in the vessel can be regulated via the pressure regulator 3 The barrier fluid is circulated to the seal and back to the system by the thermosyphon effect
3
www.aesseal.com