Fluid Handling magazine November/December 2014

HELPING TO

KEEP YOUR

BUSINESS

FLOWING

The publishers of internationally renowned Tank Storage magazine are proud to bring you Fluid Handling magazine, a new publication entirely dedicated to liquid handling and transfer equipment in the food & beverage, pharmaceutical, wastewater and oil & petrochemical industries.

The magazine, launched in 2013, will bring you updates to regulations, the latest technology developments and technical articles exploring market challenges.

The digital magazine is sent to over 12,000 utilities, plant engineers, managers and operations directors. On top of this the Fluid Handling website is updated daily. Sign up for free now at www.fluidhandling.com to receive both the magazine and fortnightly newsletter.

Sent out 12,000 in to dus professio try nals

NOVEMBER/DECEMBER 2014 ISSUE 3 • VOLUME 2

Horseshoe 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@horseshoemedia.com PUBLISHER & EDITOR Margaret Dunn Tel: +44 (0)20 8687 4126 margaret@tankstoragemag.com DEPUTY EDITOR Keeley Downey Tel: +44 (0)20 8687 4183 keeley@horseshoemedia.com ASSISTANT EDITOR Natasha Spencer Tel: +44 (0)20 8687 4146 natasha@horseshoemedia.com STAFF WRITER Daniel Traylen Tel: +44 (0)20 868 74126 daniel@horseshoemedia.com ADVERTISING SALES MANAGER Belinda Smart Tel: +44 (0)20 8648 7092 belinda@fluidhandlingmag.com PRODUCTION Alison Balmer Tel: +44 (0)1673 876143 alisonbalmer@btconnect.com SUBSCRIPTION RATES A one-year, 6-issue subscription costs £150 (approximately $240/€185 depending on daily exchange rates). Individual back issues can be purchased at a cost of £30 each Contact: Lisa Lee Tel: +44 (0)20 8687 4160 Fax: +44 (0)20 8687 4130 marketing@horseshoemedia.com

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Margaret Dunn Publisher & Editor

Here we find ourselves again already, another issue of Fluid Handling magazine and our last for the year 2014. We’d like to thank you for all of the feedback we received following our September/October edition, our first in print and a difficult act to follow!

Thankfully, within these pages we have some great content to see you through to the New Year. For the flow-conscious among our readers, Fluid Components International explains the importance of flow monitoring in relation to analyser systems and Bureau Veritas provides some expertise on calibration using ultrasonic clamp-on meters, among other methods.

In the pump sector, Wilden puts a spotlight on air-operated doublediaphragm designs and offers a comparative case study, while Crane ChemPharma addresses the process of pumping fluid through piping systems and the factors that must be considered to operate efficiently.

As well as these you’ll find a wealth of expert articles on the components that keep so many businesses running successfully. There has been no shortage of innovative and forward-thinking technology to talk about recently and 2015 looks set to be an exciting time for advances in the process industries.

In the meantime, we hope you enjoy reading this issue and look forward to hearing from you in a couple of months’ time.

Best wishes, Margaret

HELPING TO

KEEP YOUR

BUSINESS

FLOWING

Follow us on Twitter: @fluidmagnews 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 Tank Storage 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.

ISSN 2057-2808

Front cover courtesy of Clarke Industrial Engineering, introducing the Shutter Valve

Dymax develops new micro-spray valve for contaminate-free dispensing Dymax has released a micro-spray valve designed to be more precise and flexible in order to allow for a range of spray-pattern adjustment.

The Model 455 Micro-Spray Valve features an inert, 100% disposable fluid path which carries materials from the material reservoir to the spray nozzle in a sealed path.This prevents materials from coming in contact with the valve’s inner components and ensures a contaminate-free dispensing process.

The fluid path is easy to replace and requires minimum clean-up, allowing for rapid material changeover. The valve can be supplied with fluid paths of varying materials and sizes for optimum material compatibility. The pneumatic pinch valve, outfitted with a stainless steel spray nozzle and spray regulator assembly, utilises tube overpinch, a feature that extends tube life, enhances

repeatability, and offers precise control over material flow.

The spray nozzle is an external air-mix type which utilises a standard luer-lock design allowing different gauge tips to be exchanged to adjust flow rate needs. The combination of tip variation and integrated pneumatic controls allows control over the amount of air relative to the amount of fluid. The controls feature a builtin delay system that atomises the tiny droplet that would normally remain on the nozzle when the valve is shut off. This enhances repeatability and guarantees drip-free operation.

Dymax develops oligomer, adhesive, coating, dispensing, and light-curing systems for applications in a range of markets.

Major markets include aerospace, appliance, automotive, electronics, industrial, medical device, and metal finishing.

Sun Hydraulics and Sturman Industries enter licensing agreement for digital valves Sun Hydraulics, a designer and manufacturer of high performance screw-in hydraulic cartridge valves and manifolds, and process controls specialist Sturman Industries have entered into a Technology License Agreement related to the use of Sturman’s digital valve technology.

Under the agreement, Sun will manufacture and sell valves which incorporate Sturman digital valve actuation technology into screw-in cartridge valves used in fluid power markets.

‘Customers are asking for products which are smaller in size, lighter in weight, use less power, are less expensive and operate faster.

New electro-hydraulic cartridge valves under development as a result of Sun teaming up with Sturman will provide these features and create new markets for Sun,’ says Allen Carlson, Sun’s CEO and president.

‘We are very happy to be partnering with Sun Hydraulics to bring Sturman’s digital valve technology to Sun’s customers,’ says Carol Sturman, president of Sturman Industries.

‘Under the agreement with Sun, Sturman will perform the research and development for select new valve products, while Sun will be responsible for production engineering, manufacture and commercialisation of them.

We’re pleased to support Sun in bringing forward solutions that can benefit the hydraulics industry.’

Carlson adds, ‘We look forward to bringing these exciting new products to market during 2015. We believe there are next generation applications in the mobile and industrial segments which can benefit from the use of digital valve technology.’

New elastomer-free pressure regulating valve from GFPS is ‘market-first’ GF Piping Systems has announced availability of a new Pressure Regulating Valve (PRV) family with an elastomer-free design to stop particle shedding.

The new valves eliminate elastomers, exterior metal parts and re-torqueing, and can be used in a range of markets including water treatment, chemical processing, microelectronics, pharmaceutical, life sciences, and solar.

Key to the new design is a unique patent pending piston that eliminates the use of elastomers in the valve, thereby ending particle shedding for improved high purity operation.

This is important in demanding applications that require only minimal amounts of particles in the flow stream.

In addition to its elastomer-free capability provided by the proprietary piston design, high-

purity operation is further enhanced via the valve’s threaded bonnet, which has no exposed metal bolts. The central housing nut does away with re-torqueing for easier operation and compact design enables installation in limited space. Other outstanding characteristics include its modular system that allows the user to easily adjust the set pressure range and quickly go from reducing to retaining (or vice versa) by simply switching the cartridge.

The initial product introduction includes two different PRV types in five materials – PVC, CPVC, PROGEF Standard PP, SYGEF Standard PVDF, and SYGEF Plus PVDF-HP – in sizes from 3/8” to 2” (DN 10 – DN 50). Standards include ISO 9393 for tightness and EN 12266 for leak rating.

News in Brief Graco acquires UK valve manufacturer Graco, a manufacturer of fluid handling equipment, has acquired the stock of Alco Valves Group, a UK-based manufacturer of high pressure valves used in oil and natural gas and other industrial processes.

Alco offers a portfolio of brands, including Alco Hi-Tek, Alco Valves, Alco Sub-Tek, and Alco Process. It operates manufacturing facilities in both Manchester and Leeds. In addition, it has warehousing and sales operations in Houston, Texas; Toronto, Canada; and Singapore. The newly acquired business will maintain its manufacturing and engineering base in the UK. Alco generated approximately £19 million (€24 million) of revenue and approximately £6 million of EBITDA in the most recent trailing 12 months. The acquisition was a cash transaction which closed for £72 million and is subject to normal post-closing purchase price adjustments.

Bonomi NA introduces new butterfly valve series Bonomi North America has introduced a new series of groovedend butterfly valves for use in commercial and light industrial applications.The new valves are built with an ISO mounting pad and stem for simple automation with electric or pneumatic actuators.

Standard features of the new Bonomi L700E Series include an epoxy-coated ductile iron body, EDPM-coated ductile iron disc, and a 410 stainless steel ISO square stem.An ISO 5211 mounting pad is integral, making it easy to add any ISO 5211 standard actuator or manual operator.A BUNA-N coated disc is optional.

Available in sizes 2” to 12”, the L700E is designed to meet ANSI/AWWA C606 and MSS SP-67.Typical applications include hot and cold water, HVAC, chilled water, and fire protection systems.

Maximum working pressure is 200 psi.

All Bonomi butterfly valves are tested to 100% of their rated pressure before shipping.

Bonomi is a fully integrated manufacturer of both electric and pneumatic actuators and direct mount valves.The L700E can be performance-matched to the company’s Valbia-brand actuators.

Crane ChemPharma expands Pacific Valves Wedgeplug line Crane ChemPharma & Energy has expanded its Pacific Valves Wedgeplug line for low steam consumption within severe service applications.

Wedgeplug valves are specifically engineered to address the challenges in severe service applications. Now available in ½” to 36” sizes, the range has been expanded to increase the breadth of solutions for customers in the refining, petrochemical and power generation industries.

The valve’s design offers users a number of benefits, including: 1. Increased return on investment: When not actuating, Pacific Wedgeplug consumes no steam, resulting in industry-leading low steam usage and DCU operational savings

of more than $150,000 (€118, 488) per year.

2. TAR servicing: With inline decoking and service, the valve body stays in the piping system to deliver a shorter TAR schedule and lower trade costs.

3. Enhanced safety: A single valve offers double block and bleed capability, reducing upstream and downstream concerns and enabling users to purge and gauge the valve body for safety permissives.

Pacific Wedgeplug valves are designed to ASME B16.34, API Standard 599 and API Standard 600, latest edition, where applicable.

Testing is to API Standard 598, latest edition. Special hydrostatic testing and nondestructive examinations are available.

When valve failure is not an option.

New knife gate valve from Flowrox for heavy-duty applications Flowrox has launched a brand new knife gate valve specifically designed for demanding and heavy industrial use.

The SKW design includes new features based on direct feedback from the field, including a new load distribution ring that prevents over compression during the installation and ensures 100% sealing between the ring sleeve and the valve gate. To add to ease of maintenance, the load distribution ring has been integrated into valve sleeves.

SKW allows bi-directional flow of slurry due to its closing mechanis. The body of the valve is made as one casting, reducing the number of parts, meaning there is no need for sealing between the body halves. The valve also features a universal tower design that allows any actuator to be easily connected

to the tower structure. They can also be changed after the valve has been installed in the pipeline. The tower also ensures that the top plate, body and actuator are always aligned with the pipeline and the gate is in the right position.

The SKW valve is suitable for processes where the medium includes solids or abrasive substances.

Applications: • Mining and metal industries • Mineral processing • Power generation • Sand and gravel • Cement • Waste and wastewater treatment.

Face-to-face dimension of the valve is according to an industry standard.

CHEP Pallecon Solutions launches food-grade bags with improved discharge valves CHEP Pallecon Solutions recently launched new MaxiValve Liners in the Asia Pacific region to complement its existing suite of intermediate bulk container (IBC) rental solutions. The new liner range is pre-fit with the MaxiValve, a disposable ball valve, capable of reducing container discharge time by up to 33%.

The 1000l liner bags are food contact, Kosher, and Parve-approved, and designed for use with CHEP Pallecon Solutions’ IBCs, for the transport of bulk liquid. The liners, available in both aseptic and non-aseptic films, are offered as part of the company’s full service container rental programme. Depending on the application type, either a pillow or form-fit version of the liner can be utilised.

The EB125MV is the first bag in this product line. Manufactured in Australia, the

liner includes a three-layer construction, providing high-flex resistance while transporting. The ball valve, unlike butterfly valves, delivers an unrestricted flow of product without additional fitting requirements and has a tamper evident numbered security clip to protect the integrity of the product.

Suitable for applications with fill or exposure temperatures under 80°C, the bags can be steam sterilised for up to 30 minutes at a temperature of up to 130°C and a pressure 3bar.

CHEP Pallecon Solutions provides Intermediate Bulk Containers (IBCs) to customers around the world and across a range of industries including food, beverage, dairy, pharmaceutical, cosmetic, chemical and general manufacturing.

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In response to the large demand for power plant valves in countries using ANSI/ASME standards, the KSB Group has further developed its range of gate valves, globe valves and check valves.

Under the type series names SICCA and ZTS, KSB valves now cover all pressure classes up to ANSI Class 4500. Their nominal diameters range from ½ to 32”. Operating temperatures, depending on the material, can be as high as 650°C. The maximum permissible pressure equals 600bar or 8,700 psi.

Forged and cast steels to ASTM standard are used as

materials. Depending on the type, the valves are designed for shutting off or throttling boiler feed water, steam and condensate.

They are manufactured at KSB sites in Germany and India to uniform standards to ensure that products and services are available worldwide.

The demand for ANSI valves is particularly prevalent in the growing markets of China, India and the US, as well as in Europe.

By adding these valves to its programme, KSB has countered the decreasing demand for power plant valves to DIN standard.

Copyright: © KSB Aktiengesellschaft

KSB valves for ANSI/ASMEcompliant power plants

Under the type series names SICCA and ZTS, KSB valves now covers all pressure classes up to ANSI Class 4500.

Flowrox launches new industrial valve for processing abrasive and corrosive substances Flowrox, a specialist in heavy-duty industrial valve manufacturing and services, is launching a new slurry knife gate product designed to enhance current pipeline equipment and processes using enhanced technology for fluid control.

The Slurry Knife Wafer (SKW) valve was developed for use in the oil and gas, mining, minerals and metallurgy, power and wastewater industries,

where abrasive or corrosive slurries, powders or coarse substances are processed.

Flowrox has engineered the valve at full-bore with no flow restrictions, allowing processes with abrasive or corrosive fluids – such as lime slurry or mineral slurries – to move without compromising performance. The main benefit to a full-bore design is that the SKW valve itself becomes a part of the pipe and allows it to

process the same fluids in the harshest of conditions.

In addition to its resistance to aggressive slurries, the valve is designed as a full-port fluid control device that allows a more efficient process, requiring less pumping energy to operate.

The SKW valve incorporates incorporates a cast singlepiece body, which eliminates any potential leak paths from the body and offers a versatile tower construction that will

accept manual, electric, hydraulic or pneumatic forms of actuation.

When in the ‘open position’, the valve’s heavy-duty rubber ring sleeves are the only parts in contact with the medium in order to reduce any potential corrosion or deterioration due to wear-and-tear, even when processing the most abrasive slurries. Load distribution rings are embedded into the rubber ring sleeves to prevent their compression and destruction.

Total Valve Systems introduces new pressure relief valve Valve and gauge application specialist Total Valve Systems has introduced a new nonreclosing pressure relief valve with patented technology.

The model 6820 TRV can be reset in seconds from the field or remotely, the first of its kind to do this. Related product model 6220 is a shutdown version that shuts off when the valve reaches the set pressure or is triggered remotely.

Total Valve’s engineering department has worked for a number of years to develop the ASME ‘UD’ certified Total Relief Valve (TRV) module, considered the ‘brain’ of the system.

The proprietary TRV system includes the TRV module, actuator and isolation valve, making it a reliable and accurate

high flow capacity relief valve or shutdown device to help prevent downtime and catastrophic accidents. The system offers reliability for non-reclosing relief devices because it does not rely on the prediction of material failures.

No external power is required for 6820 TRV operation and its performance is not impacted by system backpressure. Module operation allows for complete control of valve set pressures at +/2%. Options for dual sensing lines and fluid media filters are provided and the system is ideal for gas service where dirt, hydrates and high moisture levels occur in the fluid media.

Triple offset valves are standard due to their

performance and reliability across the spectrum of temperature, pressure and sealing classes. They operate from -267˚C to 815˚C in accordance with valve specifications. Its non-rubbing seat design offers a bubble-tight sealing performance.

Industry-proven actuation systems are integrated to the valve and TRV module. The system’s design can include the use of special valve features such as accumulator tanks, thermal protection plugs and customer-specific devices. Additional systems can be added optionally to the actuator for PLC and control room remote operation.

Operation can be paired to data acquisition systems for

monitoring set pressures and relief points.

Also included is a test connection port for in-the-field testing. The device is a full-face design with pipe flange bolting for lug, wafer and short pattern configurations. Flange ratings are 150, 300 and 600. Set pressures are from 3-1500 psi.

The US-designed and manufactured system is available in two basic configurations: 6820 TRV-SP for single positive sensing line pressure applications, and 6820 TRV-DP for positive differential pressure applications. The system can also be used with gate and ball valves. When coupled with a ball valve, it has pigging capabilities and provides overpressure or shutdown protection.

Cat Pumps launches ‘Wash-Saver’ for hygiene and sanitation cleaning systems Cat Pumps has introduced an energysaving high pressure pump package for centralised hygiene and sanitation cleaning systems.

Called ‘Wash-Saver’, the package utilises a variable frequency drive (VFD) and returns typically 85% mechanical energy efficiency irrespective of operating speed.

The Wash-Saver concept uses a feedback signal to the VFD to control the pump speed. The pump, drive motor, accessories and VFD panel come fully assembled, tested and pre-configured at Cat Pumps’ UK facility, to match individual endusers’ requirements. The option of a pre-piped water header tank is also available, and installation into an existing centralised high-pressure pipe system is an uncomplicated procedure. The control panel can readily be incorporated into a factory automation system or linked into a local area network.

Cat Pumps’ Wash-Saver only uses as little water as required, as the pump only runs when wash-down guns and lances are activated. As the pump remains fully primed and pressurised even when in idle mode, water is delivered at the required

pressure and flow as soon as any wash-down gun is activated. Thus, it is not necessary to keep high pressure water recirculating and the pump running constantly at high speed.

This capability saves energy and reduces wear on the pump and its components. As each additional gun is opened, the pump speed ramps up in response to the increased demand, then slows down when no longer required. As a result, each operator will not notice any drop-off in cleaning performance when coworkers activate adjacent guns.

When left in idle mode for longer periods of time, the control stops the pump completely to save energy, yet the system still responds instantly when any wash-down gun is activated. Finally, built-in protection against dry-running should there be any disruption to the water supply, as well as automatic detection of both minor and major pipework leaks, comes as standard.

The Wash-Saver concept can be applied to any of Cat Pumps’ reciprocating high pressure positive displacement triplex plunger pumps, enabling individual configuration to any size of wash-down plant.

The Wash-Saver’s pump, drive motor, accessories and VFD panel come fully assembled, tested and pre-configured

Verderflex peristaltic pumps replace mag drive pumps in water treatment Verderflex recently provided a solution to a Swiss airport that had been experiencing significant problems with its water softening treatment. The local water supply required treatment to prevent scaling in the pipework.

The existing treatment system required a salt solution to be dosed from a storage tank close to the pumps over a 350m pipe-run to the water supply. The piping system had a series of valves and pipes which were not sealed correctly when they were installed and the pipe work contained a large proportion of air.

Consequently, although the mag drive pumps that were transferring the solution were of good quality, intermittent use meant they ran dry, leading to bearing failure. These mag drive pumps had to be replaced every three months, resulting in plant downtime and high maintenance costs.

Due to the scale of the airport’s construction and layout, it was not possible to install new pipe work and valves and a far more robust pumping solution was needed which would not only dose the solution accurately, but also one that required less maintenance when compared to a mag drive centrifugal pump.

A Verderflex Dura 35 peristaltic hose pump was used for this application. A peristaltic pump consists of a hose, housed

Verderflex utilised its Dura 35 peristaltic hose pump at the airport

in a casing and squeezed by a rotor. As the only part in contact with the fluid is a flexible hose, the pump can run dry and certainly tolerate air in the pipes. The pump itself was sized to run slowly, so as to increase the hose life.

The estimated running time of less than

1,200 hours per year with one year between hose changes was considered favourable.

The Verderflex Dura brand is established in the water and wastewater industry for the delivery of abrasive and corrosive solutions such as lime chemical, sodium hypochlorite and sodium hydroxide.

Hydra-Cell excels in zero liquid discharge The addition of super duplex stainless steel to the range of liquid head materials available now enables pump manufacturer Wanner’s Hydra-Cell G15 pumps to manage the toughto-handle wastewaters processed in zero liquid discharge (ZLD) systems.

As water becomes an ever more expensive commodity, industrial, oil, chemical and petrochemical companies are increasingly turning to ZLD systems, minimising wastewater discharge and maximising water recovery.

Frequently these wastewaters have high levels of total dissolved solids (TDS) and many contain particulate matter that can cause severe wear in pumps with tight tolerances and rapidly degrade seals. Having no tight tolerances and no dynamic seals to wear, Hydra-Cell pumps are proving to be ideal for this application.

Many of these waste streams have a high chloride content, which causes rapid corrosion, even within stainless steel pumps.

Because of the way the Hydra-Cell pump

is designed, it has only been necessary to incorporate 2507 Super Duplex liquid ends (manifolds and valve plates) in order to overcome this potential corrosion problem.

A plunger or piston pump would require substantial modification of many components in order to overcome such a corrosion threat.

Hydra-Cell pumps meet the pressure requirements of membrane filtration systems and concentrators while requiring little in the way of maintenance.

Milton Roy unveils latest pump offering Milton Roy, the world’s largest manufacturer of controlled volume pumps, has unveiled a new metering pump for deeper offshore wells.

The Primeroyal X is the latest pump in the Primeroyal series. Conforming to API 675 standards, the new pump provides 20,000 psig to withstand the extreme pressures associated with operating at deeper depths.

It is designed to provide consistent chemical delivery

Great Plains Industries launches new line of heavy-duty transfer pumps Great Plains Industries (GPI) has launched a new brand of commercial grade fuel transfer pumps and products.

The GPRO brand is a line of heavy-duty, professional grade fuel transfer pumps and products for commercial and professional-grade applications.

‘The new line was developed for the special needs and demands of the professionals who themselves demand performance from the products that support them,’ says Derek Griswold, GPI marketing manager.

The GPRO line launched with the PRO20 Extreme Temperature Series and PRO25 pumps. GPRO products come with a new four-year warranty.

with chemicals such as methanol, monoethylene glycol and corrosion inhibitors to improve flow and enhance product recovery. The pump helps to prevent hydrate formation, wax deposits and corrosion.

Milton Roy offers a range of products for fluid handling applications, including a side entry mixer designed for large storage tanks (up to 200,000m3).

It is quickly and easily mounted on the tank flange to deliver the most effective mixing results.

The Primeroyal X metering pump for deep offshore well applications

Flowserve to supply pumping systems to French power generation firm Flowserve, a provider of flow control products and services for the global infrastructure markets, has received a major order to provide multiple pumping systems to Alstom, a France-based company specialising in power generation.

The orders, totalling approximately $30 million (€23.6 million), were booked in the second quarter of 2014. The pumping systems will be used for boiler feedwater and condensate service at two units for a new ultra-supercritical (USC), coal-fired power plant in Opole, Poland.

The two units, each generating 900MW, will be operated by Polska Grupa Energetyczna (PGE), Poland’s largest power-producing company. This USC coal-fired power plant will be the largest coal-fuelled facility in Poland

upon its anticipated completion in 2019. The pumping systems servicing the two units include type CHTA main feedwater pumps, which are double casing, multistage barrel pumps; and type HDX booster pumps, which are single-stage, radially split, double-suction pumps. These pumps are built specifically to withstand ultra-high temperatures and pressures, making them ideal for safe and reliable operation at USCs. Flowserve will also supply APKD condensate pumps, which are canned vertical pumps.

In addition to the main feedwater and booster pumps, the Flowserve systems will include electric motors, variable speed hydrocouplings, support systems and required instrumentation. Flowserve will also supervise the installation and start-up of the equipment.

Alfa Laval to supply Framo pump systems for Atlantic oil platform Alfa Laval, a company specialising in heat transfer, centrifugal separation and fluid handling, has won an order to supply Framo water pumping systems to an oil drilling platform that will be located in the Atlantic Ocean off the Canadian coast. The order, booked in the Marine & Offshore Pumping Systems segment, has a value of approximately SEK 120 million (€13.1 million)

and delivery is scheduled for 2015.

The order consists of water pumping systems for an offshore oil platform that will be located east of Newfoundland.

It is the second large order for Framo products since the brand was included in Alfa Laval’s offering through the acquisition of pump supplier Frank Mohn AS.

NOV Mono equipment chosen as offshore sewage handling solution Three TR Munchers and three Compact C range pumps from NOV Mono have been chosen for a demanding sewage handling operation in the Caspian Sea. They will be used to macerate and pump black water on a deepwater semi-submersible drilling rig which is located there.

The Mono equipment has been selected by Wärtsilä Water Systems, which provides products and solutions for offshore facilities used in oil and gas exploration, development, and production, as well as marine vessels.

‘The equipment we provide for a project such as this will have to withstand some extremely harsh offshore conditions and comply with environmental legislation. So we need pumps and macerators that we can rely on,’ says Wärtsilä’s projects manager, Jeremy Freeman.

The Mono TR Munchers will be used to macerate the black and grey water produced on the platform, at a capacity of 8.8m3/h. They are designed specifically for the maceration of abrasive sludges, and are effective in capturing irregular shaped objects thanks to layback cutter shafts which are set at an angle to the incoming flow. The shafts operate at different speeds to tear apart any solids, while a cantilever shaft design reduces the number of wearing components

As the old English expression goes: “If you pay peanuts, you get monkeys...”

by eliminating the need for bottom bearings and seals Each Muncher also features Mono’s EZstrip technology which allows the unit to be maintained in place, reducing the maintenance time required. Any rejected objects are allowed to fall into an easy-access waste trap which is set below the cutter stacks to prevent damage.

Munchers can be supplied to comply with the ATEX Directive 94/9/ EC for this type of hazardous area application.

The three Mono Compact C Range progressing cavity pumps, which operate with a Wärtsilä Water Systems membrane bioreactor, provide a fluid transfer solution that will fit into the compact space of the platform and still perform at 2bar pressure. These high-pressure pumps are available in cast iron or stainless steel, and with a choice of rotor and stator materials for different applications.

They offer a suction lift capability of over 8m and, in addition to applications such as this one, their positive displacement, progressing cavity action also makes the C Range pumps ideal for accurate process control and variable speed dosing duties. As with the TR Muncher, the Compact C Range pumps can be supplied to comply with the ATEX Directive 94/9/EC.

NOV Mono technology has been chosen for sewage handling operations on a deepwater semi-submersible drilling rig that will operate in the Caspian Sea

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New vortex flowmeter from Krohne Krohne has introduced a new vortex flowmeter for the measurement of conducting and non-conducting liquids, gases and steam.

The Optiswirl 4200 is targeted at auxiliary and supply applications in various industries, such as internal monitoring of energy flows for saturated and superheated steam or hot water, and heat metering applications. Areas of usage also cover steam boiler monitoring, burner consumption measurement or compressed air network monitoring, including FAD applications.

In addition to gross heat calculation for steam, the Optiswirl 4200 includes net heat calculation for steam and condensate (hot water) as well. With one temperature sensor integrated as standard, the device can be installed a heat meter in the feed line directly connected with an external temperature sensor in the return line. The gross and net

heat calculation can be fed into a DCS to support advanced energy management.

Temperature and pressure compensation options are also available for the flowmeter to enable calculation of standard flow volume under fluctuating pressures and temperatures (online density compensation).

Both compensation functions are based on the standards of NIST (for gas) respectively IAPWS (for steam). Another advantage is that by combining three measurements (flow, temperature and pressure) in one 2-wiredevice, the line has to be opened only once for installation.

In addition to the standard sensor range, a version with integrated reduction of nominal diameter up to two sizes is now available for space-saving installations and large measuring spans.

The remote version Optiswirl 4200 F with field housing converter is available with

connection cable up to 50m. A dual version with two independent sensors and two signal converters is also available for multiproduct pipelines, redundant measurement or increased safety demands.

Enhancements have also been made on the electronics side: equipped with new AVFD function (Advanced Vortex Frequency Detection), the newly developed signal converter VFC 200 of the flowmeter features advanced signal processing and filtering.

Redundant data management prevents loss of calibration and configuration data when changing electronics or display.

By default, all Optiswirl devices are wet-calibrated at factory (traceable to international standards) and pre-set to match customer specifications. The Optiswirl 4200 also comes with an installation wizard to ease installation; e.g. in a steam application it will only show related settings.

Coriolis flow transmitter for improved flow measurement Emerson Process Management has introduced a coriolis flow transmitter designed to translate measurement data into meaningful insight and instruction.

The Micro Motion Model 5700 Transmitter is applicable for a range of applications, from liquid and gas custody transfer to simple process control.

‘The Model 5700 transmitter was developed using Emerson’s Human Centred Design approach to technology innovation,’ says Jason Leapley, product manager.

‘We performed usability testing to fully understand user information demands and real-world application requirements. Every feature of the Model 5700 was designed to reduce the time and expertise needed to

install and operate the coriolis meter.’

The transmitter provides users access to detailed measurement history for troubleshooting or optimising the process.

The graphical user interface was designed for intuitive operation, with simplified installation, configuration, maintenance and troubleshooting. The new transmitter translates coriolis measurement data into useful operating insight through robust, time-stamped history files for process and meter health data, and logs for configuration changes and alarms.

Digital signal processing architecture provides fast flow response time, making it optimal for custody transfer proving and short batching applications. The historian

feature also improves Micro Motion Smart Meter Verification, which provides measurement of the full meter health without process interruption.

Compatible with new and previously installed Micro Motion ELITE coriolis sensors, the Model 5700 has a field-mount design that is suitable with most hazardous area installation practices and with both integral and remote installation options.

It currently includes options for analogue, pulse, discrete and Modbus outputs and an analogue or HART input. The Model 5700 and additional digital communication options will be available for other Micro Motion meters and platforms in the near future.

Titan Enterprises low inertia meter for measuring refrigerant flow Titan Enterprises has developed and is supplying a high pressure version of its 900 Series turbine flowmeter for measuring refrigerant flow.

Adapted with steel reinforced polymer components, to give a pressure rating of 40bar, the low inertia turbines of the 900 Series flowmeter are designed for measuring the low viscosities (0.3 to 0.4 centipoises) encountered with volatile refrigerant fluids measured in the liquid form. With careful sensor selection, the pressure drop through the 900 Series flowmeter has been designed to be low enough to prevent gas break-out and ensure reliable flow measurement.

The flowmeter is designed to give high performance (+/- 0.1% repeatability) across six flow ranges from 0.05 to 15 litres per minute. It’s

chemically resistant components make it suitable for the metering of a wide range of fluids from -25°C to 125°C. To ensure the highest degree of inertness to metered fluids, the flowmeter’s polymer components are moulded in an The 900 Series turbine flowmeter from Titan Enterprises FDA-approved grade of PDVF and detector. The output is a NPN mounted in a 316 stainless steel body.

At the heart of the flowmeter pulse that is readily interfaced is a precision turbine that rotates with most electronic display or freely on robust sapphire bearings recording devices. This combination and contains encapsulated ceramic of materials and technology ensures magnets that are detected through a long life product with reliable operation throughout. the chamber wall by a Hall effect

ABB releases new flowmeter for oil and gas upstream sector ABB, a power and automation technology group, has launched a new multi-phase flowmeter for measuring real-time production in the oil and gas upstream sector.

The Vega Isokinetic Sampling (VIS) multi-phase flowmeter is designed for monitoring the flow rates of produced oil, gas and water close to the wellhead.

VIS allows the measurement of three different phases at the same time.

VIS is based on a patented technology – the isokinetic sampling method that allows the withdrawal of a small representative portion of the main stream and separation into the different phases.

The flowmeter has been developed in collaboration with TEA Sistemi, a research company active in the upstream oil and gas sector based in Italy, and is designed to meet the

most demanding requirements of the oil and gas sectors, including well testing, production monitoring, production allocation and reservoir management.

Unlike traditional multiphase solutions, the ABB VIS is radioactive-free. This is important when dealing with shipping, handling, commissioning and decommissioning procedures. It also important

when applying for import and export permits and with any maintenance action performed on the device.

The flowmeter has no size limitations and can be applied to all the usual pipe dimensions.

In addition, the design can be customised in order to increase the gas turndown up to 100:1.

The largest turndown ratio for this application available on the market.

IST technology allows element adaptation for liquid flow measurement Thermal mass flow sensors and measuring systems are well-known devices that are offered in a wide range of products by a handful of suppliers in the marketplace.

Most of the designs are compact, ready to use systems with an inlet and an outlet, and a channel including a passive or an active output. These systems are sufficient for many general-purpose applications where component price and size are less significant, but they are not well-suited for pricesensitive and limited-space flow control

solutions.

The new Out-of-Liquid element from IST AG is designed to provide customers with the flexibility of easily adapting the element to an application and at a lower cost. Measuring flow directly in a liquid channel has proven a difficult task without dramatically shortening the lifetime and damaging the sensor especially because of debris and other contaminating elements in aggressive liquids.

Due to the external placement of the

Massa sensors

sensors, the Out-of-Liquid element from IST AG allows the possibility to create a go/no go application or to measure the flow going through the channel with double elements.

The principle used is IST AG’s proven thermal mass flow measuring principle. A heater and a sensor chip, both with backside metallisation, are soldered on the tube’s outer surface providing thermal contact with the liquid without being in direct contact with it, meaning the Out-of-Liquid element is suitable for aggressive liquids.

New valve stem packing material from Garlock available worldwide Sealing specialist Garlock has announced the availability of Style 5882 valve stem packing material through the company’s global network of distributors.

Recently released only in North America, Style 5882 is now available worldwide. It provides low-friction performance for airoperated valves built to handle water, air and steam.

Style 5882 products are manufactured using a high-quality braided carbon fibre

core sheathed in a durable PTFE layer, which delivers low-friction performance without sacrificing enhanced service life and durability.

Three Garlock Style 5882 valve stem packing line options are available: Garlock Style 5882 Spool – Spool-based material offers low-friction performance for applications up to 260°C. Garlock Style 5882 Die-Formed – A dieformed material featuring bevel cut rings for

New NanoScreen multiformat liquid handling system for laboratories NanoScreen, a specialist in automated liquid handling products for the life sciences, has released a new liquid handling workstation.

Orion is a flexible, multi-format, high precision pipetting robot designed to meet the liquid handling needs of today’s laboratories.

‘We wanted to design a high performance liquid handling workstation that is easily accessible, programmable, expandable and simple to integrate,’ says Imad Mansour, chief science officer. ‘Orion is ideal for any plate-based application.’

The workstation features a 12-position deck and many dispense head options. Its compact size allows it to be used in most laboratory fume hoods or on any standard laboratory bench top.

Orion’s human interface, Cosmo, is designed with the ‘walk up’ user in mind. Users do not have to drill down through menus and multiple dialog boxes in order to do the most basic of things, such as building methods and screening compounds, allowing simplicity for high throughput screening in the laboratory.

Boca Bearings releases ceramic bearings for harsh environments Boca Bearings has released a ceramic bearing line specially designed for the harsh environments and the machinery used in wastewater management, water treatment, and liquid handling. Boca Bearings provides solutions for wastewater treatment facilities by offering bearings which can work in different types of machines and steps of the fluid handling process.

The company’s ceramic bearings require little to no lubrication or other maintenance and can be applied to different water/fluid handling machinery, such as pumps, flowmeters, and hydraulic equipment.

As ceramic bearings do not corrode or rust they can be used with different chemicals, from ion or sodium to alkali.

All Boca Bearings’ bearings can be supplied without lubrication or with specialty lubricants, such as a solid poly lube or ultra-dry lube.

precise and easy installation during planned outages.

Garlock Style 5882 LSP Set – Engineered with die-formed graphite middle rings and lower PTFE content for higher heat dissipation. This material is a combination of Graph-Lock and Garlock Style 5882 rings.

Garlock Style 5882 valve stem packing materials are available with carbon bushings, and can be custom designed for unique dimensional requirements.

Denver Thomas releases damper for specialist applications A special standard damper has been developed by Gardner Denver Thomas to offer a solution for portable and stationary devices for medical, analytical and other applications that require an extremely low sound and low vibration level of all functional parts.

In the past individual adaptions have been created by customers in cooperation with the component manufacturers.

The zero vibration damper consists of a standard kit including the mounting plate, shock mounts and assembly screws. By mounting the pump on the damper unit and then to the OEM’s device, the vibration transmitted from the pump to the end unit is greatly reduced. Hereby, the overall sound level is attenuated as

well. The design enables a reduction of vibrations in all levels and the startup torques can also be balanced. The customer has to consider just two fixing points which enables a simple integration of the new module pump-damper.

Positions possible are hanging or standing.

All tooled parts have been qualified in order to guarantee the fatigue resistance of all parts and have successfully completed a drop test.

The damper is available in three sizes and specifically designed to fit existing and upcoming Thomas product lines including different motor options.

The solution is suitable for various applications including patient monitoring systems, chemical and clinical analysers, printing systems and more.

New Victaulic assembly system for offshore oil platforms Victaulic, a manufacturer of mechanical pipe-joining systems, has introduced the Style DLY Delta-Y assembly, a combination of pre-assembled Victaulic cast grooved fittings, rigid couplings and butterfly valves. The Delta-Y assembly is designed specifically for bulk cement/barite systems on offshore oil platforms and is also ideal for drilling mud and other associated systems.

The Victaulic Delta-Y assembly speeds fitting and valve installation. Each preassembled unit is delivered complete with all fittings and valves oriented correctly as required by system design. The unit is joined to the piping system with three Style 107 QuickVic rigid couplings, easing

installation.

The assembly is designed to improve the operational efficiency of cement/barite piping systems. The offset disc within the valves provides a larger flow area for more efficient flow, low operating torque and leak-tight sealing. The fittings maintain full wall thickness and have a smooth inner flow path to minimise abrasion and blockages. The Delta-Y assembly is also available with 5D Long Sweep fittings that increase fitting life and maximise flow capabilities for faster cementing operation.

The Victaulic Style DLY Delta-Y assembly is available in 5” and 6” pipe sizes (125 and 150mm) and has a pressure rating of 300 psi (2,065 kPa).

Waukesha Bearings puts new thrust bearing platform in the spotlight Waukesha Bearings recently introduced its new thrust bearing for high-temperature electric submersible pumps (ESPs).

The Hidrax HT tilt pad thrust bearing can sustain unit loads of 1160 psi (8 MPa) at oil bath temperatures up to 300°C. Technological advances in steam-assisted gravity drainage (SAGD) are increasing ESP operating temperatures and placing increased demands on the thrust bearings located in the motor seal/protector section of the ESP string.

The Hidrax HT bearing is

a drop-in replacement option for equipment requiring increased load capacity at high temperatures. The bearing is available in sizes up to 200mm (8”), with centre or offset pivot designs. Given the hardness of the Hidrax HT bearing surface, the rotating thrust collar surface must be hard as well.

Waukesha Bearings can supply an appropriate thrust collar that is designed to work well with the Hidrax HT bearing.

The Hidrax tilt pad thrust bearing platform is well-proven with polymer surfaces, with 200,000 supplied to date.

The Hidrax HT thrust bearing for high-temperature ESPs

Dover acquires Accelerated Companies in multimillion dollar deal Global manufacturer Dover has acquired Accelerated Companies, a supplier of artificial lift and fluid handling solutions to oil and gas production markets, for a purchase price of $430 million (€338.6 million), subject to a customary adjustment for working capital.

Headquartered in Texas, US, Accelerated’s core offerings include electric submersible pumps (ESP), hydraulic jet pump systems, gas lift systems, surface pumping and modular

process systems for filtration, separation, heating and other fluid handling operations.

Accelerated will become part of Dover Artificial Lift, a business unit within Dover’s Energy segment.

Accelerated’s offerings in ESP and jet pump technologies complement Dover Artificial Lift’s position in systems, components and automation for rod lift, gas lift, plunger lift, progressing cavity pump applications and surface production.

Numerex introduces new remote systems for oil and gas field automation Numerex, a provider of interactive and on-demand machine-to-machine (M2M) enterprise solutions, has launched a portfolio of monitoring solutions preconfigured for oil and gas well sites.

AVIDwireless allows users to monitor and control pump site machinery remotely utilising M2M technology. This offering fits any size remote well site, from small marginal wells to large multi-location fields.

The end-to-end monitoring solutions are designed to improve performance, reduce costs, and improve efficiencies for oil and gas well operations. These remote monitoring solutions act as a gateway for checking, analysing, and reporting data from smart sensors; providing information from all of the assets in the field. The three new AVIDwireless preconfigured solutions include: • AVIDwireless tank monitoring – Constant monitoring of capture-tank levels allows automated pump shutdown when a high-level condition is detected.

Control pumps remotely from the website or by utilising a mobile device

in the field. Alerts and notifications can be sent immediately, keeping operators informed and assisting in avoiding capture-tank issues.

• AVIDwireless generator monitoring – Wireless remote monitoring, control and diagnostics for power generator systems help maximize uptime through monitoring of fuel levels, power, runtime, and by providing the physical location of equipment. Mitigate performance risks through remote monitoring of battery level, block heater performance, and other common failure points.

• AVIDwireless site automation – Designed for multi-site applications, this solution offers constant monitoring and remote control of levels (tank, pressure, temperature, pump status, flare, ESD events) utilising AVIDSmartNodes and an AVIDdirector controller. The solution features Modbus protocol for easy connection with existing equipment.

Operators can deploy multiple AVIDSmartNodes, with a range of 2km; permitting control of multiple wells from a single AVIDdirector.

The acquisition puts Dover in a position within the US shale well development market.

Accelerated’s 2014 revenue is estimated to be approximately $225 million. Dover expects this acquisition to be approximately $0.03 dilutive to fourth quarter 2014 continuing earnings per share due to normal transaction-related costs, including purchase accounting amortisation. In 2015, Accelerated is expected to be $0.05 to $0.06 accretive to continuing earnings per share.

Technip investing in modernisation of flexible pipe plant in France Technip has announced an investment over four years to modernise its flexible pipe manufacturing plant, Flexi France, in Le Trait, France.

Further strengthening Technip’s industrial capabilities at the site will reinforce its position in the production of flexible pipes for the development of offshore oil and gas fields.

The modernisation plan focuses on the installation of new-generation machines and site optimisation to fit 12m diameter reels on which flexible pipes are spooled.

Increasing the reel capacity from 9.6 to 12m in diameter will provide room for twice as much flexible pipe on each reel. Technip’s investment will also create a new area dedicated to the testing of these pipes.

This investment amounts to €68 million and is part of Technip’s technological innovation and differentiation strategy. Field developments are becoming increasingly complex, including deepwater operations with higher pressure levels and more corrosive fluids.

Flux drum emptying system for transferring high-viscosity fluids German pump technology firm Flux-Geräte is now offering customers a solution for transferring high-viscosity materials from special sea container drums.

The follower plate and process seal of the Viscoflux mobile drum emptying system is designed for opening diameters of lidded drums with 560mm and 571mm as standard.

During the fluid transfer process the process seal adapts to beadings and slight dents. The wall of the drum is stripped so that it is almost entirely residuefree, meaning that residual quantities of less than 1% (less than 2% for drums with aseptic bags) can be achieved.

In contrast to ISO lidded

drums, special sea container drums have a single drum rim that tapers slightly, resulting in a smaller opening diameter. The challenge lies in configuring the follower plate and process seal so that they can reach into the narrow drum opening without exerting great pressure.

On the other hand, they must bear enough tension to allow for the drum wall to be stripped properly. This has been achieved by reducing the size of the follower plate, whilst at the same time marginally strengthening the process seal. The Viscoflux mobile can achieve the same results with drums suitable for containers as with a standard ISO lidded drum.

The Viscoflux system can gently transfer high-viscosity materials, such as Vaseline, even from special sea container drums

Be informed. Be inspired. Be there.

Frankfurt am Main · 15 – 19 June 2015

➢ World Forum and Leading Show for the Process Industries

➢ 3,800 Exhibitors from 50 Countries ➢ 170,000 Attendees from 100 Countries

www.achema.de

Ultrasonics in Uerdingen divisions. The isocyanates methylene diphenyl diisocyanate (MDI) and tolulene diisocyanate (TDI) are important intermediate products for the production of polyurethane.

MDI is a raw material used particularly for producing rigid polyurethane foams. They have the best dye insulation performance Flexim manufactures a range of systems for non-invasive flow measuremernt of all material currently available on the market and are used product during the production of MDI. It in cold chains as well as for heat insulation in is then reprocessed and transferred to the the construction industry. TDI is used in large chlorine division at the Chempark plant in volumes to produce flexible polyurethane a concentration of approximately 32%. The foam for upholstered desired concentration is set by adding diluted furniture, mattresses and acid to the HCI absorbers. In order to load car seats. them evenly and add the correct amount of Alternative technology with a longer Bayer MaterialScience diluted acid, the quantity of HCI gas must service life was sought in Uerdingen operates a multibe measured at the inlet of the absorber. line MDI plant at its The facility cannot be operated without flow Uerdingen site. All measurement at this point.

Due to the specific requirements regarding common measurement processes are used the reliability of the measurement, this was conventionally done using a measuring orifice for flow measurement up until now. However, even this apparently here: magnetic-inductive sound measuring equipment did not reach flowmeters and measuring satisfactory service life. In particular, the small orifices, coriolis and tubes of the pressure transducer proved vortex flowmeters, in-line to be susceptible to wear. The result was ultrasonic devices and frequent leakages. Necessary maintenance clamp-on systems. work means the system must be shut down and an enormous amount of work is involved.

Non-invasive flow The pipelines are emptied and cleaned under measurement of compressed air conditions.

HCl gas The installation of the Fluxus G clamp-on ultrasonic measuring system means trouble Hydrochloric acid with leaking pressure transducers and plant is produced as a by-

It seems as though the flow rate could be miraculously measured by simply laying a hand on the pipe. However, the times of scepticism towards non-invasive ultrasonic flow measurement technology are over.

Clamp-on ultrasonic technology is now extremely popular. In saying that, not every measuring task is a standard practice. Hightemperature applications and non-invasive flow measurement of gases are still jobs to be done by specialists.

Flow measurement with clamp-on ultrasonic technology means no wear and tear by the medium, no risk of leakages, and no pressure loss. As ultrasonic transducers are simply attached to the outside of the pipe, there is no need for pipe work. The measuring point is usually fitted during ongoing operation.

As is the case in many modern chemical companies, staff at Bayer MaterialScience in Uerdingen appreciate the advantages of noninvasive measurement. Bayer MaterialScience’s business is the plastics and chemical industry.

With sales of €7.5 billion in 2009, it is among the world’s largest polymer companies. The polyurethane sector is the most important of Bayer MaterialScience’s three business

Acoustic measurement is accurate over a wide range

downtimes for maintenance work on the measuring equipment are now a thing of the past. Due to its working principle, non-invasive measuring technology has an advantage over measurement according to the pressure difference method. Measuring orifices only make reasonably accurate measurements in a very limited measuring range. The acoustic method, on the other hand, provides high accuracy over a wide measuring range.

Superior acoustics Admittedly, measurement is not as easy as it might appear. ‘A few years ago no one would have ever dared to imagine that the flow of gases could be measured non-invasively with clamp-on technology,’ says Heinrich Brucks, who is responsible for the plant in Uerdingen.

The challenge lies in the difficult acoustic conditions. As with the flow measurement of fluids, the Fluxus G ultrasonic measuring systems also measure the flow of gases according to the transit-time difference method. The acoustic transducers which are clamped onto the pipe send and receive ultrasonic signals which are directed in and against the direction of flow in the pipe. The flow velocity is calculated from the measured transit-time difference and the geometry of the measuring point. Contrary to the undemanding clamp-on flow measurement of fluids, only part of the sound enters into the medium to be measured during gas measurement. The remaining sound produced stays in the pipe wall and acts as background noise there. The measuring transducer effectively takes on the role of digital drudgery for separation of wanted signals and disturbing signals. Since the density of the gas increases with rising pressure and its acoustic impedance approaches that of the pipe wall, coupling of the ultrasonic signal is considerably better at high pressures. Therefore, noninvasive measuring methods work very well at high and extremely high operating pressures which are often associated with high costs and a great deal of effort in many other methods.

However, a slight vacuum of approximately -20 mbar prevails at the measuring point in the Uerdingen MDI plant.

Due to several improvements in all areas of signal generation, integration and processing, the minimum pressure required for non-invasive gas flow measurement could be reduced further. As the aggressive and hazardous HCI gas is guided in PVDF plastic pipes with a GRP coating, the measuring signal is integrated very well into the medium. The relatively large nominal pipe width DN400 is also not a problem for the Fluxus G 800 measuring transducer. Due to its significance, the measurement was carried out on two channels. The flow rates measured by Fluxus G are fed into the process control system and used for automatically controlling the addition of dilute acid.

High temperature measurement of liquid MDI During industrial production of MDI from diaminodiphenylmethane, a complex compound MDI oligomer mixture is formed at first and then purified by distillation in several distillation columns. In order to ensure safe and reliable processing, the various product flows must be measured continuously. This also includes the mass flow which is returned from the bottom area of the distillation column. In this case, high temperatures and viscous media place high demands on the reliability and efficiency of the flowmeters used.

Flexim installed a WaveInjector for flow measurement of the bottom product of MDI distillation. The patented high temperature measuring device thermally separates the ultrasonic transducers of the Fluxus from the pipe while also ensuring their acoustic coupling.

Non-invasive measurement technology distinguishes itself with a number of advantages: unlike vortex meters, which were previously used at this point for flow measurement, clampon flow transducers, which are attached to the outside of the pipe, are not subject to wear and tear by the medium and do not cause any pressure loss. In addition, the measuring system is attached simply during ongoing operation without any pipe work. The ultrasonic sensor, installed instead of the vortex meter which is prone to wear and tear, did not deliver permanently reliable measurement results.

Now the ultrasonic measurement system made up of the Fluxus and WaveInjector measures the return flow rate reliably and smoothly.

For more information: This article was written by JĂśrg Sacher, corporate communications, press & PR, Flexim.Visit: www.flexim.com

MDI product flows must be measured continuously

Positively precise Positive displacement flowmeters (PD meters) have been utilised among important applications such as petroleum trading for many years, since PD meters, in principle, can measure the volumetric flow directly with high accuracy.

The recent concerns about energy conservation and environmental issues have made it imperative for companies working in these applications to seek highly accurate measurement of fuel consumption. Society also demands an improvement in accuracy for petroleum measurement as it is a high-priced commodity and vast amounts are traded every day. The establishment of reliable flow measurement requires national standards that provide flowmeter manufacturers and petrorelated calibration facilities with the standard values for high accuracy.

Using Japan as an example, it is for these reasons that ISO17025 and the Japan Calibration Service System (JCSS) are defined

Clearance and leakage

Construction of the axial-flow PD meter

to ensure the traceability of national standards in the country.

To satisfy these market demands, Tokyobased manufacturer Oval has developed a

PD meter capable of accurately measuring petroleum fluids which vary in material values, and where viscosity and other characteristics dramatically fluctuate depending on the temperature – the UF-X axial-flow positive displacement meter.

In general, PD meters form measuring chambers with the casing and rotors. The rotation of the rotors transport the measured fluid from the inlet to the outlet. This principle is practically the same as measuring the fluid with a bucket continuously and has been used through the ages for direct volumetric

Leakage in an axial-flow PD meter

The performance evaluation test result of UF-X

measurement.

There are small clearances between the casing and the rotors to allow rotors to revolve without touching the casing. However, for the measurement of extremely low flow rates and processes which require high accuracy, the leakage from the clearance cannot be ignored. This slight leakage is generated by the pressure difference at the clearance and is not included in the volume of the measuring chamber resulting in an error.

As for oval-gear PD meters, clearances exist at the top and the side of the rotors, each causing leakages.

Features As opposed to typical PD meters with rotors obstructing the flow, the axial-flow PD meter utilizes rotors whose axes are placed concentrically to that of the flow passage.

The measuring principle of an axial-flow PD meter uses the energy of the fluid to generate torque on the spindles which continuously transport the fluid from the flow inlet to the flow outlet via the volume of the measuring chamber. Pulse signals are generated relative to the rotation of the rotors. The most notable feature of an axial-flow PD meter is that there is no side-clearance as with an ovalgear meter, thereby limiting the leakage to the top-clearance to achieve high accuracy.

Mechanism The UF-X holds a pair of isometric dualhelical ridged rotors. The only difference between the two rotors is the direction of the spiral. Manufacturing single-ridge rotors is more feasible; however, intense vibrations generated by dynamic imbalances at high rotational rates limit the allowable flow range.

Additionally, the bottom-to-edge ratio of the rotor ridge diameter is set high so that the discharged volume increases proportionally to the rotor size. These methods improve the accuracy at low flow rates, widen the allowable flow range, and avert vibrations at high rotational rates. The rotor ridges are also

UF-X appearance

engineered to achieve high sealing capability and low rotational resistance. Therefore, the UF-X can measure without being affected by the material values of the fluid.

Performance The graph above shows the result of performance evaluation tests. The plot shows instrumental error after temperature correction on the vertical axis, and flow rate on the horizontal axis. In the tested flow range, instrumental error is kept within ±0.1% for each type of fluid and repeatability is kept within ±0.05%. Considering the repeatability and influence of temperature on each fluid, the span of instrumental error is within 0.2%.

Furthermore, no significant fluctuation of instrumental error was observed to be caused by differences in temperature and fluid type, suggesting the reduction of leakage in the measuring chamber.

Positive displacement meters have earned users’ trust during their long history, especially in the field of petroleum trading. The UFX

axial-flow PD meter operates with high accuracy and satisfies the requirements for the specified secondary standard instrument which is necessary for JCSS registration.

The demand for petroleum in Japan is predicted to gradually decrease due to the recent transition of energy sources from petroleum to gas.Yet, the measurement of petroleum continues to play a critical role due to thermal power generation supplementing the shrinkage of nuclear-generated power.

For more information: This article was written by Mr. Hideki Ishikawa, deputy general manager, marketing division, and Mr. Tomoyuki Shoji, manager, international sales division, Oval Corporation.

Visit: www.oval.co.jp/english

General specifications of the UF-X 1. Nominal diameter: 50mm (2”), 80mm (3”), 150mm (6”) 2. Applicable fluids: petrol, kerosene, light oil, heavy oil (max. 100 mPa•s) 3. Operating temperature range 1) Fluid: 0 to +80˚C (+75˚C for explosion-proof configuration) 2) Atmosphere: -20 to +70˚C (-20 to +50˚C for explosion-proof configuration) 4. Maximum operating pressure: 7.7MPa (varies with flange standards) 5. Accuracy 1) ±0.07%: for one liquid (petroleums) under 5mPa•s 2) ±0.10%: for three liquids (i.e. petrol, kerosene, and light oil) 3) ±0.15%: for four liquids (i.e. petrol, kerosene, light oil, and heavy oil) 6. Flow range 1) 50mm: 3 to 30m3/h 2) 80mm: 5 to 50m3/h 3) 150mm: 30 to 300m3/h

The importance of

flow monitoring No matter how sophisticated a fluid analyser system may be, it will be ineffective if a sample flow fails to reach the analyser sensor or if the sample is contaminated or stale. The most advanced systems in the world cannot provide accurate results without a valid fluid sample.

Gas chromatographs (GCs), mass spectrometers, optical spectrometers, and photometers are a few examples of analyser technologies applied in process and plant systems that need sample flow assurance.

It is an accepted industry best practice that sampling systems have some type of flow monitor to assure valid samples and analysis.

Failing to monitor fluid flow to the analyser may result in contaminated product batches and discharging regulated substances. The costs of analyser failure are potentially huge in terms of affecting product materials, damage to equipment, regulatory fines, liability and more.

While there are a number of fluid flow monitoring technologies on the market, immersible thermal dispersion technology combined with packaging and sensor designs optimised for sampling systems has emerged as the new ‘best-in-class’. Thermal dispersion mass flow sensors have proven themselves for decades as extremely reliable in other demanding process and plant applications— often in relatively close proximity to analyser systems.

Recent developments The trend to mount the sample-handling system at the process has greatly enhanced process efficiency. Recent developments in packaging and speed now make it possible to run analyser systems more efficiently, utilising the real time information to process on line in batch mode. Developments in continuous flow reactors combine with analytics and new sampling systems to improve reaction times. More and more systems now provide

Typical sampling system

analysis of the process in real time, making the integrity of the readings that much more important to the success of the process. The ideal flow monitor should provide the form, fit and functions that will accommodate both these new generation analyser systems and traditional legacy and hybrid designs.

Depending on the analyser type, sampling fluid is often transported in DN6 (1/8”) to DN15 (1/2”) tubing. Most systems typically draw small samples in DN8 (1/4”) tubes.

Also growing in popularity are systems based upon the industry standard SP76 manifold.

SP76 is an ANSI/ISA standard approved in 2002 that is supported and has been adopted worldwide by major chemical and refining companies.

SP76 and NeSSI basics Leading the way for the SP76 standard is the New Sampling/Sensor Initiative (NeSSI) organisation, initially created in 1999 through discussions in a Centre for Process Analytical Chemistry’s (CPAC) oil and petrochemical focus group. Other organisations have embraced and are promoting NeSSI/ SP76, including the International Forum for Process Analytical Chemistry (IFPAC) and the Federation of Analytical Chemistry and Spectroscopy Societies (FACSS).

Each block of a typical SP76 train is 38 x 38mm2 (1.5 x1.5”) and effectively becomes a convenient plug and play modular surface mount interface for numerous sampling

FS10A mounted in SP76 manifold

system components. The NeSSI group remains active in advancing enhancements for the process analysis community. Beyond the initial physical interface of the SP76 manifold itself, the group has defined progressive levels of sophistication, known as Gen.1, II and III, which provide for digital bus communications, hazardous location approval types and the Sensor Actuator Manager (SAM).

Flow technologies Regardless of the analyser fluid sampling system configuration, flow monitoring is essential to ensure proper analyser operation. There are numerous methods and technologies available to monitor sample flow

Integral mounting on SP76 platform

on a real time basis. These can be mechanical spring or gravity loaded pistons, variable area types, differential pressure and thermal mass flow.

In most cases, a simple relay contact or solid state output change is all that is desired to indicate a reduction or absence of flow at a predetermined setting. A recent trend is driving the output requirements to include an analogue or digital communication signal to monitor the sample flow rate throughout the flow range. This allows operators to better predict flow declines due to disruptions caused by clogging filters, line contamination from fouling fluids, leaky or failing pumps, and other time and wear susceptible components in the system.

Mechanical devices normally have the advantage of not requiring power to operate.

However, a minimum amount of wires are still required to transmit an electronic signal (contact closure) back to the control system.

These devices are triggered by the force of the flow stream such that specific and fixed application details, including the sampled fluid’s density, viscosity, temperature, pressure, flow rate and, if non-adjustable type, the trip point, must be known and be specified when ordering them.

Furthermore, because springs, magnetic components and seals are all in the wetted flow stream, their material compatibility must also be evaluated by the specifying engineer.

While mechanical devices with factory fixed trip points can be one of the lower priced solutions, those with adjustable trip points are often double the cost and approaching the price of some of the more robust and sophisticated technology solutions mentioned later.

The leading drawback and most frequent user issue with these mechanical devices is their susceptibility to sticking over time. As all mechanical designs have moving parts in the flow stream, contaminating fluids can be a serious source of future failure. Fouling contaminants can progressively build up over months or years and are only detected when other failures in the system are detected.

These devices can also have areas that are exposed in the flow stream as they displace the flow path volume. In addition to being another area subject to clogging, they can trap previous samples or purge media which can contaminate subsequent samples.

Piston actuated devices also have no continuous visual indication of normal or abnormal flow conditions for the operator, other than their preset trip point.

Variable area meters have the advantage of continuous visual display of flow; however, they also are susceptible to sticking over time in many fluids. Their longer term

reliability is a concern expressed by analyser users. Adding a magnetic pickup to provide an electronic relay trip or an analogue output adds significantly to their cost.

Variable area meters tend to take up more valuable enclosure space than desired as they are orientation dependent and their flow input and output access are typically on different planes. FS10A in tube tee Differential pressure (dP) devices can be a sound technology to monitor analyser flow rates. Even in the small line sizes and at very low flow rates associated with analyser sampling systems, a properly sized orifice and sensitive pressure transducer can yield desirable results.

The two main disadvantages of dP technology are: (1) its limited flow rate turndown capability, and (2) the large errors incurred at the low end of the flow rate readings.Very often it is the low end that is critical for sample flow assurance and flow monitoring in analysers and sampling systems.

Unfortunately, optimising the flow range to the low end of dP sensors can result in an appreciable pressure drop and poor flow measurement performance at normal flows.

Similar to piston driven switches and variable area meters, dP flow monitors must be selected knowing the density and a specifically narrow flow rate range of the sample process. There are limited dP devices designed for the SP76 manifold. They require at least two block spaces and are the most expensive of all the monitoring devices.

Solving the problems An ideal flow monitor for an analyser sampling system would be one that can be adapted on site and adjusted specifically in the application. In addition, a more robust flow sensing technology married to flexible and user programmable electronics, which can be specified without detailed and finite validation of process variables such as density, viscosity, flow range, fluid type, etc., also would alleviate a pain point for the analyser system supplier and site engineering team.

Flow monitors designed with thermal

relative to a second thermal sensor measuring the process temperature. The temperature difference changes with flow rate.

In the case of gases, the measurement is directly related to mass flow. Immersible thermal flow monitors are very effective over wide flow ranges in gases, and over smaller low flow ranges in liquids.

Thermal technology is particularly advantageous in process analyser systems because it has no moving parts to wear, stick or foul. With their tiny thermowells and wetted materials typically made of 316L stainless steel and/or Hastelloy alloys, they are highly compatible FS10A in remote configuration; hot process sampling system (VAM/new shelter) and well suited for application in most dispersion technology match up well with analysers and sampling systems. the ideal universal use criteria to support an The thermal probe can be threaded into analyser sampling system. Depending on the industry-standard tube tee branches (e.g. manufacturer’s flow element and electronics Parker, Swagelok, Circor) or even into a design, they can be user set-up in situ to single block in the previously mentioned SP76 assure the field engineer a successful, first manifold, resulting in minimal dead space. time correct installation. These devices may be There are no cavities to trap previous samples configured in the field to operate in gases or so sample integrity is always the highest. liquids at almost any density or viscosity with Another key characteristic of thermal flow no special consideration at time of ordering. monitors for analyser applications is their There are two major types of thermal sensitivity to low flow rates. devices on the market. One type utilises a It is not uncommon to find analysers capillary bypass technique and is better known requiring preheated or hot process fluids. as a Mass Flow Controller or MFC. MFCs As thermal devices typically do not require divert a portion of the main flow into a small elastomer seals, and can be easily configured bypass and sense the heat transfer of flowing with the sensor element and electronics fluid in the bypass channel. This technique can separated (remote), they are often the best be very effective; however, the capillary tube and only solution for higher temperature is highly susceptible to contamination and service requirements, up to 260°C is common. clogging and should only be considered for Other features may include indicators/displays use with clean or pre-filtered fluids. Capillary of trip point status and flow rates, isolated bypass flow monitors are generally applied in SPDT alarm contact and analogue and/or lab use and agency approvals (e.g. FM, CSA, digital output to monitor flow trends.

ATEX, IECEx, etc.) for use in hazardous, Perhaps the most important benefit explosive environments are rare. Flow range of some types of thermal devices is their selection is also important when specifying ability to be field set and field adapted by MFC type flow monitors. the user for inexact, unknown or changed process and application conditions. Precisely and completely defined process conditions Immersible thermal dispersion and fluid variables are often lacking during technology the preliminary design and engineering The other type of thermal dispersion flow phase.Variations in tubing configuration, monitoring device is one that uses thermoflow direction layout, ambient and fluid wells in the flow stream, sometimes referred temperature conditions, pressure and density to as immersible-type. These types of devices variations, viscosity, flow range, fluid type typically apply heat to one thermal sensor and trip points are variables that are often

only finally determined after installation and site commissioning. Thermal dispersion flow technology based products with smart electronics can provide maximum field adjustability and site adaptability.

Based on its 50-plus years of experience with immersible thermal dispersion technology, FCI has developed the FS10A Analyser Flow Switch/Monitor specifically for gas and liquid process analysers and sampling systems. It features a fast responding, highly repeatable sensor that installs easily into a standard tube tee fitting or new SP76 (NeSSI) modular manifold. Its microprocessor-based electronics, on-board keypad and serial I/O computer port provide easy and extensive field adjustability. FS10A’s are also small, compact and lightweight so they fit in virtually any tubing array or mounting orientation. They are now operating successfully in multiple user sites worldwide.

Conclusions Flow sensors and monitors are just one of the components required in complex process analyser and sampling systems. While there are several flow monitoring technologies available that can be considered, their diversity can make proper selection a major challenge. The question becomes, ‘Which flow technology is optimum for the particular type of analyser application and its operating environment?’

Properly selecting a flow sensor for an analyser sampling system can take an inordinate amount of an engineer’s time because of the complex factors that must be reviewed. Consideration must be given to: • Diversity in measuring range • Fluid type and condition compatibility • Temperature and pressure condition suitability • Outputs and user interfaces • Approvals for Ex locations • Site adaptability and adjustability • Tube tee and SP76 compatibility • Dimensions, weight and orientation • Total installed cost.

Even then there is still worry about whether or how well the chosen flow monitor really functions when the system is commissioned, launched and put into operation.

To resolve these issues, look for the most flexible flow technology solution. A flow monitor that is adaptable and can be site set for almost any field condition variables, such as those based on immersible thermal dispersion technology, provides maximum confidence that the analyser system will perform as expected upon installation. The end result is an analyser that operates reliably, avoiding costly reworks and delays.

For more information: This article was written by Sam Kresch, product manager, Fluid Components International (FCI).

Visit: www.fluidcomponents.com

Calibrating profitability Global oil production now exceeds more than 90 million barrels per day (bpd), an increase of more than 1 million bpd over the 2013 average. For an industry that regularly communicates and tracks progress in millions of barrels and billions of dollars, a calibration error of just 0.5% seems insignificant at best.

However, such calibration errors are adding up to billions in potential profit lost every day.

Consider, for example, an active well producing approximately 5,000 barrels of crude each month. Using an arbitrary value of $90 (€71) per barrel, the well will generate $2.7 million over six months. If, however, production quantification is off just 0.5% (typical flowmeter uncertainty is 0.2-0.5%), the potential loss for that well is $13,500 over a typical six-month calibration interval.

If quantification measurements are off for an estimated 5% of production sites as some industry experts say, 57,000 of 1.15 million wells in the US alone are losing an estimated $1.5 billion every year.

Clearly, mere profitability is not a measure of full optimisation.

those from Bureau Veritas, are knowledgeable about the intricacies of making detailed measurements using a variety of calibration instruments. The expertise of such third-party specialists increases calibration accuracy to substantially reduce uncertainty as well as impacts to operations and the bottom line.

Whether the goal is custody transfer, process control or production allocation, qualified specialists using state-of-the-art quantification and calibration procedures and protocols ensure measurements are accurate so maximum profitability is achieved.

Calibration ensures measurement accuracy Numerous calibration methods exist, but all are designed to provide accurate, precise and repeatable results.

For storage tanks, ‘tank strapping’, a common calibration method for upright cylindrical tanks, employs a measuring tape – itself calibrated to National Institute of Standards and Technology (NIST) standards – to encircle the tank shell. For this method,

the calibration technician takes measurements at specified heights on the tank, recorded to an accuracy of 0.01 feet. These precise measurements are then used to calculate the tank’s volume and set the strapping tables.

Measuring horizontal cylinders and spherical tanks entails similar protocols which are established by American Petroleum Institute (API) standards.

As tank sizes have increased, tank strapping has become more difficult due to measuring tape sag and limited tape length; it does, however, remain one of the most costeffective and commonly used methods of tank calibration around the world.

Using liquid to measure volumetric meters is another method of tank calibration. This process requires the technician to fill the tank to be calibrated with clean fresh water flowed over a positive displacement meter to accurately measure volume used. The measured amount is compared to meter readings to complete calibration. While time consuming, this method is the most accurate calibration method.

Several optical methods of calibration

Achieving maximum profitability Investments that improve the efficiency of drill site identification and drilling technology have dramatically reduced the time and cost of turning a new location into a fully functioning production site. However, investments in the implementation of well-managed quantification and calibration programmes have lagged for many producers.

Over time and for many reasons, meters and quantification equipment can develop errors which result in quality issues, regulatory violations, unsafe working conditions and, of course, decreased profitability. Calibration defines and quantifies these variations by comparing against known quantity, called the standard. Optimisation ensures equipment is working properly and minimises any measurement uncertainty by accommodating for deviations from normal settings.

Third-party calibration specialists, such as

Equipment optimisation ensures correct working order and minimal uncertainty

through consistency and control. Each calibration must be highly accurate, so attention to detail is critical.

Counting every drop Flowmeters also require frequent calibration.

Hydrocarbon deposits, wear, damage, and time can negatively affect flowmeter performance, but regular calibration keeps equipment operating efficiently.

A Lease Automated Custody Transfer, or LACT unit, is commonly used for A range of calibration services are available flowmeter calibration. LACT unit calibration is performed by flowing liquid, usually water, through the were developed in the 1970s that remain in common use today. The Optical Reference flowmeter in question and the LACT unit. The Line and the Optical Triangulation methods difference between the two measurements both employ a theodolite to accurately is then used to update calibration tables so production numbers can be adjusted determine tank volume. The Electro-Optical appropriately.

Distance Ranging Method incorporates Ultrasonic clamp-on meters, which use a single optical laser linked to a distance ultrasonic beams to capture the flow of measurement device to ascertain the fluid in a pipe, are also effective flowmeter measurements needed to calculate tank calibration tools. In this procedure, the volume. These optical methods compare calibration specialist installs the ultrasonic favourably to manual tank strapping and are meters on the pipe’s also used regularly. exterior wall to measure In recent years, lasers have been put to use the volume moving through for high definition strapping measurements. the line. This data is then Using a reference circumference as a baseline compared to flowmeters measurement for comparison, laser strapping measurements are highly accurate and quick. for the same line to They can also scan and account for all surfaces quantify any differences. and fixtures on the tank. The laser scan For gas meter provers, collects thousands of data points to create the preferred calibration a 3D image for determining highly accurate technique is the waterdraw strapping tables. These images also serve as a method. This involves record of everything present on the tank at measuring the volume of the time of the measurement. water between the prover Calibration processes must conform to detectors by ‘drawing it well-documented industry procedures and off’ into calibrated test API standards, which assure quality, keep costs equipment. As with all down, reduce waste, and minimise confusion industry calibrations, the

process for waterdraw calibrations must follow API standards.

Technology has also contributed to modern calibration methodologies. Remote monitoring of production is possible with cloud and internet-based metering using proprietary Supervisory Control And Data Acquisition (SCADA) systems which enable early identification of issues and real-time adjustment of production. Cellular technology will soon make it possible to observe production numbers from a smart phone or tablets.

Enhancing margins Despite the refinement of various tools and techniques, many producers still view regular calibration of tanks, meters and provers as a compulsory production expense rather than an effective way to maximise profits and achieve benefits beyond mere compliance.

For example, a reputable third-party provider routinely makes observations regarding equipment maintenance to help operators avoid unexpected repairs or fines from state and federal regulatory agencies for non-compliant metering equipment. Correct and verified production measurements also support accurate allocations and contract

Third parties like Bureau Veritas can assist with the calibration process

negotiations, and provide critical data for future production.

Employing best practices and professional third-party expertise to ensure accurate quantification and calibration not only achieves the full optimisation of resources, it ensures maximum profitability over the life of the asset.

For more information: Many producers see calibration as an expense rather than a profitable opportunity

This article was written by Laurence Hayden, regional director for Inspectorate America, a Bureau Veritas company.

Visit: www.inspectorate.com/usa

Gearing up for change Pumps and flowmeters are no strangers to the automotive industry, having been used in various production processes for years – most notably for painting and coating. However, new demands for advanced lightweight materials mean manufacturers are now turning to special resins, carbon fibres and plastics to meet production goals. Advanced pumps – notably gear pumps – and flowmeters are at the forefront of facilitating these changes.

Basic principle The gear pump is the simplest of rotary positive displacement pumps, consisting of two meshed gears that rotate in a close tolerance casing. This design provides a ‘fixed volume displacement’ therefore each tooth cavity traps a known volume of the fluid per revolution and forces it around the outer periphery of the pump housing. Given the fact that fluid is a non-compressible medium, it cannot travel where the teeth mesh, thus providing the ‘seal’ stopping the fluid from flowing back to the suction. Housed within a centre plate the gears are enclosed by two additional side plates ensuring the fluid only flows in the direction intended. Within a gear pump the only point of contact should be where the teeth mesh

creating the aforementioned seal. However, within any pump there must be clearances for the pumping parts to move. These clearances allow ‘back leakage’ or ‘slip’ of the fluid from the high-pressure outlet side of the pump back to the low-pressure inlet side. It therefore follows that the thinner the fluid and the higher the pressure, the harder it becomes for the pump to achieve 100% volumetric reliability.

Where the pump can be considered the ‘driver’ moving the fluid through the system, the flowmeter (which can be of a similar ‘gear’ design and therefore resemble a gear pump) is considered to be ‘driven’ by the fluid. In reality, it is controlling the pump by monitoring its performance and reporting back to the controller, therefore enabling the output flow to be regulated by changing the speed of the pump to match the desired volumetric requirement and in doing so provide an accurate transfer, mix, dosing or dispensing system/principle.

This is one of a number of positive displacement pumping methods – each principle, whether it be radial, axial or reciprocating, will have its own merits and detractions depending on the application. This can also be said for flowmeters.

With such a high degree of accuracy,

gear pumps – aided by flowmeters – have comfortably found a number of applications within the car industry that are a bi-product of new technologies and who’s process, whether it be components or assembly, are highly dependent on an exact volumetric flow. Regardless of a high or low pressure application, where the volume flow is critical a manufacturer will need this type of pump/ meter.

Resin Transfer Moulding (RTM) – part manufacture With the world’s chemists making massive leaps in polymer technology, the manufacture of fibre reinforced parts is quickly becoming standardised in order achieve goals such as fuel efficiency by weight reduction and increased structural strength. The RTM process enables manufacturers to create strong, lightweight, heavy duty and complex parts – from very small components to almost a complete cabin made of carbon fibre.

The RTM process involves pumping a measured amount of resin and catalyst into a mixing chamber or mixing head, where the two components are mixed then pumped into a closed mould containing a fibre pack or preform. Heat from the mould initially reduces the viscosity of the resin so it flows into all parts of the mould cavity but, at the same time, it begins to cure the polymer. The mould stays closed until the polymer has cured, then the product is removed. Depending on the process and the fluids these machines can be either of high or low pressure design.

A wide range of resins and chemicals can be used and both the pump and flowmeter play a big part in ensuring that each part of the mix is correctly proportioned.

Transfer – bulk store to the RTM machines These RTM machines are also usually fed the fluids from larger storage tanks and need

parts this bonding process may also have a pre-mix requirement and therefore a similar proportional mixing method would apply. One thing to note is that, given that the dispensing is likely to be either via robotic arm or by hand, the pumps need to be generally lighter depending on the machine’s configuration.

In summary

Gear pump principle

both pumps and meters to ensure the right quantity is pumped locally to the machine and its smaller operation tank within. These will potentially be larger pumps and meters as they could be servicing more than one RTM machine and at various pressures depending on the distance from the machine and pump plus the viscosity of the fluid(s).

Gear pumps and their benefits when monitored by a flowmeter (via the unit’s controller) are utilised in a number of small but growing high-tech processes and applications within the automotive industry.

When considering the ‘car’ as a whole, it is clear that pumps and flowmeters play a massive part in production and that, even as these processes advance, there will always be a traditional technology behind it.

For more information: This article was written by James Lees, technical sales, UK Flowtechnik.Visit: www.ukflowtechnik.com

Bonding – parts to the car Once the parts are completed and ready for assembly they will in some cases need to be bonded to the sub frame or shell of the car. This requires a high accuracy flow to ensure the right amount glue or bonding agent is dispensed. As with the RTM process used for the component

The RTM process

The proof is in the pump

The air control spool of the Pro-Flo Shift meters the air to prevent overfilling with no reduction of product yield

With operating efficiency and cost reductions being a major focus of businesses today, AODD pump manufacturers have introduced new technologies in ADS to increase pump efficiency and meet these demands. The new ADS technologies that are utilised range from electronic controls to mechanical innovations.

However, the resulting savings in compressed air usage and increase in pump efficiency varies considerably by system.

The challenge In AODD pump operations, energy use is directly related to the rate of consumption of air used to drive each stroke of the pump during the pumping cycle. With increasingly high energy costs, facility operators understand that the initial purchase and installation of a new pumping system is but a small part of the total cost of ownership and operation during the pump’s life cycle. Routine costs of energy and maintenance remain the primary cost drivers in the total cost of ownership.

Much like cars, pumps can be rated according to efficiency. The goal is to utilise the least amount of air to pump the greatest amount of product. The ultimate objective is to reduce the rate of air consumption in relation to the product flow rate while also minimising the overall amount of air that is not producing product yield (wasted energy) during the pumping cycle. If attained, this combination will directly impact an operation’s bottom line – the profitability being determined by something as simple as the volume of air being consumed and the energy required to compress it.

In addition to wasted energy, air overfilling stretches the diaphragm unnecessarily. This stretching

produces excessive diaphragm wear and tear, resulting in more frequent replacement and downtime, while also increasing operating costs.

Although the technology is more than 50 years old, AODD pumps can be made more efficient by recent ADS developments that better control the air flow and prevent wasteful air overfilling, which will reduce air consumption, and operating and maintenance costs.

Two primary methods have been introduced to control air flow and prevent overfilling by cutting off the air supply to the air chamber before the end of the pump cycle: electronically controlled and mechanically actuated ADSs. Electronic control has two shortcomings. First, the electronics raise an entirely different set of maintenance and operational concerns, including prohibition of use in explosive environments like mines and an inability to be submerged.

Second, this electronic ADS technology requires a ‘learning period’ of 30 to 40 seconds where it monitors the operation of the pump The race is on for AODD pumps to move volume faster and more cost effectively

The Wilden ProFlo Shift ADS is designed for maximum energy efficiency

before it can estimate when to cut off the air supply prior to the end of the stroke. This can result in erratic and sometimes wasteful flow rates during this learning period.

During the time period from the end of each stroke to the completed shift of the valve, the air is allowed to ‘overfill’ the air chamber without any corresponding displacement of fluid. This volume of compressed air is entirely wasted.

The mechanically actuated method is a simple yet extremely effective way to control the air with each stroke and prevent wasteful overfilling. The air is mechanically controlled on a constant basis to maximise efficiency, minimise complexity and maintenance considerations, and allow for operation in explosive and submerged pumping environments.

fitted with traditional, electronically controlled and mechanically actuated ADSs. Common conditions of service that are seen in the field were replicated in the laboratory. This simulated application required each pump to produce a flow of 320 litres per minute (L/min) (85 gpm) against a head pressure of 2.1bar (30 psi).

To achieve a fair comparison between these competing pumps, each pump was run at the inlet air pressure needed to meet the common condition of service. Air-consumption data was then recorded.

The solution

The data gathered in the objective AODD testing shows conclusively that Pump D (Wilden Pro-Flo Shift) beats the competition in all three key points of measurement with the lowest air consumption in standard cubic feet per minute (SCFM), the lowest strokes per minute and the highest volume of fluid pumped per SCFM. Pump D averages an overall 30% reduction in air consumption compared to Pumps A, B and C. It also manages the largest The controlled comparisons reduction in air consumption among the four pumps while still managing the best overall volume of fluid moved per stroke, requiring the To create real-world conditions to measure lowest strokes-per-minute. the effectiveness of various ADS technologies The air distribution system in Pump D is not industry-wide, a controlled, objective headjust an improvement in ADS technology, but an to-head test was arranged comparing the industry’s top AODD pumps that have been entirely new way of looking at how pneumatic pumps operate.

To combat overfilling, the Pro-Flo Shift restricts the air flow into the filling air chamber at the end of the pump’s stroke to minimise the compressed air that is wasted. The air control spool of the pump meters the air to prevent overfilling with no reduction in product yield. The result is reduced air consumption while still maintaining maximum operational efficiency and flow rates. Compared to the electronic ADS solution, which requires an electrical power source and the delayed ‘learning’ period after each startup, the Wilden pump has no electrical In a controlled head-to-head test comparing eight of the power requirement or delay industry’s top AODD pumps, this sample of four illustrates the needed to achieve peak dominance of Pump D and the wide range of energy and operation. strokes required to achieve similar fluid output

Conclusion Although reliably utilised in a host of applications for more than 50 years, AODD pumps can be enhanced to deliver greater efficiency and cost savings through improved ADS technology that prevents air overfilling.

The Pro-Flo Shift ADS does not require electrical power, allowing it to be submersible and ATEX-compliant. While competing pumps may offer ATEX compliance and increased efficiency ADS options, these come with additional costs that contribute to the frontend expense.

Wilden’s pump addresses the overfilling waste of traditional AODD pumps, providing savings by decreasing air consumption while still maintaining the same fluid-volume output to provide better output efficiencies when compared to other systems.

For more information: This article was written by Carl Glauber, diaphragm pump product manager for Wilden Pump & Engineering.Visit: www.wildenpump.com. To view the video documenting the laboratory pump demonstration of the Wilden Pro-Flo Shift versus some of the industry’s top competitors, visit www. profloshift.com/proof.

Wilden’s Pro-Flo Shift pumps are available in multiple sizes, materials and configurations

PUMPING FLUID

through piping systems There are a wide variety of pump designs to aid flow through piping systems, but they fall into two general categories: kinetic and positive displacement.

Centrifugal pumps Centrifugal pumps, which fall into the ‘kinetic’ category, are the most common in industrial applications.

A centrifugal pump is characterised by the use of a rotating impeller to increase the pressure and flow rate of a fluid, and is the most common type of pump used to move liquids through a piping system. Entering the pump impeller near the rotating axis, fluids are accelerated by the impeller, flowing outward or into a diffuser or volute chamber before exiting into the downstream piping system.

Typically used for higher flow rates, centrifugal pumps are commonly utilised in water, sewage, petroleum, petrochemical and boiler feed applications, among others.

Among centrifugal pumps there exists a vast array of pump types, including submersible, end suction, split case and column pumps, for example. The varying designs handle different fluids, pressures, flow capacities and other system conditions, and the selection of a pump should take into account all of these factors.

DEPA DH airoperated double diaphragm pump, a type of positive displacement pump

Manufacturer’s typically present pump head and capacity information in the form of a pump performance curve, which represents performance characteristics over the operating range of the pump. To properly select a pump and evaluate system performance, a number of factors should be considered, outlined below.

Centrifugal pump sizing and selection

•

•

•

recommended by the pump manufacturer in which the service life of the pump is not seriously reduced by continuous operation Best efficiency point (BEP): The flow rate on the pump curve where the efficiency of the pump is at its maximum. Operating near this point will minimise pump wear Preferred operating region (POR): A region around the BEP on the pump curve, defined by the user, to ensure reliable and efficient operation Maximum flow rate: The end of the manufacturer’s curve for the pump, commonly referred to as ‘run out’ Net positive suction head required (NPSHr): The amount of suction head above the vapour pressure needed to avoid more than 3% loss in total head due to cavitation at a specific capacity.

Selecting the proper centrifugal pump for an application requires careful evaluation of the following criteria:

•

Pump curve: The pump curve is developed by testing the pump according to industry standards and consolidating the resulting head and flow rate data into a curve. Pump manufacturers often provide a performance curve for a single impeller size and speed, or multiple curves for a range of impeller sizes or speeds. Elements found on the pump curve include: • Total head: The energy content of the liquid, imparted by the pump, expressed in feet of liquid • Pump efficiency: The ratio of the energy supplied to the liquid to the energy delivered from the pump shaft • Shutoff head: The head generated at the condition of zero flow where no liquid is flowing through the pump, but the pump is primed and running • Minimum flow: The lowest flow rate at which the manufacturer recommends the pump be operated • Allowable operating region (AOR): The range of flow rates

Net positive suction head available: The net positive suction head available (NPSHa) refers to the head provided by the piping system to the pump suction. It is influenced by the configuration of the system and the properties of the fluid. Properly calculating the NPSHa is essential to ensure that it exceeds the manufacturer’s NPSHr and prevents cavitation in the pump.

System variables can be optimised to increase NPSHa at the pump suction, including: • Pump location: Lowering the pump suction in relation to the tank will increase NPSHa • Pump suction piping: Minimising suction pipeline head loss will increase NPSHa.This head loss will be a factor of pipe size, pipe roughness and any components installed in the pipeline.

In addition, as flow increases through the suction pipeline, head loss will increase, effectively reducing the NPSHa. For most pumps, NPSHr will increase with flow rate • Fluid properties: Fluid properties such as vapour pressure, density and viscosity vary with temperature. The net effect of a change in fluid temperature on NPSHa should be evaluated • Supply tank: An increase in supply tank pressure, elevation or liquid level will

increase the NPSHa • Atmospheric pressure: Changes in atmospheric pressure can affect the NPSHa. Viscosity corrections: Most published pump curves reflect the performance of the pump with water as the operating fluid. A more viscous fluid will lead to an increase in required power and a reduction in flow rate, head, and efficiency. Pump performance should be corrected for viscosity to obtain the most accurate representation of operation.

Pump affinity rules: Affinity rules predict pump performance in response to changes in impeller speed or diameter. For example, when a pump’s rotational speed is changed, the head, capacity, and power for a point on the pump curve will vary according to the pump affinity rules.

Trimming an impeller will change the vane angle, thickness and impeller clearance.

Although these changes will impact pump performance, they are not accounted for by the affinity rules. Therefore, the affinity rules should be used only for small changes in impeller diameters, as increased inaccuracies may occur with larger changes. Interpolation between two known impeller diameters on the pump curve typically provides more accurate results.

Pump power calculations: Pump horsepower can be used to appropriately size a motor for the pump and calculate operating costs based on pump and motor efficiencies.

Positive displacement pumps A positive displacement pump differs from a centrifugal pump in that it moves fluid by trapping a fixed volume in a cavity and then forcing it out into the discharge pipe. Liquid flows into the pump as the cavity on the suction side expands, and it flows out as the cavity collapses.This maintains a constant volume through each cycle of operation.

The two main categories of positive displacement pumps – reciprocating and rotary

– add this energy in a periodic, rather than continuous, fashion. Reciprocating pumps use reciprocal motion such as pistons or diaphragms to directly displace fluid, while rotary pumps employ a variety of designs including peristaltic, screw and gear pumps to displace fluid through the application of rotary motion.

Positive displacement pump applications: The fact that positive displacement pumps add energy by direct force on a fluid makes them a suitable choice for certain applications. They impart little shear force to the fluid, making them suitable for fluids with high-viscosity and low-shear requirements, as well as for fragile solids. By directly moving a volume of fluid, they can meet high-pressure/low-flow, and precise fluid delivery requirements, as well as offer efficient pumping of two-phase fluids.

Positive displacement pump curve: Positive displacement pump curves are not limited to a flow-versus-head relationship.

Flow-versus-speed and flow-versus-discharge graphs are also commonly used. With the exception of slip, capacity in a positive displacement pump varies directly with speed, independent of head. Positive displacement pumps typically exhibit slip, which is fluid leakage from the high-pressure side to the low-pressure side of the pump. At higher pressures and/or lower viscosities, this will result in an increasing loss of capacity through the pump.

Centrifugal vs. positive displacement pumps While centrifugal pumps are the more common of the two pump types, there are a number of reasons to choose a positive displacement pump in specialised situations: Highly-viscous solutions: As mentioned above, positive displacement pumps are the better choice when handling high-viscosity fluids, as these will affect the flow rate and efficiency of a centrifugal pump and can result in increased energy costs.

High-pressure applications: While pressure limits can vary with the design of individual pumps, positive displacement pumps are often better able to produce extremely high pressure than centrifugal pumps, especially at low flow rates, even when operated in series.

Variations in pressure and viscosity: Debris, pipe corrosion and even modest changes in valve operation or pressure can greatly affect the efficiency of a centrifugal pump, whereas positive displacement pumps are able to maintain their flow rate.

Cross section of a standard centrifugal pump

Shear-sensitive fluids: As pump speed increases, so does the tendency to shear

liquids. Therefore, high-speed centrifugal pumps are typically not the ideal option for shear-sensitive liquids, and positive displacement pumps offer a better solution.

Operating away from the middle of the curve: Centrifugal pumps have a specific range on the pump curve at which they operate with maximum efficiency – the greater the deviation from this range, the greater the risk of cavitation, deflection and pump failure. Positive displacement pumps, however, are able to more efficiently accommodate operating conditions at any point on the curve.

Head vs. flow for centrifugal, rotary and reciprocating pumps

Pump selection process The process of pump selection can be broken down into a series of distinct steps: • Determine pump capacity: This is the desired pump flow rate, usually in gallons per minute • Determine head requirements: The pump must overcome the static and dynamic head losses of the system • Find NPSHa: This can be calculated by hand • Select the pump: Typically, a selection chart is consulted to create a short list of pumps for evaluation, the curves are then individually considered to find the best fit • Correct for fluid density and viscosity: Both of these will impact the shape of the pump performance curve and need to be adjusted for the fluid being pumped • Find the pump horsepower: Curves for horsepower may be included on the published pump curve, if not it can be calculated using equations.

Whether your application requires a centrifugal or positive displacement pump, there are myriad factors to consider in ensuring that a system is compatible with the selection and able to operate with maximum efficiency and minimum costs.

The information contained within this article has been gathered from Crane’s Technical Paper No. 410, first published in 1942 and continuously updated to reflect the evolution of the fluid handling industry, with the most recent revision having been completed in 2009.Visit: www. flowoffluids.com.

Putting pumps into practice In the modern industrial world, it is becoming more common to move increased volume of chemical and acids around by ship, lorry and in Intermediate Bulk Containers (IBC’s) for use on sites, and so the chemical distribution market has seen massive growth and investment to utilise ‘best practice’ to ensure the safe and efficient handling of toxic and corrosive liquids.

Continued government legislation and the reclassification of liquids under the ADR and IMDG regulations means the industry is preferring to unload road tankers by means of pumped discharge, as opposed to ‘blowing’. The blowing method is achieved by pressurising the supply vessel, and the differential pressure results in emptying of the transport tank to storage tank. With this, however, come a number of design and safety

Tanker unloading has a reputation for being a troublesome process

issues to address.

Changing pump design and technology, as well as advancement in materials for construction, has evolved in recent years to make sure that potentially troublesome

A long operational life can be assured for pumps if best practice is followed

unloading is safe and efficient. One example is the development of CDR Pumps’ RunSafe bearings, a technology which allows magnetic drive pumps to safely run dry for periods of time along with construction materials.

The mag-drive pump has long been an important pump design in the heavy chemical and pharmaceutical industry, finding its way into some of the most arduous applications and proving to offer extended operating life as well as zero emission to atmosphere of toxic, corrosive or explosive liquor or vapour.

Tanker unloading via pumped discharge is also proving to be a cheaper option for customers as fume cleaning devices are not required.Vapour can be safely returned to the tanker, thus eliminating the need for costly fume scrubbers.

Trend is leaning toward lined pump units, whether that be polypropylene for general chemicals, or indeed ETFE or PFA for solvent based liquids and other more corrosive products.

When assessing the problems the pumps will face in such an application, there are three major potential issues to be concerned with; priming of the pump prior to start up, dry running of the pump unit when the tanker

becomes empty, and nozzle loads and forces.

The issue of priming is simply a case of installation, plant layout and operational procedure to ensure that, once the tanker is connected, the system can be effectively primed up to the pump impeller and suitably vented to a fume scrubber or other vapour cleaning device. If installation is to prove troublesome, magnetic drive self-priming pumps are available for such applications.

The dry running issue has a number of points to consider. With non-metallic pumps comes the advantage of eliminating a big problem area which is eddy currents. With a non-metallic shell you simply do not generate heat in the product – eddy currents are an effect of passing moving magnetic forces through a stationery static metal component.

In the case of a pump, the magnets rotate around a static isolation shell.

With modern bearing material coupled with impeller and magnetic coupling design, dry running of magnetic drive pumps can be readily achieved. However, this is still not best practice as the pump will be suffering excessive wear on the bearings. With the use of a modern pump protection device, the pump can be controlled to automatically stop once the tanker becomes empty.

The general trend is to use flexible pipework from the road tanker to the pump, often by cam-lock style fittings. With the

Tanker unloading via pumped discharge requires no fume cleaning devices

regular movement of pipework as tankers arrive and depart, the robustness of a lined pump is favourable, as these provide far superior mechanical strength to withstand hydraulic and mechanical forces.

Successful tanker unloading applications are achieved by ensuring some key practices are implemented. Once installed correctly, a

long operational life can be assured for plants, with minimum risk to operators and the environment.

For more information: This article was written by Ashley Fenn, managing director, CDR Pumps (UK).Visit: www.cdrpumps.com

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Feeling the pressure In complex processing environments, operational safety, reliability and economic performance are intertwined. Any industrial process that operates under conditions of significant heat and pressure is challenged to meet strict safety codes. But finding a way to implement standards-compliant overpressure protection can result in operating efficiencies that reduce pressures on other areas of a business as well.

The obvious benefits of a well-designed overpressure protection system include avoidance of damage to personnel, equipment or reputation. An understanding of the range of options available for protection schemes can also result in solutions that reduce downtime, improve reliability and limit waste.

Changes to processing facility designs can be driven by regulatory mandates, such as the new EPA standards for power plant carbon emissions, or simply by wear-and-tear on existing components that affect system performance. However, even minor changes to a system can alter pressure conditions and potentially introduce new risks. In the real world of plant design and maintenance, the available protection schemes must be carefully analysed before changes are implemented.

Protecting against hazardous overpressure scenarios is a legal requirement in almost every situation. In North America, the ASME Boiler and Pressure Vessel Code is the authoritative source for system design and regulation in numerous industries, including chemical and petrochemical processing, nuclear power generators and boiler-driven manufacturing plants, to name just a few. Similar codes in the EU, Japan, Australia and other regions also address requirements for overpressure protection in these environments. In addition, the American Petroleum Institute (API) provides

specifications for pressure relief valve sizing and other characteristics.

Experienced valve engineers can be of assistance to process designers by evaluating alternative pressure protection techniques and finding ways to approach challenging situations where code-compliant solutions may appear daunting. One approach that has proven successful in many applications is to identify an upstream source of pressure and sense changes there that can be used to trigger a safety device on a protected vessel further down the process.

Overpressure protection technologies In 2008, a revision to ASME Code, Section VIII, UG-125 introduced the term ‘overpressure protection’ in place of language that simply mandated the installation of a pressure relief device. The change emphasised the importance of a comprehensive approach to system design and documentation. The end user (or designated agent) was named responsible for identifying all potential overpressure scenarios and the method of protection used to mitigate each of them.

Three types of pressure control devices are approved for use under the ASME Code: direct spring operated pressure relief valves (DSORV), pilot operated pressure relief valves (POPRV), and the non-reclosing rupture disc. (The generic terms ‘PRV’ or ‘SRV’ for ‘safety relief valve’ are sometimes used where the device is not specified). To meet code, all relief valves must be self-contained and not dependent upon any external power source to operate. Safety relief valves are also designed

to fail open in a safe manner.

Rupture discs operate as the name implies, bursting open when conditions exceed the set pressure. They do not reseal, thus are inherently single-use devices and often used as a backup for PRVs. DSORVs operate by utilising a spring, set at a specific pressure, to provide a force on a seat and nozzle to keep the valve closed. When system pressure exceeds the set pressure, the spring force is no longer present, thus allowing the valve to open. Due to the simplicity of this design, DSORVs are the most commonly used PRVs with the largest installed base in the process industry. There are limitations to their use when users are optimising their processes.

One significant limitation with DSORVs is that they can only sense the process pressure at the valve inlet. Therefore any adverse conditions at the valve inlet, for example inlet line loss, cannot be avoided with a DSORV. POPRVs operate by utilising the process pressure to provide a force on a piston and seat to keep the main valve closed. The process pressure is sensed by a pilot valve that

controls the main valve’s opening and closing functions. Although POPRVs are certified on ASME Section I and VIII by the National Board, they are the least commonly used pressure relief devices due to their complexity and limitations. However, POPRVs are the most flexible in demanding applications, due to the many options and accessories available. These include variations of pressure sensing and outlet configurations.

Selecting practical overpressure protection schemes can be a process engineering design challenge. Many applications involve overpressure protection equipment that is required to perform in applications that are very ‘dirty’, and/or at very high temperatures.

With a complete understanding of a process design, valve specialists can often recommend relatively simple, but innovative, solutions for some of the most difficult applications. A commonly applied feature of a POPRV is the option for remote pressure sensing.

The advantages of remote pressure sensing In practical experience, finding a way to address challenging overpressure scenarios often results in the use of pilot operated valves and devices.

The operating principle of a POPRV is that of a differential area piston. It consists of two primary components: the main valve (MV), which provides the capacity, and a pilot that controls the main valve. In the closed MV, the active area of the piston face at the inlet is 30% smaller than the piston dome area, providing a 1:1.3 ratio between the two areas and resulting in greater downward pressure. Any time the piston dome pressure (P2) is reduced to below 70% of the MV inlet pressure (P1), the piston will lift, opening the MV. A POPRV has the capability of sensing the process pressure at a remote point in the process, as shown above. Remote sensing is most often used in applications where undesirable inlet line loss is present that will cause rapid cycling or chatter. Chatter occurs when the inlet line loss exceeds the blowdown of the PRV. For example, if the PRV’s blowdown is 5% and the inlet line loss is 7% of the PRV’s set pressure, the PRV will immediately reseat when the valve reaches set point. When the PRV reseats, the pressure in the system will build back up and cause the PRV to open briefly and close again, leading to wear and tear, costly maintenance, and loss

Schematic diagram of a POPRV

Integral pressure sensing

Valve open

Remote pressure sensing

Valve open

Schematic of integral and remote pressure sensing

of product through the PRV. A POPRV with applications in which the source of overpressure remote sensing gives users the ability to avoid is relieved, rather than releasing the pressure Typical charateristics of by bypassingVessel vessel being protected. adverse relieving conditions the insidePressure the vessel(s) PRVs pressure requirements inlet line loss issue.

Many variations Working together Maximum can be offered in remote 110 relieving sensing applications.

A major advantage of pressure this is the ability to mount the POPRV in an Good management of overpressure conditions acceptably low operating in a processing Maximum temperature point in Allowable environment not only offers Accumulation a process, while Overpressure sensing the process pressure protection from disastrous system failures; it can also reduce operating expenses, lower at a much higher temperature point in the process. Most POPRVs contain soft goods wastage and improve efficiency. Implementing (plasticsSetand/or a remote pressure-sensing MAWP configuration may pressureelastomers) at the seal and 100 seats that have limited acceptable operating involve higher upfront costs, but can offer Blowdown temperatures. When the performance of a long-term advantages in terms of improved reliability and lowered total cost-of-ownership POPRV is desired, system designers often Inlet line loss (7%) for process owners operators. select the remote pressure-sensing feature. 95 Reseatand pressure The function of the pilot valve (PV) is to When faced with challenging overpressure protection scenarios, process design engineers sense the process pressure (P1) via a pitot 93 should be encouraged to consult with tube and control the piston dome pressure.

Typical operating When the PV senses set pressure, it will have experienced vendors and valve specialists.

90 pressure reduced the piston dome pressure to +/-70% Suppliers often have exposure to a wide of the sensed pressure, allowing the piston to variety of industries and can draw on lift and open the MV. experience with relevant scenarios and It is possible to have the pilot sense pressure applications. By sharing process design at a remote point in the process, information and requesting feedback on Integraland isolate Remote pressure pressure protection schemes, the remote sensed pressure from the function Valve open proposed overpressure Valve open sensingthe POPRV. sensing system owners and operators can ensure that of providing the force to actuate The pilot valve pressure-sensing cavity is a all possible approaches – including remote completely isolated cavity, with a static sense pressure sensing techniques – are explored. line. There is no flow in the remote pressure Finding a way to a safe, cost effective solution sense line. The POPRV main valve piston is often a team effort. operating force is derived from the pressure For more information: of the process, at the point where the POPRV This article was written by Jason Knudson, associate product is mounted. The simple remote sensing manager – pressure relief valves, Pentair Valves & Controls. option only requires that the remote sensed Visit: www.pentair.com/valves pressure is a pressure that Typical charateristics of is comfortably higher than Vessel Pressure vessel PRVs pressure requirements 70% of the pressure at the Maximum MV inlet.

110 relieving The flexibility of pilotpressure operated safety relief Maximum Allowable Overpressure Accumulation valves has helped in solving some very difficult overpressure protection MAWP Set pressure 100 applications where a workable solution was not Blowdown immediately apparent.With Inlet line loss (7%) Reseat pressure an understanding of the 95 remote sensing operation, 93 the following difficult Typical operating overpressure protection 90 pressure applications are easy to Inlet line loss diagram comprehend.These are

No compromise Man-made valves have been around for thousands of years. The first examples were discovered in Roman and Greek ruins and were used to regulate the flow of water in aqueducts and public fountains.

Modern valves were developed in the years following WWII as industrial productivity grew rapidly and more efficient facilities were required. Many new valve types were put forth; the cream that rose to the top consisted of ball valves and butterfly valves.

Ball valves allow unobstructed flow and high pressure sealing capability but are not well suited to partial open positions due to very high turbulence. The violent, unstable pressure forces of turbulence lead to damage of the valve’s mechanical components as well as the supporting infrastructure (pipes, connectors, etc.). This valve type can also be bulky, heavy and expensive to manufacture.

Butterfly valves provide better dynamic flow control and the more expensive models can even seal very high pressures. However, these valves provide an obstruction to the fluid passing through it, reducing the efficiency of the entire system. The large central disc also creates massive turbulence which is detrimental to long-term reliability, while also consuming large amounts of power when it opens and closes. Furthermore, the valve is not piggable, or easy to clean, given the disc in the centre.

Industrial operators often must reluctantly choose between which features they need most, inevitably leading to compromise and, sometimes, improper selection.

Valve reliability has also become ever more important due to financial pressure in the current economy, further creating a need for a better valve.

Noticing the differences between the two most prominent industrial valves and the compromises that they caused end users, Kyle Daniels, founder of Clarke Industrial Engineering, developed the Shutter Valve, an industrial valve that combines the advantages of the ball and butterfly valves and expands on them.

The Shutter Valve is quarter turn, fully piggable, opens full bore and can be specified

to 3-A sanitary Clean-In-Place (CIP) capability.

The valve is also designed to fully conform to industrial standard ASME B16.34.

It has a basic minimalist design of three interlocking petals that are supported by a compact, simple mechanism. This design gives it the ability to seal at very high pressures like a ball valve. However, unlike the ball valve, it has a compact design that can be disassembled by a trained technician in 15 minutes or less in most instances for field maintenance or repairs.

The compact body of the valve is designed to handle all standard size flanges and pipes.

It also maintains the same standard face-toface dimensions of the ball or butterfly valve, allowing the end user to replace their existing valves without any adjustments to their current system (‘plug-and-play’).

With its modified design based on a mechanical iris, it enables the end user to control flow by moving the petals into any position needed. Flow can be restricted from a fine mist all the way to a full stream like a fire hose and everything in between. This allows the end user to precisely control their operations.

At full open, the Shutter Valve has 0% pressure drop (delta-P) and because there is nothing that is constantly in the flow path when open (like a disc of a butterfly valve for example) cavitation, water hammer and overall wear and tear are lowered. The flow characteristics of the Shutter Valve are ideal for control valve applications due to the precision aperture control capability and the petal designs.

Another attribute of the low cavitation in the Shutter Valve is that very little noise is generated by the valve in partial open positions.

Low noise provides a safety benefit for anyone who works in facilities as well as improving valve and pipe life through reduced high frequency vibratory modes.

Altogether, the Shutter Valve, an evolution of the iris valve, is ideally suited to industrial customers that require the unobstructed flow and sealing capability of a ball valve with the precise flow control and low noise of the butterfly valve. Combined, these features lead to low cavitation, reduced turbulence, high

reliability and lower cost actuators through reduced torque requirements.

With triclamp sanitary flanges fitted to the valve body, the valve is presently operational at a major Fortune 500 company in its toothpaste production The Shutter Valve facility. The system utilises a 100 psi pump and 1” diameter steel tubing that is fully pigged and sterilised once per day.

The operation previously required two valves per position: a butterfly valve to control process pressure, and a ball valve substituted in its place during the pigging and cleaning cycles. The Shutter Valve allows them to maintain one valve per position, with improvement in process control, cost and man-hour reductions and improvement in batch quality and production volume.

The industrial manufacturing segment is growing rapidly and the demand for industrial valves is expected to rise by 5.1% per year through the year 2017 according to Freedonia Group statistics. With the ever growing pressure for modern industries to generate more product, while using less power and less space, the Shutter Valve is expected to play a major role in shaping the demands of the industrial valve market.

For more information: This article was written by Kyle Daniels, CEO & president, & Ryan Werner, sales manager, Clarke Industrial Engineering.

Visit: www.clarkeindustrialengineering.com

The ball and the butterfly Skid mounted heat transfer systems represent a growing segment in the commercial, institutional and industrial markets. Heat media fluids, from water to oil to glycol, are stored in insulated tanks on the skid and moved through a process heater by pumps designed to operate at high temperatures. The heated fluid is then used to heat a process system and returned to the insulated storage vessel in a self-contained closed loop.

Efficiency is paramount to cost-effective skid system design. Engineers are constantly searching for ways to make their systems more compact, lighter, more efficient and more economical.

One US manufacturer recently focused on replacing the 3” stainless steel ANSI 150 flanged full-port ball valves in a heat transfer system as a path toward better meeting these objectives. The performance of the seven electric actuated valves, used in on/off and isolation service, was not the issue. Reducing size and weight while increasing efficiency was the goal.

Butterfly valves considered, rejected The system engineer first considered high-performance butterfly valves to replace the original flanged ball valves. That seemed like a logical choice. Butterfly valves offer a significantly narrower face-to-face dimension, using less metal than the split-body flanged ball valve. The lower weight would reduce pipe stress and the number of pipe supports needed. It would also make the valves easier to install, reducing the man-hours involved in building the system.

However, butterfly valves, even highperformance models, cannot match the flow performance of a full-port ball valve. A full-port ball valve has almost no pressure loss because the interior diameter of the valve is equal to the interior diameter of the pipe itself, with no obstructions. It is essentially invisible to the flow media in the system. A 3” full-port ball valve has a flow coefficient (Cv) of nearly 1,300, similar to 3” of the pipe

to which it is attached. By comparison, the average Cv of a 3” butterfly valve is just 260.

The system’s pumps would not operate properly at this level of flow. Using butterfly valves with the resulting pressure loss would have required the entire system to be redesigned from scratch.

The Valpres 725000 Series from Bonomi NA

The butterfly valve alternative Given the lower flow capabilities, butterfly valves were disregarded as a possible solution.

In the search for other options, the recentlyintroduced Valpres 725000 Series ‘true’ wafer stainless steel full-port ball valve from Bonomi North America was decided on.

Designed for use in ANSI Class 150 flange applications, the wafer design of the Valpres 725000 makes it a viable alternative to high-performance butterfly valves in OEM applications, skid-mounted systems or any tightly-confined area. Like the high performance butterfly valve, the Valpres 725000 series offers reduced space wafer design, lighter weight and lower cost compared to the full-size flanged ball valve originally used in the system, but with advantages in flow and minimal pressure loss that butterfly valves could not match.

It can also handle higher temperatures. The Valpres 725000 with steam trim is suitable for steam service or liquid media (water, oil or gas) up to 204.4˚C, well within the requirements of the system. PTFE ball seats are standard. Stem seals available are PTFE and FKM. They are TUV T.A. Luft approved, and also meet NACE MR 0175/ISO 15156 and NACE MR 0103 standards.

Built with a stainless steel body, ball and stem, the new valve also features an anti-static stem design suitable for potentially hazardous environments. This is an important feature since the heat transfer system is designed for use in environments such as refining, chemical handling and processing.

Lever handles on the new valves are lockable in the open or closed position. A standard ISO 5211 mounting pad simplifies valve actuation.

All seven of the new wafer ball valves on the updated heat transfer skid system are operated by Bonomi’s Valbia-brand electric actuators. When automated through use of either pneumatic or electric actuators,

of the new wafer ball valve is only 0.25” less than the same diameter flanged ball valve, but it reduces total height by more than an inch providing additional clearance in the tight space of the design.

As noted earlier, smaller size and lighter weight also lead to reduced installation or manufacturing cost. An additional advantage of the new valve is that it requires only one set of four bolts for secure installation. A standard ANSI 150 flanged ball valve requires two sets bolts, one for each flange. By choosing the Valpres 725000, the skid manufacturer not only reduced installation time but also reduced materials cost.

Components of the ‘true’ wafer stainless steel full-port ball valve

the torques of the 725000 Series are more consistent than conventional high performance butterflies, thus allowing smoother operation and longer service life. In addition, and because of the lower torques, the total envelope of the package is smaller and less expensive due to the use of smaller actuators.

The new valves are available in seven sizes from 1” to 4”, meeting the size requirement of the system.

Smaller, lighter, smarter Aligning lugs on the valve body mean that the 725000 can be securely installed between two ANSI 150 raised-face flanges. This reduces

lay-length and weight significantly compared to conventional flanged ball valves.

For example, a standard ANSI 150 flanged full-port 3” stainless steel ball valve is approximately 8” long and weighs nearly 40lbs or more. The Series 725000 stainless steel ‘true’ wafer ball valve is less than 5” in length and weighs only 22lbs – a reduction of about 45% in weight and 40% in lay-length.

The Valpres 725000 wafer ball valve also offers a lower profile than either ANSI 150 flanged ball valves or butterfly valves. In the 3” size required for this application, the top to centerline profile of the new valve is more than 2-1/2” shorter than the same diameter butterfly valve. The top to centreline profile

Results As a result of the changes allowed to the system, the company saved more than $3,000 (€2408) per skid system in valve costs alone compared to regular ANSI 150 flanged ball valves. The smaller size of the valve body uses less steel, which equals lower cost per valve. It also allowed the use of less pipe and pipe supports, leading to additional savings in material and labour. Total savings equalled about $5,000 per completed skid system.

For more information: This article was written by Rick Wentzell, Bonomi North America.Visit: www.bonominorthamerica.com

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Due to the cyclical nature of the range of temperatures handled by shell and tube heat exchangers, engineers have tolerated poor performance, particularly with regards to leakages. Available sealing options have previously been unable to effectively operate across the entire temperature spectrum, which has led to plant operators instigating processes to mitigate leakages rather than be able to address the root cause.

Shell and tube heat exchangers are commonly used items of process equipment in many industries. Depending on how they are operated, heat exchangers can present technical challenges with regard to achieving leak free sealing performance. Fluctuations in axial load and radial shear effects brought about by thermal transients around the tube sheet girth flanges during start up or normal operation affect seal performance.

Additional factors such as available gasket load imposed by exchanger design, available space, the presence of stress raising nubbins, and ease of access and installation can also have a bearing on gasket design.

Refinery processes, for example, involving heat exchangers can be particularly demanding and equipment is often old and can involve elevated temperatures, high pressures and cyclic operation. It is said that every refinery has its problem exchangers. Additional requirements for improved asset efficiency and emissions compliance place ever increasing demands on gasket performance.

A novel approach International manufacturer of industrial seals and gaskets Flexitallic has been manufacturing and supplying girth, tube-sheet and floating head gaskets for use on shell and tube heat exchangers for many years. As a consequence, its applications engineers are familiar with the apparent idiosyncrasies associated with the sealing performance of individual exchangers and have developed a next-generation solution, which is now proven to address these issues.

The novel gasket, developed by Flexitallic and known as ‘Change’, offers benefits over traditional gasket styles more commonly used in heat exchangers, such as metal

Heat exchangers present a challenge when it comes to leakages

jacket, corrugated metal, spiral wound and kammprofile gaskets. Change offers long-term sealing performance, particularly in bolted connections subject to thermal transients.

To address the shortcomings of traditional gasket styles in problematic heat exchanger applications, extensive R&D work was undertaken that resulted in the production of the Change gasket. The gasket has been designed to possess the optimum combination of both stiffness and resilience and, as a consequence, be capable of creating a high performance seal under conditions of longterm cyclic service, such as those routinely encountered in demanding sealing applications.

Gasket manufacture The manufacturing approach to Change involved producing a gasket from a wire strip, therefore offering both maximum manufacturing flexibility and cost savings with optimum material utilisation. The strip is spirally wound; however, the strip profile and thickness differ significantly from that used in the manufacture of the spiral wound gasket – a product pioneered by Flexitallic more than 100 years ago.

The wire strip used in the manufacture of the gasket is five times thicker than that used

in the production of spiral wound gaskets. As a consequence, Flexitallic developed specialist equipment to enable its manufacturing.

Upon winding, the unique profile and increased thickness of the wire results in a stiff yet resilient interlocked structure with greatly improved handling characteristics compared to that of a standard spiral wound gasket. The resulting stiffer construction can, in many instances, negate the requirement to control gasket compression, allowing its use in applications where space may be limited.

A soft filler material, such as graphite, is incorporated into the gasket during the winding process. Once wound, the resulting profile of the gasket sealing faces bears resemblance to that of a kammprofile gasket.

Both sealing faces are subsequently covered with a layer of soft facing material, providing low stress sealing and good conformance on poorly-finished flange surface faces. Other materials such as PTFE for chemical service and Thermiculite for high temperature applications can also be used depending on the process conditions.

One of the main manufacturing challenges was how to permanently fix the winding strip at the start and termination of the winding process. Conventional resistance spot welding could not be used because of the increased

wire thickness. Weld integrity in an unconfined spiral wound seal arrangement such as this plays a crucial role in maintaining seal integrity. Following extensive trials, high power, precision laser welding was selected.

Due to a reduced heat-affected zone compared with traditional welding methods, thermal stresses are kept to a minimum resulting in a high-strength weld.

taking the gasket through 100 thermal cycles.

Spiral wound gaskets have been shown to perform well in radial shear testing and they typically give rise to an average bolt relaxation value in the order of 25%.

In comparison, average bolt relaxation for the Change gasket was only 15% with no significant leakage observed – a 10% improvement on the performance of the spiral wound gasket.

Since the development and introduction of the Change gasket, many have been supplied and are currently being used in nonstandard connections in shell and tube heat exchangers around the world.

Laboratory testing During the development programme the Change gasket was subjected to the usual battery of both standard and non-standard laboratory testing. ASME VIII, PVRC ROTT and EN13555 testing was undertaken to assess sealing behaviour under assembly and dynamic loading conditions and to generate the relevant gasket constants.

Thermal testing However, to assess long term multi-cyclic load conditions and attempt to accurately simulate shell and tube heat exchanger conditions, particularly at the tube sheet gasket positions, testing was undertaken using a modified and extended version of the recognised Shell Thermal Cycle test.

At the request of customer engineers, a test containing 24 cycles was undertaken to more accurately represent the level of exposure the gasket receives in heat exchanger applications.

This test is part of the Shell Type Approval Testing requirements for semi-metallic gaskets involve subjecting a standard gasketed bolted connection to a series of thermal cycles.

Leakage performance is determined by a series of pressure decay tests carried out at defined stages during the test.

In addition to testing the Change gasket, benchmark testing was undertaken, for comparative purposes, against other commonly used gaskets.

Testing revealed that kammprofile, doublejacketed gasket and spiral wound gasket styles

The Change gasket from Flexitallic

The Shell test

gave similar levels of performance, all failing the test after exposure to between 14 to 16 thermal cycles. The corrugated metal style gasket performed even worse, failing the test after five thermal cycles.

In contrast, testing proved the Change gasket out-performed all other gasket styles and was the only gasket able to meet the requirements of the test. After the completion of all 24 cycles the measured pressure drop was only 0.07bar (1 psi). The test was subsequently repeated with several Change gasket samples and the results proved to be consistent, demonstrating the gasket’s improved sealing performance under thermal cycling conditions compared to traditional gasket styles.

Radial shear An important consideration when designing a gasket for heat exchanger applications is the possibility of the gasket being exposed to radial shear. This can occur due to differences in radial expansion when the tube sheet is exposed to a thermal gradient resulting from different temperatures on the shell and tube-side of the exchanger.

Radial shear can result in gasket damage and seal failure.

Work carried out in the past has shown that certain gasket styles are superior to others at resisting radial shear.

A test protocol has been developed by Yarmouth Research in the US, which involves exposing a gasket located in a tongue and groove flange arrangement to a thermal differential induced by heating one of the flanges to 300˚C while cooling the other using water. The test involves

Refinery application As an example of effectiveness, Change technology has been successfully utilised on heat exchangers within a UK refinery on the East Yorkshire coast.

Flexitallic engineers were consulted following repeated leakage issues on two banks of shell and tube heat exchangers on the visbreaker unit. This refinery had experienced repeated issues with heat exchangers since the equipment was commissioned 25 years ago and had never been able to seal them effectively.

Visbreaking is one of several cracking processes used on modern complex oil refineries and is designed to reduce the viscosity and pour point of the heavier hydrocarbon fractions resulting from vacuum distillation (VD) of crude oil.

Since the gaskets were installed over a year ago, the visbreaker preheaters have been in constant use and exposed to multiple thermal cycles. Since installation there has been no requirement to undertake shell side cleaning so the tube-sheet connection has not been opened and the gaskets have not been replaced.

Regular visual monitoring of the connections has shown no incidence of leakage across any of the refinery’s previously problematic tube-sheet connections.

Plant engineering personnel reported that had conventional gasket technology been in operation an incidence of leakage would have been extremely likely over this time period and that the adoption of Change gasket technology represents a significant improvement in the maintenance of joint integrity on these problematic units.

For more information: This article was written by Dene Halkyard, applications engineering manager, Flexitallic.Visit: www.flexitallic.eu

Best practices for bearing protection Bearing protection is During virtually every VFD switching cycle, particularly important shaft voltage discharges from the motor shaft in many fluid handling through the bearings to the frame, leaving tiny applications where pits (usually 5-10 microns in diameter) in the bearing race. downtime can be extremely costly due These discharges are so frequent (millions per hour) that – through the process of to product spoilage or lost revenues. These electrical discharge machining – they create critical fluid handling millions of fusion craters, or pits. Before long, the entire bearing race can become marked applications include refrigeration systems; with countless pits known as frosting. In a evaporators and phenomenon known as fluting, the operational condensing fans; data frequency of the VFD shapes frosting into centre CRAC units washboard-like ridges in the bearing race.

Fluting can cause noise, vibration, increased and rack cooling; water friction, and catastrophic bearing failure. cooled chillers and circulating pumps; form, As the bearings wear, high temperatures can cause bearing grease to burn, degrade, and fail, fill, and seal systems; causing decreased bearing life and premature tray depositors; filling/ The bearings of VFD-driven motors can be damaged by currents capping carousels; bleed from three sources: capacitive induced shaft voltage (A), highfailure. The arcing blasts tiny particles of metal from the race wall that contaminate table pumps and casers; frequency flux produced by common-mode voltage (B), and sinusoidal voltage (C) the grease and further intensify abrasion. packaging and sealing systems; compressors; and boiler pumps.

Too often, the end result is costly, unplanned be installed during motor repairs or on new Commercial ship applications include downtime. motors before they are put into service. desalinisation pumps and potable water Failure rates vary widely, depending on a pumps, wastewater pumps and sump pumps, Damage black water tank pumps, ballast water treatment pumps, and bilge pumps.

By now it is widely The use of variable frequency drives (also understood that known as VFDs or inverters) to control the induced shaft voltages speed or torque of a motor can generate discharge through the energy savings of 30% or more. Some VFDs bearings of many VFDalso offer advanced data collection capabilities controlled, alternatingthat can be used for process analysis and current (AC) motors. optimisation. But VFDs are not without their The high switching frequencies of today’s drawbacks.VFDs induce harmful voltages VFDs produce parasitic on the shafts of the motors they control – voltages that can discharge through bearings, capacitance between a motor’s stator destroying them and dramatically shortening and rotor. Once the motor life. Without some form of bearing resulting shaft voltages protection, these savings can be short-lived, reach a level sufficient easily wiped out by bearing repair or motor to overcome the replacement costs. dielectric properties To protect both VFD-driven motors and of the bearing grease, the savings they generate – to make them they discharge along truly sustainable – effective long-term bearing Voltages arcing through the bearings of VFD-driven motors create the path of least protection is needed. To ensure uptime and thousands of pits, which cause increased friction and noise and resistance – typically reliability, motor shaft grounding rings, such as the potential for costly unplanned downtime as bearing grease through the bearings. those offered by US manufacturer AEGIS, can deteriorates

for electrical pitting/ frosting/fluting.

Grounding If inspection of the old bearing indicates electrical damage, the best way to protect replacement bearings is to install a shaft grounding ring that has a full 360˚ of circumferential In a process called fluting, pits form washboard-like ridges on a conductive bearing race wall – ridges that cause still more noise and vibration microfibres touching and accelerate bearing failure the motor shaft. Such number of factors, but evidence suggests that a a ring will conduct harmful shaft voltages away significant portion of failures occur three to 12 from the bearings and safely to ground.With a months after system startup. Because many of ring installed, voltage will travel from the motor today’s motors have sealed bearings to keep out shaft, through the ring’s conductive microfibres, dirt and other contaminants, electrical damage to its housing, then through the motor’s housing has become the most common cause of bearing to ground. failure in AC motors with VFDs. All paths must be conductive, so paint on the motor’s faceplate must be removed. Likewise, the motor’s shaft must be clean down to bare metal, Inspection free of any coatings. Depending on its condition, the shaft may require scrubbing with an emery Cutting and carefully inspecting the bearings cloth or a similar material. Even when the shaft of motors needing repair will often provide appears clean, wiping it with a nonpetroleuminformation that can be used to prevent a based solvent will remove unseen residues. After recurrence of the problem. Following established cleaning, the conductivity of the shaft should be safety precautions, repair shop technicians checked with an ohm meter. If the reading at the should: portion of the shaft that 1. Inspect the bearing cavity, retaining a sample will contact the ring’s of the lubricant in case further analysis is warranted to detect contaminants, signs of microfibres is higher excessive heat, hardening or blackening of than 2 ohms, the shaft grease, or grease that has escaped the bearing. should be cleaned again.

2. Cut the outer race in half.

A grounding ring 3. Inspect the grease inside more closely, again should never operate searching for signs of contamination. over a shaft keyway, 4. Clean the bearing’s components with a solvent. which has sharp edges 5.With a microscope, inspect the race walls that could damage

The best grounding rings are lined with flexible, conductive microfibres that completely surround the motor shaft

microfibres and reduce conductivity. On some motors, the dimensions of the spacer and mounting screws can sometimes be adjusted/ changed to avoid a keyway. If this is not feasible, the portion of the keyway that will contact the ring’s microfibres should be filled with epoxy putty.

Conductivity should be further enhanced by lightly but evenly coating with colloidal silver any portion of the shaft that will contact the ring’s microfibres.This will also help retard corrosion.

Threadlocking gels and liquids other than conductive epoxy are not recommended for the screws that mount the ring to the motor, as they might compromise the conductive path to ground.

The ring should be centered on the motor shaft so that its microfibres contact the shaft evenly.

After installation, testing with an ohm meter is again recommended.The best method is to place one probe on the ring and one on the motor frame. (The motor and drive must be grounded to common-earth ground in accordance with applicable standards.)

For environments where the motor will be exposed to excessive amounts of dirt, dust, or other debris, it may be necessary to protect the ring’s fibres with an o-ring or v-slinger or install the ring inside the motor’s housing. Bearing isolators with built-in circumferential grounding rings are also available.

A channel locks the ring’s conductive microfibres in place around the motor shaft and helps protect them from excessive dirt, oil, and other contaminants

The six-step (or square) oscilloscope waveform shown here is typical of motors exhibiting maximum peak-to-peak shaft voltages, but no discharges through the bearings

Prior to installation of a grounding ring, the motor shaft must be cleaned down to bare metal, free of any paint or other nonconductive material

Installation variations

Testing and analysis

Most of the recommendations above also pertain to grounding rings mounted to a motor’s housing with conductive epoxy instead of screws, split rings designed to slip around an in-service motor’s shaft instead of over its end, larger rings designed for higher voltage motors and generators, and rings press fitted, bolted, or bonded (with conductive epoxy) into a bearing retainer or custom bracket inside a motor’s housing.

For internal installations, an additional machined spacer can keep the ring farther away from the bearing grease cavity. Metal-tometal contact is still essential, of course, so a bearing retainer must be free of any coatings or other nonconductive material where it will touch the ring.

For horizontally or vertically mounted motors with horsepower of 100 (75kW) or less and single-row radial ball bearings on both ends, a shaft grounding ring can be installed on either end. For horizontally mounted motors with horsepower greater than 100 and single-row radial ball bearings on both ends, the bearing housing at the nondrive end must be electrically isolated to disrupt circulating currents. Options for achieving such isolation include insulated sleeves, nonconductive coatings, ceramic bearings, or hybrid bearings. The grounding ring should be installed at the drive end.

For any motor in which the bearings at both ends are already insulated, the drive end is preferred for the installation of a grounding ring, to protect bearings in attached equipment such as a gearbox, pump, fan, or encoder.

For any motor with cylindrical roller, Babbitt, or sleeve bearings, the end with such bearings should be electrically isolated, and the grounding ring should be installed at the opposite end.

Measuring shaft voltage on a VFD-driven motor provides valuable information for determining whether or not there is a risk of electrical bearing damage. The best time to take such measurements is during the start-up of a new or recently repaired motor. Every motor has its own unique parameters. Combined with vibration analysis, thermography, or other diagnostic services, results (including saved oscilloscope-screen images) can be presented in a report to the customer. Results should also be used in developing preventive and predictive maintenance programmes.

Shaft voltages are easily measured (using appropriate safety procedures) by touching an oscilloscope probe to the shaft while the motor is running. The best probe will have a tip of high-density conductive microfibres to ensure continuous contact with the rotating shaft. A portable oscilloscope with a bandwidth of at least 100 MHz should deliver accurate waveform measurements. Probe/ oscilloscope kits are available.

Just as shaft voltage measurements can show that a motor’s bearings are in danger of electrical damage, they can confirm that a shaft grounding ring is working. If a proven ring has been properly installed, typical discharge voltage peaks should be less than 10 volts, depending on the motor.

Given the critical nature and high cost of motor failure in many fluid handling applications, protecting the bearings of VFDdriven motors from their first day of service may well be the best practice of all.

For more information: This article was written by Adam Willwerth, sales and marketing manager for Electro Static Technology. For a 44page handbook on the practices summarised in the above article, visit: www.est-aegis.com/bearing

The above waveform shows the rapid voltage discharge through the motor’s bearings that occurs when shaft voltages reach a level where they overcome the dielectric properties of bearing grease

The continuous discharge pattern indicated by the relatively low-voltage waveform on this oscilloscope screen is the result of the bearing lubrication becoming conductive

With an effective, properly installed grounding ring to protect its bearings, a motor produces an oscilloscope waveform like this one, with peakto-peak discharges of only two or three volts

Improving fluid-transfer connections The ongoing surge in oil and natural gas production in the US has not only led to record levels of production and supply, but also had a positive effect in many other areas. One group involved in the oil and gas industry that has specifically benefitted from the increase in production are oilfield equipment manufacturers. It goes to reason that an increase in the amount of production and the number of drilling sites – whether conventional or unconventional – will result in increased demand for oilfield equipment.

In fact, a report released by the research group MarketsAndMarkets.com states that demand within the oilfield equipment rental market will reach a global value of $46.8 billion (€35.5 billion) by 2018. Driving this growth over the next five years will be North America, with its continuing focus on unconventional shale plays and the overall growth of the domestic oil and gas market.

Just as increased oilfield activity means growing demand for equipment, increased production means a higher amount of crude oil, natural gas and other petroleum and chemicals that must be handled safely, for both oilfield personnel and storage terminal operators. This means the need for flowcontrol equipment that can adequately and reliably prevent any leaks or spills when handling, storing, transferring or transporting petroleum products.

The Kamvalok dry disconnect coupler

hose and the fixed pipe end when the hose is disconnected. These couplings can be used in any liquid-transfer application where loss of fluid upon disconnection cannot be tolerated because of environmental regulations, worker

Staying high and dry Throughout all stages of oil and gas supply change, operators are taking special precautions to prevent unnecessary contamination of the environment, while helping to ensure the safety of their employees.

Whereas quick-disconnect technology has traditionally been the coupling style of choice, today dry-disconnect couplers have become a front-of-mind technology option where safeguarding people and the environment are paramount concerns. The effectiveness of dry-disconnect technology dovetails nicely with the wishes of operators, who are placing a heightened emphasis on reducing liquid discharge at hose connection points.

Dry-disconnect couplings have been designed and tested to be an automatic, highly reliable mechanism that seals off both the

The Drylok dry disconnect coupler

safety considerations, the high value of the fluid or where cleanliness is a concern.

Although dry-disconnect products are not necessarily newcomers to the connection business, the demand for these products has

continued to rise sharply as environmental consciousness and compliance have become more prevalent. Additionally, the engineering, design and materials of construction found in dry disconnects have become more and more advanced, offering the optimum connect/ disconnect solution at a reasonable price point.

Recognising the desires and demands of operators for an increased level of liquid containment throughout the supply chain, OPW Engineered Systems offers several types of dry disconnects, each offering unique benefits depending on the type of liquids being handled or the level of protection required, most notably: • ‘Kamvalok’ dry disconnect couplers use a unique poppet-action design that provides a solution to prevent spillage during connection or disconnection. Connections and disconnections are accomplished by simply closing and opening two cam arms, which lock into the machined groove around the circumference of the mating adaptor.

This design enhances flow while simultaneously reducing the risk of unacceptable product loss. A foolproof safety interlock prevents accidental opening, and a sealing arrangement results in a dripfree dry disconnect. Kamvaloks are also designed to automatically shut off in the event of accidental disconnection.

• ‘Drylok’ dry disconnect couplers are the industry’s driest disconnect technology, as the coupler’s flat face helps allow as low as 1cc of fluid loss from a 3” unit. An interlocking handle prevents uncoupling while the valve is open. Dryloks are also ideal for high-pressure line applications because they can be opened and closed against 150-psi maximum head pressure.

Their 360˚ orientation ensures proper seating and alignment, and with no clamps, clips, loops or tabs, the potential for human error is vastly reduced.

Conclusion With the rapid production growth in the oil and natural gas industry comes a corresponding growth in risk for both personnel and the environment. One primary area of risk is the increased chance of leaks or spills of raw materials or finished products during their handling, transfer or transport.

One way to effectively minimise this risk is to pair advanced dry-disconnect couplers with all transfer hoses and fittings. Using drydisconnect couplers will not only minimise the risk associated with hazardous-liquid transfer, but ensure that high-value commodities are not lost to costly leak or spill incidents.

For more information: This article was written by Dave Morrow, director of product management for OPW Engineered Systems, part of Dover Corporation’s OPW division.Visit www.opw-es.com

Why are dry disconnects better than quick disconnects?

Various styles of couplers and hose/ pipe fittings are used throughout the supply chain every day. However, the chance for a leak increases if using quick-disconnect technology versus a dry-disconnect coupler.

The basic quick-disconnect technology is not always able to offer total product containment, which is a major concern for site personnel and the environment when handling hazardous liquids.

Traditional quick disconnects can also be hard to handle, with connections oftentimes difficult to complete and hard to verify.

The goal of any dry-disconnect technology, such as the OPW Drylok dry disconnect coupler, is to optimise environmental protection, while allowing operators to perform safer, cleaner and faster connections and disconnections throughout the supply chain. OPW Drylok couplers are designed to be easy to use and are operated in the following manner: 1. Push coupler onto adaptor by first engaging lower jaw of coupler under lip of adaptor and tilting the coupler upward to engage top jaw (Fig. 1).

Figure 1

Figure 2

2. Turn handle counter-clockwise until lock engages. Coupler and adaptor are locked together but valve is closed (Fig. 2).

3. Press down button on coupler and turn handle counterclockwise until it locks.Valve is now open and product will flow (Fig.3).

Figure 3

4. To disconnect – press button on coupler and rotate handle clockwise until it locks.Valve is now closed.

5. Press button on coupler down and turn handle clockwise to the ‘in-line’ position. Press tab on opposite side of coupler to release the upper jaw and move coupler away (Fig.4).

Figure 4

The word ‘automate’ has been around since 1945, about 20 years before the introduction of industrial robots. It implies the replacement of a human operation with an automatic one, either through the application of hardware, software, or a combination of the two. True automation requires a control system, or ‘brain’. For a dispensing system, the robot usually acts as the controller, positioning for fluid placement, and sending signals to external devices for their actuation.

Robots can quickly orient around difficult to handle parts, cut down process step completion times, eliminate process bottlenecks, increase overall throughput, while simultaneously removing a human operator from a repetitive, monotonous, and potentially dangerous task.

Pairing fluid dispensing equipment with an automated robot to apply material correctly on every product can greatly improve delivery and save production costs. Tabletop dispensing robots are a cost-effective way to increase output, accuracy, and quality in manufacturing processes where assembly fluids like adhesives, lubricants, and silicones must be applied – without hiring additional personnel or making a major investment in capital equipment.

These compact, versatile machines have the capability to apply virtually any assembly fluid with much greater accuracy and consistency than manual applicators, like squeeze bottles or brushes, and with more precise placement than operator-controlled pneumatic dispensers. By increasing productivity, improving quality, and reducing costs, automated robots can provide a significant advantage in today’s competitive global market.

While some companies are still using manual fluid applicators, these methods provide minimal control over the amount of fluid applied, and rely entirely on the operator to control the size and placement of the fluid deposit. On larger production lines with several operators, even with expert training, slight variations in the amount of material applied can negatively impact scrap rates and material waste.

Replacing the brain

Dispensers

One solution to operator variation is to use a dispenser. Pneumatic fluid dispensers are a dramatic improvement over these manual application tools. By using controlled air pressure and precision timers to regulate the amount of material applied, these machines remove subjective operator judgment from the dispensing equation. This improves accuracy while reducing rework, rejects, and waste. Most pneumatic dispensers can be set up on an existing production line, are easy to use, and are operator friendly.

With a precision fluid dispenser, the amount of fluid applied is determined by three parameters: the size or gauge of the dispensing tip, the amount of pressure applied to the fluid, and the length of time pressure is applied, known as the ‘dispense time’. Because these devices produce consistent fluid deposits, regardless of who is performing the operation, they are ideal for manual dispensing

Nordson 781S Series spray nozzle

applications. However, it is still up to the individual operator to determine where and at what rate fluid is applied. While the amount of fluid applied will remain constant, there will still be slight operator-to-operator variations in the placement of the deposit, and different operators will work at different speeds.

Automating the process This is where tabletop dispensing robots can provide a distinct advantage. Instead of leaving it up to the operator to position the dispense tip, a robot system automatically positions the needle and deposits the fluid in the same place every time. Dispensing robots combine a precision fluid dispensing system (typically syringe or valve-based) with an electronically controlled positioning platform. By automating both the positioning and dispensing processes, this setup allows fluids to be applied faster and with greater positioning accuracy than even an experienced operator can provide.

Once the syringe or dispense valve has been mounted on the positioning platform, a teaching pendant or PC is used to programme the placement of the dispensing tip to produce the desired dot, line, circle, arc, or fill. Each production process is programmed and stored, so that it can be easily called up to manufacture the same parts over and over again. No additional operator training is required.

With dispensing and positioning parameters set, the fluid can be automatically applied in the correct amount and location without further operator intervention. The operator simply loads the part or parts onto a fixture, places the fixture on the robot’s work table, and initiates the dispensing cycle. As fluid is being applied automatically, the operator is free to load the next fixture or perform other, more value-added tasks.

With all variations in the deposit placement, size, and speed eliminated, workflow and product quality are improved, bottlenecks are reduced, and production rates become more predictable. Most of these systems are small and self-contained and are easily

moved to different locations, where they can be set up for other dispensing applications as needed. Manufacturers have been known to mount systems on carts for this purpose so they can be easily transported through their production facilities. Newer systems include vision and laser-height sensors, which can detect what part is placed on the fixture plate and run the correct programme automatically.

Beyond the choice of robot itself, accessories and options also need to be considered. In general, this might include vision options, end effectors, safety enclosures, etc. For fluid dispensing applications, a fluid delivery system (like a fluid reservoir, regulator, or a pump) and dispensing technology (like a non-contact jetting valve) must also be selected.

Conclusion Automation offers a number of benefits aside from accuracy, including increased throughput in terms of decreased process time per unit (or batch cycle time), less down time, and decreased transition time. Changing parts can be as simple as changing the active programme.

Tabletop dispensing robots are an efficient way to increase output and quality while

reducing production costs, and they are simple to reconfigure for different products and applications as needed. Dispensing robots offer the flexibility of working either as a standalone system or as a key part of an automated solution, and are easily integrated into existing systems.

Dispensing robots offer manufacturers seeking to gain a competitive edge a cost-effective, easily implemented way to: • Produce more parts • Reduce process time Tabletop dispensing robot Close up of robot’s needle • Reduce labour costs for each part be guided by each company’s particular application and what it would like to achieve, • Prevent bottlenecks and reduce work-inprocess but common considerations will include • Increase output without adding personnel the robot model, level of desired precision, and types of interfaces or communication • Reduce rejects and rework related to inaccurate fluid placement required.

• Minimise non-value-added activity For more information: • Quickly produce different products on This article was written by Steven Neves, product line demand. associate, Nordson EFD.Visit: www.nordsonefd.com or The level of automation selected should contact the company at info@nordsonefd.com

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TEMPERATURE TROUBLES The Ameren Sioux Energy Center Unit 1, part of the expansive supercritical coal-fired plant located in St. Louis, US, was experiencing progressively worse temperature control problems into year 2012 with a circulating cooling water system.

The circulating water system provides cooling water to the condenser, low and high pressure raw water systems, condensate cooling system and auxiliary cooling water system.

Temperature control of the existing system was problematic and the heat exchangers had become extremely fouled over roughly 45 years of service and had lost significant heat transfer

capability. Due to this loss, the control valves typically operated at or near full open condition.

Stephen Williams, a consulting engineer at the plant’s owner Ameren Missouri, was tasked with resolving this problem. New heat exchangers were needed to restore the heat transfer capability of the system and new control valves were needed to reliably regulate temperature across the range of expected operating conditions.

Williams built computer models to simulate the hydraulic behavior of the system and assist with new control valve selection.

Very few valves were available that would fit in the existing piping configuration. Multiple models were constructed which verified that a single valve would not work. Large valves did not have sufficient turndown to accurately control the low end flow, while smaller valves would fail to achieve full flow at fully open conditions. The model predictions showed that a 24” valve would have to be used for the high end of the flow range and a smaller valve for the low

Hydraulic computer model of cooling water system with two parallel control valves

range flows. The picture above shows the AFT Fathom hydraulic model with the two control valve arrangement.

Based on the model results, a parallel valve arrangement was selected using a 10” Fisher V150 V notch control valve in parallel to the 24” butterfly valve. The control logic was setup such that the 24” valve would be used above 20% open, and the 10” V notch valve would be used for flows below. The AFT Fathom model determined the control cutover point to be at 3,500 gpm

Field data compared to AFT Fathom model predictions

Field data

AFT Fathom predictions

1A CWP discharge pressure

8.8 psig (60.7 kPa g)

9.22 psig (63.6 kPa g)

1B CWP discharge pressure

8.7 psig (60 kPa g)

8.86 psig (61.1 kPa g)

B JAW inlet pressure (manual reading)

6.5-6.7 psig (44.8-46.2 kPa g)

5.18 psig (35.7 kPa g)

B JAW outlet pressure (digital manometer)

12.83 psia (189.8 kPa)

12.3 psia (186.1 kPa)

Total flow

~277,000 gpm (62,900 m3/h)

280,988 gpm (63,822 m3/h)

B Cooler flow

11,090 gpm (2,519 m3/h)

11,368 gpm (3,101 m3/h)

(800m3/h).

‘Since this is a high flow, low pressure system, accurate modelling of expected system pressure, pressure drop,Valve Cv and resulting valve position was critical,’ says Williams.

To validate the computer model performance, field data was collected and compared to the model predictions. Results are shown in the comparison table.

This study shows how computer modelling is an effective way to evaluate potential solutions to operational problems in existing power plants. A parallel valve arrangement was used to enable control over the full range of required operation. The computer model allowed sizing of the valves. Operational data confirmed the new control valve sizes and arrangement.

For more information: This article was written by Trey Walters, president, Applied Flow Technology.

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