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VIEWPOINT
5 | Five reasons safety, PPE are so important
Safety has an integral role at any manufacturing facility.
INSIGHTS
6 | How manufacturers keep workers safe, reduce hazards
Safety is a major part of manufacturing and there are many facets to consider, but how companies approach it is quite different, even if there are universal truths all should abide by.
SOLUTIONS
12 | Navigate the challenges, tech changes in process piping systems
Process piping design is in a dynamic shift from traditional methods to innovative technologies.
16 | Nine crucial aspects for designing a process piping system
Process piping system design is a complex and involved process that has significant impact on many industrial facilities. Nine crucial aspects for design are highlighted.
SOLUTIONS
26 | How to anticipate maintenance problems with predictive analytics
Process manufacturers are combining retrospective analysis with predictive tools using advanced analytics platforms.
30 | Predictive maintenance’s role in routine compressed air system service
Predictive maintenance done as part of the system’s regular service schedule can keep a compressed air system running efficiently.
34 | How smart lift trucks enhance warehouse environments
Smart lift trucks can play a key role in keeping a warehouse moving forward efficiently.
36 | Dry bulk material handling automation choices
It's important to understand the advantages and disadvantages when it comes to dry bulk material handling choices.
41 | What is the value of process piping design?
Learn about the different types of process piping projects, and how each drives the design.
ON THE COVER:
Process piping design includes solids removal/dewatering and wastewater recovery/recirculation system (top) and nutraceutical batch processing and heat treatment system (bottom). Courtesy: Salas O’Brien
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JOHN GLENSKI, Principal, Automation & Digital Strategy, Plus Group, A Salas O'Brien Company
MATTHEW GOSS, PE, PMP, CEM, CEA, CDSM, LEED AP, Senior Vice President, CDM Smith
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Five reasons safety, PPE are so important
Safety has an integral role at any manufacturing facility
When we think about manufacturing plants and industrial facilities, we often envision a busy environment filled with machinery, noise and workers going about their tasks. It's easy to overlook one of the most crucial aspects of this environment: safety. Let's talk about why safety, fall protection and personal protective equipment (PPE) are absolutely essential in these settings.
a culture where workers look out for each other. Workers who see their colleagues consistently using PPE and following safety protocols are more likely to do the same. This peer influence reinforces a collective responsibility toward maintaining a safe work environment.
Amara Rozgus, Editor-in-Chief
First, safety is about preserving lives and health. The primary goal of any safety measure is to prevent injuries and fatalities. In manufacturing and industrial settings, workers face various hazards daily, from heavy machinery and toxic chemicals to high temperatures and loud noises. Signs with “days since last accident” are proudly displayed.
Secondly, it enhances productivity and efficiency. A safe workplace is a productive workplace. When workers feel safe, they're more likely to focus on their tasks rather than worry about potential hazards. This focus leads to better quality work and higher efficiency. On the flip side, an unsafe work environment can lead to frequent accidents and injuries, causing disruptions and downtime.
Third, safety fosters a culture of care and responsibility. When a company takes safety seriously, it sends a clear message to its employees: “We value you and your well-being.” This approach boosts morale and fosters
Next, it helps in compliance with laws and regulations. Regulatory bodies, such as Occupational Safety and Health Administration, have stringent guidelines for workplace safety. These regulations are in place to ensure that companies provide a safe working environment for their employees. Noncompliance can result in hefty fines and legal repercussions.
Lastly, it’s an investment in the future. Implementing safety measures and providing PPE might seem like a significant upfront cost, but it's an investment that pays off in the long run. Consider the costs associated with workplace injuries: medical expenses, compensation, lost productivity and potential lawsuits. These costs far outweigh the expense of investing in high-quality PPE and safety training. Moreover, a reputation for safety can attract skilled workers and clients.
Learn more about what your peers are saying about PPE and fall protection in this research study, Plant Engineering Personal Protective Equipment & Fall Protection Report at www.plantengineering.com/ research. PE
How manufacturers keep workers safe, reduce hazards
Safety is a major part of manufacturing and there are many facets to consider, but how companies approach it is quite different, even if there are universal truths all should abide by.
Question: What are some of the current hazard protection trends for industrial and manufacturing facilities?
Shawn Gregg: One of the main trends we’re seeing is greater utilization of the Internet of Things (IoT) – especially when it comes to connected safety solutions. The ability to facilitate communication between devices and the cloud, as well as between
the devices themselves, is having a major impact on safety. For example, confined space air monitor readings can be read real-time by a safety manager hundreds of miles away, and alerted in real-time if an alarm is going off. Surveillance cameras, wearable devices and other connected safety solutions can document unsafe work movements and create a database to help with accident trends.
David Kennedy: Continuing awareness of combustible dust explosions because incidents continue to occur, automation and mechanization of lifting/ bulk material handling to avoid ergonomic hazards.
Dave Opheim: Due to increased global competition there is higher pressure on industrial petrochemical producers than ever before. This is particular true for process operations that utilize flammable and/or toxic gases, liquids or solids. Three examples of evolving life safety hazards within industrial petrochemical operations include:
• Alternative fuels including hydrogen, compressed/liquified natural gas, and synthetic fuels
• Specialty chemicals and related production processes
• Renewable energy sources using advanced lithium-ion battery energy storage systems.
In addition to these flammable and toxic hazards there is often increased pressure on production operations caused by supply chain bottlenecks, workforce shortages or lack of proper training. Stakeholders should consider routine re-evaluation of their facility hazards, processes, stressors and operator training requirements to maintain safe production operations in this evolving market.
Dustin Schneider: An emerging trend in fall protection is the increased use of drone technology for inspecting and maintaining elevated structures. Drones equipped with high-resolution cameras and sensors can access hard-to-reach areas without
FIGURE 1: Effective PPE training and implementation can reduce worker injuries and improve safety. Courtesy: Wesco
exposing workers to the risk of falls. They can perform detailed inspections of roofs, scaffolding, and other elevated workspaces, identifying potential hazards such as structural weaknesses or loose components. This technology not only enhances safety by reducing the need for workers to perform these risky tasks but also improves the efficiency and accuracy of inspections, leading to more timely and effective maintenance interventions.
Question: What future trends should engineers, plant managers and designers expect for hazard protection? Looking ahead one to two years.
constraints for the high-demand safety professional group. And of course, the need for safety doesn’t end once those projects are completed.
David Kennedy: Labor shortage in manufacturing continues so automation is needed to avoid overexertion and repetitive motion injuries. Combustible dust explosions still occur today, which expose the failure in awareness of material hazards, or neglect of proper SOP. Focus is needed on improving industrial hygiene and housekeeping with solutions like continuous duty and central vacuum cleaning systems, and dust-free methods of bulk powder handling such as vacuum conveying.
Dave Opheim: Future trends expected include significantly higher productivity goals usually with the same or even less overall resource availability. In addition, customers will expect a higher level of renewable and/or green energy utilization in their suppliers. This is likely to mean changes in hazardous operations depending upon the specific nature of the business. The ability of safety managers to rapidly review, validate, and revise their work procedures and safety systems to evolving fire and life safety hazards will be tantamount.
‘ In the coming years, augmented reality (AR) will significantly enhance PPE and fall protection training programs.’
Shawn Gregg: As the landscape continues to evolve, connected safety solutions will play a greater role in helping plant managers keep their workers safe. These technologies – from wearables that provide haptic feedback to cameras with integrated sensors – can identify and monitor potential hazards, and help prevent incidents before they happen. Artificial intelligence (AI) will become more prominent as well, and will be a powerful extension of the safety manager. Also, onshoring and more mega projects could create additional safety management
Dustin Schneider: Looking ahead, the integration of the Internet of Things (IoT) devices in hazard protection is expected to grow. IoT sensors will provide real-time monitoring of environmental conditions, equipment status, and worker health, allowing for immediate responses to potential hazards. Advances in wearable technology will offer more sophisticated and personalized safety solutions, such a to design or modify systems to protect from a hazardous environment. What were the challenges and solutions?
Shawn Gregg: To begin with, it’s essential to clearly document and communicate that maintenance is a core part of your inspection safety management program. Its also important to note that safety professionals simply don’t have the option to manage the safety inspection process with paper and clipboards. They need to have systems in place to automate and streamline that process as much as possible. And even though NFPA 70B has been in place for nearly a year, the shift from “recommended” to “mandatory” means that safe-
Shawn Gregg, vice president, global safety, Wesco, Pittsburgh
David Kennedy, business development manager, VAC-U-MAX, Belleville, N.J.
Dave Opheim, business development manager, flame & gas detection, MSA Safety, Cranberry Township, Penn.
Dustin Schneider, channel sales director, Diversified Fall Protection, Westlake, Ohio
FIGURE 2: Personal protective equipment (PPE) training is an aspect that is often overlooked. Courtesy: Wesco
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ty professionals will need to take a proactive mindset when it comes to maintaining their electrical equipment.
David Kennedy: Metal powders used in additive manufacturing can be reactive requiring NFPA-prescribed explosion protection techniques such as oxidation concentration reduction. This technique requires addition of an inert gas such as argon in the vacuum conveying system to reduce the oxygen concentration below the level where combustion can occur.
Dustin Schneider: We have several instances where we had to modify machinery or structures around machinery to integrate fall protection into equipment that wasn’t initial-
ly designed with it in mind. The challenges we encounter include adding structures capable of supporting the systems without hindering the equipment's functionality or blocking access for repairs. The cost of all these modifications and securing capital budget are common obstacles we face. Finding solutions often requires innovative engineering and strategic budgeting to ensure both safety and operational efficiency.
Question: What tips would you offer to someone newly tasked with hazard protection duties?
David Kennedy: Be aware of bulk material and dust hazards from those materials used in your facility. Review SDS sheets and communicate diligent with workers about those hazards. Remove equipment that is not rated for combustible dust environments such as shop-type vacuums and eliminate compressed air blow-down practices. Facility cleanliness is not a matter of pride, it's a matter of safety.
Dave Opheim: After you have reviewed existing workflows, standard/detailed operating procedures and hazardous operation summaries, spend some time observing and interviewing personnel directly involved with performing the hazardous work job functions. Consider performing the job function yourself for a half or full day to gain first-hand insights.
Make a point of talking with your operations personnel regularly for their input on safety protocol, and don’t forget that regular formal reviews of your hazardous operations are required. Seemingly small changes in the way workflow is performed, or changes in equipment, layout or materials used in the standard work can often have a significant impact on how a worst-case event scenario plays out.
Dustin Schneider: Start by thoroughly familiarizing yourself with industry safety standards and best practices. Regularly review and update your knowledge to stay current with new developments. Secondly, establish a proactive approach to hazard identification and mitigation. Implement regular inspections and maintenance schedules, and use technology like IoT sensors for real-time monitoring. Lastly, cultivate strong communication and training programs. Ensure all employees under-
stand the importance of hazard protection and are trained in emergency procedures, creating a collaborative environment focused on safety.
Question: What role do engineering controls play in creating protective environments? Can you provide examples of engineering controls implemented in your facility to mitigate hazards?
Shawn Gregg: Safety audits should be considered annually, but not be communicated to the workflow when they will be scheduled. While some companies find it very useful to include line workers in the audits, you want to replicate a true daily workflow when assessing the work processes and PPE usage in a normal scenario of daily production. Also, written safety policies are commonly not viewed by employees, so having them readily available and discussion with the team is critical.
David Kennedy: In the petrochemical industry, "training" is not an acceptable safety method, because operator error can still occur. HAZOP studies should identify devices or instrumentation to eliminate operator errors.
Question: What role do you foresee for augmented reality (AR) in future PPE and fall protection training programs?
Shawn Gregg: Greater utilization of connected safety solutions can significantly enhance an organization’s PPE and fall-protection efforts – especially for lone workers. Wearables with integrated sensors can detect slips, trips and falls, and send alerts when an incident occurs. For lone workers, this type of technology can be lifesaving. Visual intelligence solutions and other types of wearables can also monitor for PPE compliance and proper utilization. All told, incorporating these solutions is an easy way to help keep workers safe.
Dustin Schneider: In the coming years, augmented reality (AR) will significantly enhance PPE and fall protection training programs. AR can simulate complex scenarios, enabling workers to experience and react to potential fall hazards
FIGURE 4: Submerged recovery vacuum cleaners render explosive and reactive powders inert by drawing the debris under liquid, safely separating the debris from the air stream. Designed in anti-sparking 304 stainless steel the cart-type dolly features a grounding reel and 6-inch static conductive casters for easy mobility. Courtesy: VAC-U-MAX
u
Objectives Learning
• Understand the importance of plant safety and hazard protection.
• Learn how engineers in different industries address safety and stay up to date on the latest standards.
ENGINEERING SOLUTIONS
in a virtual environment. This handson approach increases engagement and retention of safety procedures.
AR also allows for customizable training modules tailored to specific job roles and environments, providing targeted and effective learning experiences. By integrating AR into training, organizations can ensure employees are better equipped to handle real-life safety challenges, reducing the risk of accidents and improving overall workplace safety.
Question: How does leadership demonstrate a commitment to safety and how do you foster a culture of continuous improvement in safety practices?
Dustin Schneider: Leadership can demonstrate a commitment to safety by prioritizing it in all aspects of operations, from strategic planning to daily activ-
ities. They should visibly support safety initiatives, provide adequate funding for safety equipment and training, and engage in regular safety walks and inspections. To foster a culture of continuous improvement, it is essential to implement a robust system for reporting and analyzing near-misses and incidents, encouraging open communication and learning from each event. Establishing clear safety goals, tracking progress, and celebrating achievements are crucial steps. Continuous improvement is driven by regular training sessions, staying updated with industry best practices, and fostering an environment where every employee feels responsible for safety.
Question: Looking ahead, what is one major change or improvement you would like to see in the PPE and fall protection industry?
Dustin Schneider: One significant improvement I envision for the PPE and fall protection industry is the development of more ergonomic and user-friendly equipment, specifically including products designed for women. Often, workers find PPE cumbersome or uncomfortable, leading to non-compliance or improper usage.
By advancing the design and materials of PPE, we can create solutions that are not only safer but also more comfortable and easier to use, ensuring they fit both men and women properly. This would encourage consistent use and proper application, significantly reducing the risk of falls and other workplace injuries. Enhanced comfort and usability, alongside gender-specific designs, will contribute to a stronger safety culture and better overall protection for all workers. PE
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Navigate the challenges, tech changes in process piping systems
Process piping design is in a dynamic shift from traditional methods to innovative technologies
Process piping for manufacturing is a complex challenge — especially within aseptic or high-care industries. Plant managers know it is the backbone of a facility, dictating the flow and integrity of operations, but they just need it to work.
With the industry in the middle of a digital revolution, the stakes have never been higher. The shift from traditional methodologies to innovative technologies like digital twins and data-driven mainte-
nance is not just a trend. This transition demands attention, even in busy plants where focus is often stretched thin.
The introduction of digital tools into process piping design has opened a new world of possibilities, from preemptive problem-solving to enhanced operational insights. However, this digital leap brings its own challenges and it doesn’t make the basic challenges — like multidisciplinary coordination or clash detection go away.
Delving into the specifics, let's first address the foundational challenges that persist in process piping design, understanding how they coexist with and are influenced by the surge of digital innovations shaping our industry.
Multidisciplinary coordination for process piping design
Foundational challenges intertwine with the rapid pace of digital innovation. A prime example is project coordination and the hurdles of decision-making delays.
Piping projects usually revolve around enhancing efficiency or expanding capacity. However, the reality is a constant balancing act because production doesn’t stop. Plant managers find themselves in a whirlwind of daily operations, making it nearly impossible to halt their routine responsibilities to concentrate solely on a project. This ongoing hustle transforms coordination into a formidable challenge.
Critical decisions at various project milestones are essential to safeguarding the project schedule and averting the loss of time and efficiency. Having a clear procedure to process information is key, knowing precisely what is needed, when it's needed and who is responsible for delivering it. Although not traditionally seen as cutting-edge, getting those decisions at the right time is vital and its absence can lead to significant setbacks.
FIGURE 1: Nutraceutical batch processing and heat treatment system, part of a retrofit into the existing manufacturing facility of a global client. Courtesy: Salas O’Brien
Because process piping coordinates with every other discipline within a project, information flow can be complex. Consider this: each pipeline not only requires structural support but often integrates with various control systems. While the concept may appear straightforward, the reality of routing pipes is anything but. Achieving a layout that avoids dead legs, facilitates gravity drainage, doesn't obstruct door or duct functionality and maintains the integrity of temperature-controlled areas is a complex, almost artistic endeavor.
To navigate this complexity, implementing a structured approach — such as a coordination matrix — is invaluable. This tool clearly delineates the roles and responsibilities within the project, specifying who needs information, who provides it and crucially, when it is required.
While digital 3D modeling tools like Autodesk Navisworks play a pivotal role in identifying spatial conflicts, the resolution of these clashes doesn’t always happen in the digital world. It lies in the meticulous coordination between different disciplines to figure it out.
What happens when a 3-D model of process piping doesn’t exist?
While old-fashioned coordination and communication are baseline, there are places where digital advances are solving problems fast. Take this scenario for example:
A project manager at a food manufacturing plant is tasked with a master planning project. This
FIGURE 2: Solids removal/dewatering and wastewater recovery/recirculation system at at power plant greenfield project for a major U.S. energy producer. Courtesy: Salas O’Brien
‘ Critical decisions at various project milestones are essential to safeguarding the project schedule and averting the loss of time and efficiency. Having a clear procedure to process information is key, knowing precisely what is needed, when it's needed and who is responsible for delivering it.’
involves putting some production lines into temporary shutdown, decommissioning others and relocating several to a different facility to boost productivity.
The project manager shares a common concern: “Dave, we don’t have a single reliable drawing of our plant.”
This is where reality capture steps in as a gamechanger. Reality capture is a technique for creating digital models of physical spaces and objects by collecting real-world data. This is often done using laser scanning (LiDAR), which accurately captures the current state of a space or object, offering a precise and measurable digital version.
With this digital data in hand, it can be imported into design software. This allows for virtual manipulation to strategize the best ways to move and reorganize production lines. It provides a solid foundation for planning and making decisions with confidence, transforming a challenging scenario into a manageable project.
Objectives Learningu
• Discover the key challenge to process piping design.
• Find an option for plants where accurate drawings do not exist.
• Explore the role of digital tools like virtual reality and digital twins and a look at the trajectory of where it is all going.
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Enhancing process piping design with VR and digital twins
Reality-captured data can be used to create or update digital twins. These digital replicas can provide detailed 3D visualizations inclusive of dimensions, materials, components and layout configurations.
For many years, the only option was for engineers to walk a plant floor to observe the conditions. Now, engineers can explore a digital twin using a virtual reality (VR) headset, making it feel like they're walking through the space themselves. This advancement is particularly beneficial for collaboration across different locations, enabling teams from multiple plants within the same company to work together seamlessly. It also allows teams to model and visualize new process piping designs in place to see how things will come together.
"Descriptive twins," the first level of digital twins, provide a static digital model highlighting the physical details of piping systems. They can facilitate the early stages of design, offering a visual understanding of the system's architecture and allowing for simple simulations. However, without the ability to incorporate real-time data or feedback, their use is mainly for initial visualization and planning purposes.
This integration of VR with digital twins simplifies and enhances how engineers and stakeholders engage with process piping designs. It supports more effective planning and collaboration, making it easier for teams across different locations to work together and understand the system’s layout and potential challenges.
Process piping design's future: a unified model with data insights
The future is headed toward a unified approach creating a "single source of truth" — a central model (higher level digital twin) where all project data is stored, updated and made accessible to everyone involved, from engineers to project managers. This model ensures that all stakeholders have access to the same accurate information, dramatically improving coordination and achieving a level of consistency that was once out of reach.
Data analytics and machine learning (ML) add a sophisticated layer to this approach, as they turn vast amounts of raw data from sensors into
useful insights, enabling smarter decision-making. This intelligence, integrated into the centralized model, paves the way for predicting outcomes, automating solutions, mapping scenarios and streamlining project flows. The adaptability of artificial intelligence means not just faster phases of design and execution but also a proactive stance on identifying and resolving potential issues, minimizing risks and improving results.
As we integrate data analytics and ML into process piping design, we're setting new standards for how projects are approached and carried out. The shift toward a single, intelligent source of information marks a significant move away from disjointed data and toward a more cohesive, efficient method of managing and sharing data. This change is already underway, signaling a future where seamless integration and communication become the norm in process piping design.
‘ "Descriptive twins," the first level of digital twins, provide a static digital model highlighting the physical details of piping systems. They can facilitate the early stages of design, offering a visual understanding of the system's architecture and allowing for simple simulations.’
This new data-driven future has implications for the people who design and work with it.
Advice for the next generation of process piping engineers
Traditionally, our industry has placed a premium on "the expert." However, the current speed of change in our sector requires us to be adaptable learners who can make swift adjustments. Autopilot has no place in our dynamic environment. Instead, we need engineers with a growth mindset who can continually improve and consistently bring added value to clients.
True innovation leads the way, demanding not only a solid foundation of knowledge but also a persistent drive to broaden that base. While having expertise is valuable, combining that expertise with a proactive approach to learning and adapting is what really aligns with the direction our industry is heading. PE
Dave
Robinson is a Vice President and Design Director for Process and Manufacturing at Salas O’Brien.
Insightsu
Process piping insights
uProcess piping designers are using digital twins and datadriven maintenance, which are reshaping the industry.
uThis article highlights the challenges and innovations that are making a difference when navigating challenges and embracing innovations for futureready systems.
ENGINEERING SOLUTIONS
Gilbert Welsford, Jr., ValveMan, Exton, Pa.
Nine crucial aspects for designing a process piping system
Process piping system design is a complex and involved process that has a significant impact on many industrial facilities. Nine crucial aspects for design are highlighted.
Process piping refers to systems of pipes that transport fluids around industrial facilities. Chemical and petrochemical plants, oil refineries, power plants, pharmaceutical manufacturing facilities, food processing and water treatment plants are among the places where process piping is found. Less obvious industries such as automotive, mining, agriculture, residential and healthcare also use process piping. Process piping may not always be seen, but it is a critical component in many industrial settings.
Process piping systems are networks of interconnected process piping, process equipment, pumps, tanks, valves and fittings that work together to accomplish a specific task or sequence of operations. Components of a process piping system include:
Process piping system design
Optimum design of process piping systems is crucial to the success of industrial operations. A well-designed process piping system operates efficiently and trouble free, with reduced downtime. It is safe to construct, operate and maintain; and is cost-effective, considering both upfront and life cycle costs. Optimally-designed process piping systems ensure:
• Efficient transportation of materials within a process
• Decreased risk of downtime
• Improved safety for personnel and equipment
• Effective control of operations leading to enhanced productivity.
When designing a process piping system, it’s vital that engineers consider these nine aspects.
1. Understanding the process
The first step in designing a process piping system is developing a comprehensive understanding of the process. This involves two aspects: Identify the specific industrial process and determine the process requirements.
Identify the specific industrial process
• Understand the role process piping system design plays in industrial facilities.
• Learn about the nine aspects all engineers should consider when designing a process piping system.
• Understand the intricate steps involved in each step and the complex factors they need to consider.
• Pipework, including straight pipe sections, pipe fittings and connections
• Motive equipment such as pumps or blowers
• Flow control devices such as valves
• Storage equipment such as tanks
• Process equipment such as reactors, boilers and heat exchangers
• Measuring and monitoring equipment
• Safety devices such as pressure relief valves and alarms.
Each industry has unique processes which influence the design, installation, and maintenance of process piping systems. Depending on the industry, the processes involved and prevailing industry regulations, the piping system design will vary. For example, consider the differences among an oil refinery, water treatment plant and food processing facility:
• Oil refinery: The process may require pipes resistant to chemical corrosion, high pressures, temperatures, and capable of handling highly viscous fluids. Codes, standards and guidelines
from organizations such as the American Petroleum Institute (API) and the American Society of Mechanical Engineers (ASME) may be used in the design.
• Water treatment: The process may necessitate pipes that can withstand aggressive environmental conditions, and be safe for potable water applications. The American Water Works Association (AWWA) standards may be incorporated in the design.
• Food processing: High sanitary designs are required to avoid product contamination. The Food and Drug Administration (FDA) regulations and National Sanitation Foundation (NSF) standards may apply to such an installation.
Determine the process requirements
The next step is defining the process requirements, which can be categorized as performance requirements and safety requirements. Some examples are given below:
• Performance requirements outline the parameters the piping system is designed for. This may include the flow rate, pressure and temperature range at all stages of the process.
• Safety requirements outline the safety features of the process piping system. High or low flows, pressures or temperatures must be allowed for in the system design. Designs must be compliant with Occupational Safety and Health Administration (OSHA) standards, as well as the OSH Act.
Understanding the process ensures a process piping system is designed for the specific needs of the process, resulting in an efficient, safe and long-lasting solution.
2. Selecting piping material
Choosing the right pipe material is a critical step in process piping design. Each industrial process has particular requirements, necessitating careful consideration when selecting a pipe material. With so many materials available in the market, selecting the right one can be challenging.
Compatibility with process fluids
Material compatibility extends the life of a process piping system, and avoids contamination of the process fluid. The selected pipe material should be non-reactive with the fluids being conveyed. Fluids such as process chemicals, fuels and even water can be corrosive, resulting in damage to pipe-
work, leakage, pipe rupture and other safety issues. Designers should examine chemical compatibility charts for suitable pipe materials, and ensure the pipe material will not corrode or contaminate the process fluid.
Operating and environmental requirements
The material selected for a process piping system must be capable of withstanding operating requirements, such as the operating pressure and temperature range. Environmental factors must be considered, as well — these depend on the specific industrial process and the environment in which the pipe system is installed. Consider the following:
• The pipe material's pressure-temperature rating.
• Thermal expansion and contraction characteristics of the material under operating and environmental temperature ranges.
• Pressure surges and phase changes which may occur.
• Exposure to external elements such as rain, wind, snow, UV radiation.
FIGURE 1: A process piping system includes pumps, safety devices, sensors, process equipment, tanks, valves and pipework and each aspect requires thorough research and inspection. Courtesy: ValveMan
Continued on pg 20
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Continued from pg 17
• Installation details such as buried pipe, submergence in seawater or acid.
Cost and availability
Another significant consideration is budget and availability. The selected piping material must align with budgetary constraints and be available when needed. Procurement delays can have a major impact on project timelines. The following aspects are important:
• Compare the cost-effectiveness of different piping materials.
• Verify the availability of the chosen material in the local market.
• Consider the total cost of ownership (TCO), which includes the initial cost, installation cost, maintenance and replacement cost, if necessary.
• Consider the design life of the process and plant and select accordingly.
3. Pipe sizing and layout
Correct pipe sizing and optimal piping layout are essential features of a well-designed process piping system. There's much more to consider than just connecting pipes.
Determine pipe size based on flow rate and pressure drop
Piping must be sized to accommodate the flow rate and pressure loss for the industrial process. A pipe sized too small can lead to high velocity and large pressure drop, compromising the efficiency and performance of the process. However, a pipe sized too large can result in greater expenses due to the increased cost of piping, fittings, valves and ancillaries. When determining the pipe size and pressure drop in the system, consider the following:
• Fluid properties: The type of fluid in the pipe, its temperature, density and viscosity impacts the pressure drop.
• Pipe size: The velocity and friction in the pipeline are directly related to the pipe size, particularly the pipe internal diameter (ID).
• Pipe length and fittings: Longer pipes and a greater number of bends and fittings increase friction, impacting the pressure drop.
Optimize the piping layout
Designing a simple and efficient layout for the process piping system promotes optimal performance, by reducing the material cost of the system and decreasing the energy required for the system to operate. Ensuring accessibility for routine maintenance and potential repairs prevents extended downtime that might otherwise affect productivity. An efficient layout should:
FIGURE 2: When designing a process piping system, it’s important to analyze several crucial aspects such as the process, the material used, maintenance and accessibility and the standards involved. Courtesy: ValveMan
• Minimize pipe length and number of fittings to reduce friction and minimize energy requirements.
• Avoid sharp bends because they can cause flow disruption and pressure loss; sweep elbows are a better option.
• Provide access for operational activities, inspections, routine maintenance and repairs.
• Plan for future maintenance and expansion.
4. Pipe support
Pipe supports are an essential component of process piping systems. There are a wide range of options to choose from, from small clamp type supports to massive pipe racks carrying numerous pipes across an industrial facility. Pipes may sag or vibrate without adequate support. This can lead to accelerated corrosion, wear, fatigue and eventually failure. The following factors should be considered:
• Use appropriate supports for the material and size of the pipe. These might include clamps, brackets, stands or racks.
• Select a pipe support based on the desired pipe movement and degree of freedom required.
• Ensure the pipe support system caters for the full range of anticipated loading conditions. These include the weight of pipe and fluid, friction between the pipe and support, pressure and surge loads during operation. Additional loads which need to be considered include thermal, wind, ice and seismic loads.
• Account for pipe contraction and expansion. Support selections should accommodate thermal expansion and contraction to prevent damage. Pipe expansion loops or expansion joints may be required.
• Pipe supports must be optimally spaced.
5. Valves and fittings
When designing a process piping system, the type and position of valves and fittings are an
important consideration. Valves and fittings play a pivotal role in regulating the flow of fluids within a process piping system.
Selecting the appropriate valves for process control
Valve selection is a topic in its own right. The valve selection process should be rooted in a deep understanding of the process piping system's overall functionality and the varying operational requirements. There are many different types of valves and each offer distinct benefits and are the optimal choice for specific applications. For example:
• Gate, ball and butterfly valves are suitable for isolation.
• Check valves prevent backflow.
• Globe valves are a good choice for flow regulation and control.
• Pressure relief valves protect the system from exceeding pressure limits.
Flow requirements, pressure ratings and material compatibility
There are several factors to consider when selecting valves and fittings for a piping system. Some common factors include:
• Flow requirements — Dictates the size and type of valves and fittings necessary.
• Pressure and temperature ratings — This ensures chosen components can withstand the system's operating conditions.
• Material compatibility — Selected valves and fittings should be composed of materials suitable for the application, thus avoiding corrosion, leaching or contamination of the process fluid.
6. Understanding system pressure and pressure drop calculations
Effective process piping design requires an accurate assessment of flow and pressure throughout the system, for all operating scenarios. Pressure drop
‘ Piping must be sized to accommodate the flow rate and pressure loss for the industrial process.’
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refers to the reduction in fluid pressure as fluid flows through a pipeline.
Understanding the concept of a pressure drop
Pressure decreases in a piping system due to frictional losses as the fluid moves along the pipe's length, encountering obstacles such as pipe walls, valves, bends, strainers, filters, other fittings or equipment. Pressure also will decrease as the fluid moves to a higher elevation in the system. Implications of high pressure drop in a process piping system include increased energy requirements, larger motive equipment and associated capital and operational expenditure.
Calculating pressure drop and selecting the right pipe size, valves and fittings
Calculations for pressure drop in piping systems are multifaceted and require technical know-how. Parameters such as fluid density and viscosity, pipe length, pipe diameter and flow velocity significantly influence the pressure drop in a process piping system. Other factors such as fluid elevation, pipe roughness and losses through fittings and equipment also must be accounted for.
If the user has the technical know-how, a manual analysis of process piping system hydraulics may be conducted. Spreadsheet software is also a useful aid in automating the analysis. Numerous software systems are available to aid in analyzing process piping system hydraulics, helping specify the correct process equipment and the optimal pipe size.
7. Thermal expansion
Effective design of a process piping system requires an understanding of thermal dynamics and pipe flexibility. As temperatures change, piping could potentially expand or contract. Overlooking this aspect can lead to serious problems such as leaks, pipe ruptures or even system breakdowns.
Addressing thermal expansion and contraction issues
‘
Effective process piping design requires an accurate assessment of flow and pressure throughout the system, for all operating scenarios.
’
Read up on the Bernoulli equation, Darcy-Weisbach equation and Colebrook-White equations for additional information.
Pressure drop calculations are crucial in specifying process equipment such as pumps, and optimizing pipe size. Be sure to consider the following:
• Pipe size: Larger pipes minimize pressure drop due to reduced flow velocity. Conversely, smaller pipes lead to increased friction and greater pressure drop.
• Pipe length: A longer piping system results in greater frictional losses and higher pressure drop.
• Pipe roughness: Pipe which is rough internally will result in greater friction and increased pressure drop.
• Component-induced losses: Fittings such as bends, reducers, valves, and strainers have a marked impact on fluid flow and pressure along a pipeline.
When dealing with long pipe lengths or extreme temperature ranges, the strain in the pipe due to thermal expansion and contraction is a major concern. Steel pipes, for instance, can expand and contract significantly with temperature change, resulting in significant stresses within the pipe wall. Here are a few points to consider:
• Predict anticipated temperature ranges the piping system will be exposed to, due to both ambient and process temperature changes.
• Understand the thermal properties and characteristics of the pipe material planned for use.
• Ensure the design caters for and guides the anticipated movement of the piping due to thermal effects.
Incorporate
expansion joints for piping system flexibility
One way to avoid detrimental thermal effects in a process piping system is providing flexibility. This may take the form of pipe expansion loops or expansion joints. Expansion joints may be specified with various degrees of freedom, allowing pipes to move axially or rotate without placing undue stress on the system. Take note of the following:
• Provide expansion loops or expansion joints at strategic locations, like points where the
pipe changes direction or at long overland pipe sections.
• Incorporate flexible pipe components such as bellows for an adaptable pipe system.
• Design piping layouts with a degree of flexibility, allowing for slight shifts in pipework without significant detriment to the system.
Piping designers often need to find a balance between pipe stiffness and flexibility, through the careful selection and placement of pipe supports, pipe fittings and making provision for pipe expansion.
8. Maintenance and accessibility
Maintenance is a critical factor in any industrial operation. Designing process piping systems for ease of maintenance and operational accessibility should be high up the list of priorities. A well-maintained and easily accessible piping system can save time and effort, reduce costs, and lead to operational efficiency.
Design for easier maintenance and component access
A process piping system should be designed so key components can be reached for operational and maintenance activities. Routine maintenance tasks, equipment checks, cleaning and repair activities should be hassle-free. Helpful features include:
• Removable piping sections or the provision of flanges to provide access to valves and equipment
• Component layouts that eliminate the need for excessive dismantling during maintenance. The use of dismantling joints, unions or flange adaptors may assist in this regard.
• Provision of staircases, platforms and routes for easy access and operation of critical equipment.
Valve placement, pipe labeling and clearances
The process piping system design should not overlook factors like valve placement, pipe label-
ing, and clearances. Valve location directly impacts the ease of operation and maintenance processes. Proper pipe labeling is essential for safe and efficient pipe identification and operations, especially in complex systems. Pipe color coding, stenciling of pipe or product names, and flow directional arrows are a few examples.
Adequate clearances should be provided to ensure ease of inspection and repairs. These may include sufficient above-ground clearance, trench widths for underground pipes, and distance between pipe, valves and any obstructions. Access requirements and clearances for forklifts, cranes, trucks, rigging and lifting points must also be considered.
9. Codes, standards and safety considerations
Process piping systems must adhere to applicable codes and standards to ensure safety and reliability. They outline mandatory requirements and provide guidelines regarding the design, fabrication, quality control and testing of process piping systems and their components.
Ensure process piping system design adheres to established codes and standards, and encompasses the proper evaluation of safety requirements. This necessitates:
• A thorough understanding of the nature of industrial processes, fluids and materials to be used — including their toxicity, combustibility and reactivity.
• Compliance with industry-specific codes, for example the ASME boiler and pressure vessel code, and the ASME B31.3 - Process Piping code. These codes prescribe standards for pipe, fittings, valves and process equipment, amongst many others.
• Compliance with applicable local, state and federal regulations, which help ensure worker safety as well as the environment.
Incorporating safety features
Safety considerations should be prioritized in the design of process piping systems. These include
‘ Effective process piping design requires an accurate assessment of flow and pressure throughout the system, for all operating scenarios.’
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ENGINEERING SOLUTIONS
‘Codes, standards and safety considerations play a vital role in the design of process piping systems.
Continued from pg 23
safeguards for the labor force, and precautions to protect against critical system failures. It’s a good idea to incorporate safety features within the piping system design. This may include:
• Pressure relief valves, which automatically release fluid once the pressure in the valve exceeds a preset pressure limit. A variation called thermal relief valves release fluid to cater for thermal expansion of the fluid. Relief valves prevent over-pressurization, potential leakage, rupture or catastrophic failure of the pipe system.
• Bursting discs, also called rupture discs, provide an escape route for over-pressurized fluid. The discs burst open at a pre-set pressure, allowing the fluid to escape and preventing damage to equipment or potential harm to the workforce. Bursting discs need to be replaced after each failure event.
• Emergency shutdown valves (ESD) are actuated valves designed to stop the flow of fluid if a hazardous scenario is identified. ESD valves may be activated via a control system, or manual intervention.
Codes, standards and safety considerations play a vital role in the design of process piping systems. By adhering to these guidelines, engineers can ensure a system’s safety, reliability, and efficiency while mitigating potential hazards and risks.
Designing a process piping system is much more than building a network of pipes. Thoughtful and meticulous design ensures the system functions optimally, safely, and efficiently, directly contributing to industrial process performance. By focusing on the nine design aspects discussed, users can ensure improved productivity, secured operation and long-term value. PE
Gilbert Welsford, Jr., is the founder of ValveMan.
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POWERED UP - Your Guide to smart servicing Tackling the throwaway culture
Mateusz Zajac | Sustainability Lead, ABB Electrification Service
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Reducing downtime keeps waste to a minimum and profits high
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PREDICTIVE AND PREVENTIVE MAINTENANCE
Joe Reckamp, Seeq Corp., Seattle
How to anticipate maintenance problems with predictive analytics
Process manufacturers are combining retrospective analysis with predictive tools using advanced analytics platforms, empowering them to build models, project failures, determine optimal maintenance schedules and increase uptime
Across the process industries, advanced analytics can guide organizations through fruitful, problem-solving journeys by examining historical, current and predicted time series data, which unveils insights that drive improved decision-making.
Objectives
• Understand different modifiers that qualify “analytics,” especially retrospective versus forward-facing descriptors.
• Recognize the importance of full data context for solving complex process problems.
• Apply advanced analytics to transition maintenance programs from preventive to predictive.
In the past, process engineering teams relied solely on stored data to inform process changes focused on preventive maintenance, mitigation strategies and optimization initiatives for improving operational efficiency. These efforts were conducted with an emphasis on monitoring, centering on the most recent operations data available to identify problems.
As the explorations progressed organizations dove into data stored in process historians and other databases to fine-tune insights, using diagnostic analytics to investigate recent problems, such as deviations during a prior batch.
To increase efficiency, process manufacturers must shift from reactive approaches — responding to problems as they arise — to proactive approaches, which leverage historical data and context to drive more accurate process improvement decisions. Modern advanced analytics platforms are
empowering these manufacturers to implement proactive measures that anticipate and address potential issues before they swell into larger process problems, providing greater operational efficiency, higher performance and increased uptime.
Understanding advanced analytics
“Analytics” is a general and broad word, typically linked to software products, platforms and the cloud. Therefore, it must be qualified with modifiers.
For example, advanced analytics describes the use of statistics, machine learning and artificial intelligence in data analysis to assess and finetune insights. Other modifiers can be used to differentiate the analytics type based on utility and complexity.
For instance, diagnostic analytics describes the use of information from past events to respond to a given situation, investigating a raw set of historical data and applying statistical analysis to identify patterns and produce insights. With this approach, teams are often faced with an inescapable lag between the event or issue under analysis and the action taken to improve future performance, eliminating the ability to prevent damage outright.
Descriptive analytics also look at the past, with the goal of summarizing events via reports that teams can easily interpret and learn from. In this practice, the same lag occurs and it can be difficult to develop clear-cut answers on how and when to make decisions that will prevent future performance issues.
While both retrospective methods provide value, they fail to solve the whole puzzle. Predictive analytics provides the missing piece by using historical data to develop and train models that project future
FIGURE 1: An oil and gas producer used Seeq to model and predict the time to valve failure, providing early warning for operations and maintenance personnel to adapt and perform maintenance as necessary.
Courtesy: Seeq
data, enabling teams to foresee what will happen, when it will happen and the actions they should take to drive desired outcomes.
Leveraging advanced analytics in maintenance
Before looking ahead to future system behavior, an engineer must understand past and present operating conditions. This is best accomplished when equipped with a live connection to all relevant processes and contextual databases.
Industrial organizations can leverage advanced analytics platforms to connect disparate data sources to a central cloud-based source, alleviating the challenges of live data connectivity, such as retaining multiple logins or constantly bouncing back
and forth between interfaces. These platforms provide subject matter experts with simplified datacleansing tools and contextualization, enabling them to rapidly derive meaningful and reliable insights from all available data.
Once live connections are made, teams can start their journey to valuable predictions, including equipment-based predictions — or predictive maintenance — where the objective is to predict when equipment will require maintenance or fail. While techniques vary, the goals of predictive maintenance — increasing quality, reliability and uptime — are fixed.
Advanced algorithm functionality drives an advanced analytics application’s predictive capabilities in which the application matches an orga-
FIGURE 2: While troubleshooting a critical feed gas compressor failure, a petrochemical and refining company used Seeq to quickly find the five most recent shutdowns and subsequent restarts from decades of historical process data. Using “capsules” and “chain view,” they overlaid the events to identify abnormalities in the discharge pressure profile of the two most recent startups.
Courtesy: Seeq
‘
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Detecting and predicting compressor performance issues, which can cause sudden and catastrophic shutdown or environmental safety concerns, is another common area for applying predictive maintenance strategies.
nization's specific workflows and procedures to a respective law, theorem or process design principle to create key performance indicators. This enables accurate data extrapolation when expanding future timeframes for insight and analysis.
The following sections detail situations where advanced analytics helped process manufacturers enhance operational efficiency and pivot from preventive to predictive maintenance approaches.
Using advanced analytics for valve erosion prediction
Valves are found in almost every industrial facility, playing critical roles in process control. Keeping these assets in top condition is essential for maintaining efficient operations, but condition monitoring can be tricky based solely on observation. Advanced analytics solutions often provide low-effort, high-return opportunities to monitor valve conditions and reduce unexpected failures, simultaneously protecting adjacent process equipment and devices.
An oil and gas producer operating more than 50 well pads — each with a gathering system containing a critical flow control valve — was experiencing frequent valve failures. Each failure occurrence rendered the pad inoperable for days until repairs could be made. These failures were typically caused by sand erosion, and the producer had no methodology in place to determine early warning signs other than exhaustive manual inspections, which required complete shutdown and became increasingly cost-prohibitive as the asset base grew.
By deploying an advanced analytics platform to monitor process conditions, the producer was empowered to predict erosion progression and approximate the time to valve failure. To establish this analysis, subject matter experts leveraged both realtime and historical process data to calculate a metric indicating progressive erosion in the valve seat, thereby establishing an indicator to predict future failures. The team leveraged first principles to produce this metric, which was used as the basis for a predictive model to approximate time to failure (see Figure 1).
This analysis was scaled to all well pads by leveraging historian hierarchies imported into the analytics platform through its native connectors. The ability to forecast failures enabled the maintenance team to prioritize service, significantly reducing downtime and operating expenditures.
Compressor health monitoring and maintenance
Detecting and predicting compressor performance issues, which can cause sudden and catastrophic shutdown or environmental safety concerns, is another common area for applying predictive maintenance strategies. Advanced analytics can be used to monitor compressor health variables to detect poor performance and mechanical degradation without tedious time spent examining data in spreadsheets.
In one large manufacturing facility, data scientists leveraged machine learning algorithms to drill down to the root cause of compressor failure. Next, they superimposed the algorithm on live data to identify signs of degrading performance. Subsequently, they used their findings to create maintenance notifications ahead of failure, which provided insights on a visual interface for operators and process engineers.
These types of tools empower engineers to identify leading and lagging indicators of degrading compressor health and to continuously monitor variables, helping teams proactively identify risks and prioritize maintenance activities.
Reactor failure mitigation
Collaboration between teams — such as process, maintenance and reliability — can be strengthened by leveraging built-in tools within advanced analytics platforms for sharing analyses and insights in easily digestible dashboards and reports.
One petrochemical and refining company was experiencing significant reactor shutdowns caused by a failing critical feed gas compressor on a polyethylene line, and these impactful failures precluded any way to immediately restart the process. For this facility, an unplanned reactor shutdown causes a minimum of four hours of downtime, costing the plant upward of $200,000 with every incident. Previously, these compressors had been maintained on a preventive maintenance schedule, but this did not prevent unplanned shutdowns entirely.
Following one compressor trip, machinery and controls engineers worked together to identify the safety interlock that prompted the shutdown, bringing electrical engineers in to assist with the investigation. However, tracing electrical diagrams
around the pump motor was time-consuming — and it failed to yield a root cause.
A process engineer at the refinery took an alternative approach, using an advanced analytics platform to rapidly locate the five most recent shutdowns and subsequent restarts — planned and unplanned — from decades of historical process data. With timedissection tools, they focused on shutdown and startup time periods and overlaid all events, presenting abnormalities in the discharge pressure profile of the two most recent startups (see Figure 2).
Upon further investigation, the engineer also identified early warning signs on the motor amperage signal. Without a method to view the startups back-to-back, the motor degradation had gone unnoticed by operations.
As a result of this root cause analysis, the process engineer implemented a monitoring solution to identify and flag future motor degradation to prevent similar unplanned shutdowns. When an out-of-tolerance value appears, the compressor motor is now immediately added to the mainte-
nance work list for the next planned shutdown, a proactive maintenance approach that is expected to eliminate unplanned shutdowns due to this failure mode.
Making advanced analytics work for you
Accurate process manufacturing predictions rely on in-depth knowledge of past equipment behavior and outcomes. By using advanced analytics platforms to combine retrospective with predictive analytics, process experts and data analysts can easily build robust models, capable of predicting plant maintenance needs and risk-mitigating procedures.
With the right tools in their digitalization toolbox, process manufacturers can build better models to provide vast plant insights and project issues before failure so personnel can optimize maintenance schedules and prevent costly downtime. PE
Joe Reckamp is an Analytics Engineering Group Manager at Seeq Corp.
Insightsu
Advanced analytics insights
uAdvanced analytics, employing sophisticated methods like machine learning and artificial intelligence, empower organizations to convert historical, real-time and predictive data into actionable insights, thereby significantly enhancing decisionmaking processes.
uThis proactive approach allows manufacturers to anticipate potential issues and implement timely measures, ultimately improving operational efficiency and minimizing unexpected downtime.
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PREDICTIVE, PREVENTIVE MAINTENANCE
John Skalka, Hitachi Global Air Power, Michigan City, Ind.
Predictive maintenance’s role in routine compressed air system service
From oil sampling, vibration analysis and connected devices, predictive maintenance done as part of the system’s regular service schedule can keep a compressed air system running efficiently.
Reliability in a compressed air system is essential. Keeping a compressor in good running condition is key to plant uptime and efficiency. Regular maintenance and condition monitoring is required to ensure a compressed air system remains in good working order.
Predictive maintenance offers the opportunity to stay ahead of issues that can lead to breakdowns. Using data gathered from the compressor through regular system service and remote monitoring can provide insight into compressor condition and drive the preventive maintenance that ensures reliable compressor operation.
Learningu
Objectives
• Learn how predictive maintenance tools can be part of a compressed air system’s regular maintenance.
• Understand what a service tech looks for on a regular service call and the types of predictive maintenance that is performed during regular service calls including oil sampling and vibration analysis.
• Learn how analyzing data trends from samples taken during routine maintenance can help reveal the health and efficiency of a compressed air system preventing downtime.
When technicians perform regular system checks, they are interpreting a spectrum of data points to build a comprehensive assessment of the compressed air system’s health. It’s important to understand what happens during a service calls, how the data is gathered and how the information is used in predictive maintenance to keep the system running smoothly.
What happens during a typical compressed air system service call
When a service technician is called to a job site to perform preventive maintenance on an air compressor, they will start by servicing the compressor in accordance with manufacturer guidelines. For an oil flooded rotary screw compressor, this often includes air and oil filters, compressor fluid, and separator elements based on hours of operation.
While attending to the manufacturer’s prescribed maintenance items, the technician also will inspect other machine systems for proper operation. This is a great time to review the compressor cooling system for proper air or water flow and check operating temperatures to confirm proper operation. Regulators and control valves also should be inspected.
FIGURE 1: Dirty cooler filters are just one of many
Preventive maintenance service calls also provide the opportunity to gather important, predictive data from the compressor system. Most compressor manufacturers recommend regular oil sampling to monitor both fluid, and compressor air end condition. Vibration data also can be periodically collected to establish a historical trend of the rotating component condition. A best practice is to oil sample and collect vibration data twice per year, but also be sure to follow manufacturer guidelines for compressors within the warranty period. This also is a good practice to continue even after a warranty has expired.
Many modern air compressors are controlled by microprocessors that will store operating parameters including alarm and fault histories, operating hours and start stop history and compressor load profile. It is considered a best practice during service visits for the service technician to record key information from the machine controller and, when available, download a report from the compressor controller to store with the service records.
Automated monitoring and system management benefits
Compressor manufacturers recognize the importance of system monitoring and offer options to
‘
Preventive maintenance service calls also provide the opportunity to gather important, predictive data from the compressor system.’
provide operators real time views of compressor performance — outside of a regular service call. Internet-based systems can transmit operating data to cloud-based systems that presents data for facilities technicians to monitor and review. These systems are often accessed through a portal maintained by the compressor manufacturer and can be packaged in with preventive maintenance agreements.
Modern production operations have the option to integrate building management systems to control systems and monitor critical operations. Compressor controllers can provide communication options through standard protocols such as Modbus and BACnet. By connecting to the compressor controller, systems integrators can provide plant management systems with information on compressor run status, maintenance alerts, warnings and faults and even offer remote start/stop controls in between service calls.
FIGURE 2: Compressor data from internet-based monitoring systems such as run status, maintenance alerts, and faults all provide valuable insight into an air compressor’s health and performance. Courtesy Hitachi Global Air Power
ENGINEERING SOLUTIONS
Using data to monitor trends and drive predictive maintenance
There are many data points that tell the overall story of the compressed air system, and various means by which those data points can be obtained (remote monitoring, vibration analysis and oil sampling). By analyzing this data and using the information to monitor and track trends, a technician can begin developing a predictive maintenance program to keep the compressor performing and avoid unplanned downtime.
In oil sampling, the samples collected during routine service will show the progression of fluid degradation over time among other information. Compressor fluids also have varying life expectancies under normal conditions based on base stock and additive packages. Compressor run profiles and environmental conditions can lead to reduced fluid life expectancies in some situations. There are several things to learn from an oil sampling including:
• pH levels that suggest warning signs of corrosive wear of bearings.
• Acid number (AN) to indicate the remaining useful life of the fluid. Oil oxidation causes acidic byproducts to form. High acid levels can indicate excessive oil oxidation or additive depletion and can lead to corrosion of internal compressor parts.
• Viscosity to measure the resistance of a fluid to flow at a specific temperature. A higher viscosity may indicate higher operating temperature.
• Fourier transform infrared (FTIR) spectroscopy provides molecular information including additives, fluid breakdown products and external contamination. This test determines the parts per million (ppm) of wear metals and lubricant additive metals in the oil sample. Wear metals are those that originate from an internal component of the compressor.
• Water levels, which can identify leaks.
• Inductively coupled plasma (ICP) spectroscopy measures and quantifies elements associated with wear, contamination and additives.
By monitoring fluid sample results and tracking fluid condition progression, fluid maintenance can be scheduled before sample reports return a critical result that can lead to mechanical damage in the compressor system. Compressor fluid that is out of specification for acidity, pH or viscosity can cause premature wear to rotating (bearings) and sliding (valves) components that reduces the compressor’s longevity.
While it’s not necessary to gather compressor vibration data with every service visit, establishing a base line for each machine can show the starting point for overall condition of the rotating components. A vibration specialist will analyze the raw data from the vibration monitoring equipment and provide a report detailing abnormalities and actionable recommendations. By watching the rate of change over time, the condition of motor and air end bearings, as well as couplings can be reviewed and acted on as necessary where trends show accel-
FIGURE 3: Using the wrong aftermarket products and failing to have a compressed air system regularly maintained from service professionals can cause damage to the compressor’s air end and to the overall system. Courtesy Hitachi Global Air Power
erated degradation. Maintenance and repair of these components based on vibration reporting can be scheduled ahead of significant damage and subsequent failure.
Sizing, location and load impacts
Not every compressed air system is perfectly sized and operates at peak efficiency. Production demands can change over time, compressors are purchased within allocated budgets meaning installations are often necessary in less-than-ideal environmental conditions. Most compressors run best when running fully loaded with minimal cycles and start/stop scenarios. Since this is not always possible, using information from the compressor controller to understand run conditions can help determine appropriate maintenance schedules.
Compressors sized for peak demand may accumulate a higher number of load cycles due to varying plant operations. While this is normal, it is important to monitor the total number of cycles to be sure the compressor is tuned appropriately for the system. While there is not a set standard for the number of load cycles, the lower the better.
For example, a compressor running in a process with consistent demand may experience three-tofour load cycles per hour. However, a compressor that operates in a process with varying demand over short periods can see a much higher number of cycles per hour. A compressor with a higher number of load cycles can require more frequent maintenance of regulators, valves and other control system components to address wear and ensure reliable operation.
Compressors often operate in dusty or dirty conditions. Debris and other particles can accumulate on filters and heat exchangers, resulting in less efficient operation. In severe cases, air flow can become entirely obstructed. High operating temperatures can break down compressor fluids that lead to reduced fluid life and accumulate on heat sinks that increase operating temperatures of electrical components. Compressors should be monitored for consistent temperatures in range of the manufacturer guidelines. When temperatures start to rise, it’s time to inspect the fluid levels, heat exchangers, thermostatic valves and package filtration.
‘ Air compressor manufacturers will prescribe preventive maintenance guidelines based on typical operating conditions, but they don’t fit all situations.’
Warning and fault history for the compressor can also provide a preview of impending problems. Many compressors utilize sensors that measure oil filter differential pressure, air filter pressure drop, and other critical operating parameters. When these parameters fall outside of the acceptable operating ranges, the compressor controller will present a warning or fault (depending on severity) to alert the operator.
Setting appropriate maintenance schedules
Air compressor manufacturers will prescribe preventive maintenance guidelines based on typical operating conditions, but they don’t fit all situations. Predictive maintenance leans on historical operating data and equipment observations unique to each compressor system to drive proactive maintenance scheduling, which may evolve as production demands change. By monitoring operating parameters and analyzing data collected from the compressor, service providers can put together predictive maintenance programs that address key service points before they lead to problems or breakdowns.
Regular and predictive maintenance offers many benefits including a more efficient and reliable compressed air system. By leveraging different data analytics sources, predictive maintenance empowers organizations to detect and address potential issues before they escalate and cause unplanned downtime — or worse. With all this information available, these so-called “routine” maintenance checks are, in fact, an indispensable component of a well-performing compressed air system. PE
John Skalka is senior manager, customer service, for Hitachi Global Air Power.
Insightsu
Predictive maintenance insights
uKeeping a compressor in optimal condition requires regular maintenance and condition monitoring, which are essential for plant uptime and efficiency.
uUsing data from regular system service and remote monitoring enables predictive maintenance, helping to prevent breakdowns and ensure reliable compressor operation.
uTechnicians gather and analyze various data points, such as oil sampling and vibration analysis, to build a predictive maintenance program that minimizes unplanned downtime and extends compressor lifespan.
ENGINEERING SOLUTIONS
WAREHOUSING
Shannon Curtis, Raymond Corp., Greene, N.Y.
How smart lift trucks enhance warehouse environments
Smart lift trucks, thanks to technology integration and enhancements, can play a key role in keeping a warehouse moving forward efficiently.
IObjectives Learningu
• Understanding how smart lift trucks fit in the changing warehouse environment.
• Learn about the benefits smart lift trucks provide users beyond moving items around.
n today’s ever-changing warehouse environment, utilizing equipment that propels a plant forward is essential. Smart lift trucks can play a key role in keeping a warehouse moving forward efficiently by leveraging data. Thanks to technology integration, the forklift is evolving with connected technologies that allow data to be transmitted and utilized more effectively.
Smart lift trucks can reinforce best practices and training with security functions such as speed control, cameras and sensors.
These advanced lift trucks can utilize real-time monitoring, operator assist technologies, data analytics integration and management systems — all leading to enhanced efficiency and productivity within a variety of warehouses.
In addition to improved security functions, smart lift trucks also can be equipped with innovative technology that simplifies workforce management and training by providing data and metrics on operator connection histories, behaviors and system involvements.
Smart lift truck benefits in the warehouse
In an industry of constantly evolving technology, the smart lift truck offers a competitive edge to warehouse operations and their operators. The technology reinforces best practices, and operator security and confidence, and it helps optimize workforce allocation.
The smart lift truck enhances lift operator training and best practices with audible and visual notifications. Travel speeds are limited to 1 mph and lift capabilities are disabled when a connection is not detected, enhancing operator security and confidence.
Warehouse floors often become congested with multiple activities happening simultaneously. Proximity detection can help improve efficiency and coordination by alerting workers of potential collisions, helping ensure smooth interaction between workers and machinery. Proximity notification systems alert pedestrians and lift truck operators when objects are detected within a defined distance of a properly equipped lift truck, to minimize interaction with objects, truck control is activated.
FIGURE 1: Data from tether integration, like Raymond’s iWarehouse Integrated Tether System shows how operators use the lift trucks and identify opportunities for more training and best practices. Courtesy: The Raymond Corporation
smooth
Using the smart lift truck as a data source
General connected technologies pull data that moves an organization forward with scalable, flexible and intelligent solutions. Data from the tether integration shows how operators use the lift trucks and identify opportunities for more training and best practices. Access to this information allows for necessary changes and adjustments that help to keep the warehouse competitive throughout the years.
Smart lift trucks represent a significant advancement in warehouse technology, offering a competitive edge through their integration of connected technologies and data utilization. These lift trucks not only enhance efficiency and productivity but can also reinforce best practices and operator security with advanced features such as real-time monitoring, operator assist technologies and proximity detection systems.
By simplifying workforce management and providing valuable data insights, smart lift trucks enable continuous improvement in training and operational practices. The ongoing evolution of these technologies ensures warehouses can maintain their competitive edge, making smart lift trucks an essential component for future-proofing warehouse operations. PE
Shannon Curtis is product manager at the Raymond Corporation.
helping
Insightsu
Warehousing insights
uSmart lift trucks enhance warehouse efficiency by leveraging real-time monitoring, data analytics integration and operator assist technologies, which lead to improved productivity and optimized workforce allocation.
uEquipped with security features like speed control, cameras, sensors and proximity detection, smart lift trucks help reinforce best practices, enhance operator training and ensure smooth interaction between workers and machinery.
FIGURE 3: Proximity detection technology can alert workers of potential collisions helping ensure smooth interaction between workers and machinery.
Courtesy: The Raymond Corporation
FIGURE 2: Proximity detection technology can alert workers of potential collisions
ensure
interaction between workers and machinery.
Courtesy: The Raymond Corporation
ENGINEERING SOLUTIONS
Doan Pendleton, VAC-U-MAX, Belleville, N.J.
Dry bulk material handling automation choices
It’s important to understand the advantages and disadvantages of flexible screw, aero-mechanical and vacuum conveyors when it comes to dry bulk material handling choices.
With the right equipment, automating dry bulk material transfer delivers many benefits that translate to higher margins. These benefits include labor reduction, increased uptime, higher product quality, elimination of safety hazards, and preservation of expensive ingredients.
To reap the full benefits of automating materials transfer, facilities should seek out an expert in dry bulk powder transfer and not just the cheapest solution that may not deliver higher margins.
Objectives
• Learn how automating dry bulk material transfer benefits for manufacturers.
• Understand the difference between mechanical and pneumatic conveyors.
• Learn how expert advice and thorough inspections can improve these conveyors.
Handling powder and bulk solids is a specialized field with no two conveying applications quite the same. While two manufacturers might use the same material, utilize similar types of equipment or have similar processes, factors unique to each manufacturing facility and organizational objectives require considerations distinctive to the process. For one manufacturer a vacuum conveying system may be the solution, for another it may be a flexible screw conveyor, or the solution may be an aero-mechanical conveyor or the combination of both mechanical and pneumatic conveyors.
Conveyor manufacturers steeped with experience designing both mechanical and vacuum conveying systems to transfer dry bulk materials help processors and manufacturers weigh upfront cost, system benefits and down-the-line costs including maintenance, utility usage, cleaning, downtime and safety savings between systems.
There is a science to dry bulk material handling with formulas that determine system design based on factors including particle size, bulk density, conveying distance and rate. However, after all the science and spreadsheets, the success in designing a system that delivers peak performance while preserving product quality lies in the ability to understand powder characteristics and how those characteristics interact with equipment design. This type of tribal knowledge is not formulaic and draws
FIGURE 1: AEROCON Aero-Conveyors are designed to convey bulk powders via tubular housings containing a continuous loop of steel cable with polymer discs attached at equal intervals along the steel cable. Courtesy: VAC-U-MAX
FIGURE 2: Flexible auger conveying systems provide metered floor-level transfer of dry bulk powders from various sources including bag dump stations in an enclosed dust-free process. Courtesy: VAC-U-MAX
upon decades of experience with tens of thousands of materials and their behaviors to augment scientific principles.
Working with a conveyor manufacturer that offers mechanical and pneumatic conveying technologies expands the range of solutions available for each unique application. This includes the ability to deliver fully integrated systems that combine mechanical and pneumatic conveyors, such as using a flexible screw conveyor to deliver product to a mixer and then a vacuum conveyor to convey product from the mixer to a packaging machine.
Automating dry bulk powder transfer eliminates the fundamental drawbacks of manual transfer such as heavy lifting, scooping, climbing and dust clouds created with manual dumping. Those innate safety hazards of manual materials transfer have the potential to whittle away profits through workman’s compensation claims.
In addition, manual transfer of materials often requires two operators working in tandem to reduce ergonomic risk when loading materials into process vessels. Automating the process eliminates the need for two workers, reducing economic pressures caused by manufacturing labor shortages.
Understand the difference between mechanical and pneumatic conveyors
Three of the most used technologies for automating bulk dry powder transfer are flexible screw conveyors, aero-mechanical conveyors and pneumatic conveyors.
The principal differentiator between mechanical and pneumatic conveyors is mechanical conveying uses a mechanical device which is in direct contact with transferred material. Pneumatic conveying uses gas (usually air) to transfer suspended material through tubes.
Another distinctive characteristic between pneumatic and mechanical conveying is pneumatic con-
veyors have virtually no moving parts, which makes cleaning and maintenance a breeze. Mechanical conveyors, with an array of moving parts, require more maintenance and more complicated cleaning procedures than pneumatic conveyors.
The advantage of a mechanical conveyor over pneumatic is the ability to move large amounts of material with minimal energy consumption. In mechanical systems, there is only a motor driving the system. On the other hand, a pneumatic system requires a motor and air to move the material. Due to the additional power components needed in a pneumatic conveying system, and the lack of a dust filtration system in mechanical conveyors, the dollar-to-dollar comparison makes the mechanical system less expensive to operate.
Control panels on mechanical conveyors are about as simple as it gets, requiring minimal integration. Unless a company is working with a level controller or load cell, the control panel is often just a fancy motor starter, which reduces initial costs further.
In a pneumatic conveying system, the control panel includes a programmable logic controller (PLC), or programmable relay, which dictates the sequence of events that are to occur, can handle complex information and provides customers the ability to download data for evaluation.
Benefits of aero mechanical and flexible screw conveyors
Aero mechanical conveyors are regularly used as an alternative to pneumatic conveying using two parallel tubes with a sprocket on each end, and a drive motor on one end. Inside the tube is a cable with discs on it, often called a cable assembly. As
‘Handling powder and bulk solids is a specialized field with no two conveying applications quite the same.’
ENGINEERING SOLUTIONS
the cable assembly moves, it displaces air and material, thus fluidizing the material, carrying it in suspension along the conveyer to the outlet using centrifugal force.
Aero mechanical conveyors move material at approximately 20 ft3 per minute with a 3 HP motor, contingent on material bulk density. Depending on the design of the conveyor, the cost of a mechanical conveyor vs. a pneumatic conveyor for the same output can be one third the cost.
ditures. Rugged flexible screws often come with two-year guarantees against twisting out, unraveling or breaking.
3:
Pneumatic Conveying Systems increase productivity while reducing manual ingredient handling, lifting, stairclimbing and messy dumping by moving bulk powders from floor-level to up-and-over process equipment. Courtesy: VAC-U-MAX
Flexible screw conveyors provide many of the same benefits, such as speed, as aero mechanical conveyors. Flexible screw conveyors, however, utilize only one tube and instead of a cable assembly, they contain a metal spiral that rotates. The spirals look like a stretched slinky or spring (that doesn’t compress), having the same diameter from
Flexible screw conveyors move less material than aero mechanical conveyors, but they operate continuously, unlike aero mechanical conveyors. A common use for aero mechanical systems is batch processing; and, a flexible screw is ideal for continuous, batch or intermittent processing. Both can convey 2000 lbs of material into a mixer in 10 minutes, but the flexible screw conveyor can continuously operate. Aero-mechanical conveyors require a metered infeed, and they must start-up and finish without material in the tubes. Flexible screws also can be started and stopped with a headload of material at the feed end.
Conveying with flexible screws is common, which leads some to look at the equipment as a commodity item, which is not true. Heavy-duty flexible screws are more rugged than the standard and last longer, meaning less maintenance and downtime, and therefore lower replacement expen-
Where mechanical conveyors fall flat is the life of the equipment. Because mechanical conveyors contain more moving parts than pneumatic conveyors, maintenance costs are much higher, and machinery is more susceptible to unscheduled downtime. More moving parts also means more difficult to clean, making them less desirable in sanitary conditions. High-purity applications which cannot accept any foreign contamination, will not utilize flexible screw conveyors due to the plastic conveyor tube which can degrade over time. Aeromechanical conveyors can be equipped with foodgrade components, but nevertheless have disc wear over extended periods of time.
Regardless of the potential downfalls, mechanical conveyors are sometimes the better and more cost-sensible option.
Benefits of pneumatic conveyors
In contrast to mechanical conveyors, pneumatic conveyors are more versatile and available in a wide range of configurations to integrate into production lines and meet facility specific requirements. Pneumatic conveying systems integrate into existing processes by routing conveying lines between floors, through partitions, around machinery, and are re-routed to accommodate process modifications.
Pneumatic conveying systems can be either negative or positive pressure systems. Negative pressure systems suck the material through the lines, while positive pressure systems blow, or push, material down the line. Factors other than material characteristics, such as conveying distance and the need for higher conveying rates, dictate the choice between negative and positive pressure systems.
Dilute phase conveying injects more air into the conveying line and dense phase injects less air and more product into the conveying line.
Most pneumatic conveyor applications are negative pressure (vacuum) dilute phase systems, but dense phase systems are used as application dictate. There are some instances where semi-dense or semi-dilute systems are appropriate. Dilute phase systems employ higher velocity rates than dense phase systems.
FIGURE
‘One of the most common reasons to automate dry bulk powder transfer is to eliminate climbing to load materials.’
A standard vacuum conveying system consists of five basic pieces of equipment that come together to work as one — a pick-up point, convey tubing, a vacuum receiver, a vacuum producer and a control module. From the pick-up point, material flows through convey tubes to the vacuum receiver which transfers material from above process or packaging machinery through discharge valves on the bottom of the receiver. Vacuum producers are the core of pneumatic conveying systems and work with the control panel to manage the flow of material through the convey tubes to the vacuum filter receivers.
Vacuum conveying systems can accommodate an assortment of vacuum producers (such as air-powered, electric, regen blowers and vacuum pumps), based on application, configurations, and utility requirements such as compressed-air, onephase and three-phase.
Safety reasons for automating dry bulk powder transfer
One of the most common reasons to automate dry bulk powder transfer is to eliminate climbing to load materials. Most packaging and process machines need to be filled from the top, with a feed opening that could be as high as 10 feet above the ground. While that can be achieved with a vacuum conveyor, if it's permanently installed above the packaging machine, all maintenance must be performed at that elevated location requiring the use of a ladder, scissor lift or mezzanine.
Even with the most sophisticated vacuum conveying systems, equipment located out of reach still poses hazards for operators who need to clean or service vacuum conveying equipment permanently installed above process machinery.
With mobile vacuum conveying units, rolling the conveyor away from other machinery and lowering the receiver allows simultaneous cleaning of both the conveyor and machine, instead of one after the other.
Mobile and column lift conveyors are complete conveying systems that raise and lower vacuum receivers in order to load mixers, reactors and other processing equipment and then bring the vacuum receivers back down to ground level for cleaning or sanitizing.
FIGURE 4: Mobile vacuum conveying systems provide easy to use portable vacuum conveying and can be rolled-in-place over processing or packaging equipment to accommodate various discharge heights. Courtesy: VAC-U-MAX
Mobile and column vacuum conveying systems, when constructed within Food Safety Modernization Act (FSMA) sanitation regulations, are ideal for food, nutraceutical and pharmaceutical applications.
Column conveyors utilize an electric lift mechanism with a remote pendant, controlled by an operator standing a safe distance away, to raise and lower vacuum receivers above mixers, blenders, reactors, and other process vessels with fill ports 15 ft or more above the floor.
These systems, with top and bottom anchors can load side-by-side process vessels from paper bags, drums, IBC’s, boxes, bulk bags, silos, storage containers and feed bins.
Mobile conveying systems operate in the same fashion as column lift conveyors, but are portable, movable with one operator, and able to service multiple process vessels at varying discharge heights. When not in use, operators can roll these vacuum conveying systems from the work area to save on floor space.
ENGINEERING SOLUTIONS
Insightsu
Material handling insights
uAutomating dry bulk material transfer enhances margins by reducing labor, increasing uptime, improving product quality and eliminating safety hazards.
uExpert consultation in dry bulk powder transfer is crucial for selecting the optimal system, considering factors like material characteristics and organizational needs.
uMechanical and pneumatic conveyors each have distinct advantages: Mechanical systems are energyefficient and less costly while pneumatic systems offer versatility and are easier to maintain.
The ability for operators to bring equipment down to floor level for cleaning reduces downtime, labor costs and potential injury costs.
These types of units are compatible with OSHA’s Walking-Working Surfaces standard to protect against falls and slips; and back injuries from repetitively carrying bag and boxes up the stairs to load or clean equipment.
Another unique adaptation of vacuum conveying systems is direct charge blender loading, designed for the direct charge loading of blenders, mixers, reactors and any vessel capable of withstanding a vacuum.
With a facility’s blender or mixer as the primary receiver, the conveyor manufacturer configures systems specific to each application, providing the power source, filters, controls and adapters.
Direct charge blender loading reduces safety and ergonomic concerns from excessive ladder climbing for manual loading, increases blender throughput by reducing the loading time and it is a much cleaner operation than manually dumping ingredi-
‘Users also should seek advice from experts in bulk dry powder handling for an automated system to achieve cost savings.’
ents into the blenders from a mezzanine.
With the right equipment, automating dry bulk material transfer delivers many benefits that translate to higher margins. Sometimes factors dictate which type of technology is used, but when given the choice, upfront costs should not be the only deciding factor between a mechanical or vacuum conveying system. Users also should seek advice from experts in bulk dry powder handling for an automated system to achieve cost savings. PE
Doan Pendleton is president of VAC-U-MAX.
What is the value of process piping design?
Learn about the different types of process piping projects, and how each drives the design
Process piping design is a critical aspect of engineering in various industries, including chemical processing, oil and gas, power generation, food and beverage and others. Designing an effective process piping system involves careful consideration of several factors to ensure safety, efficiency and compliance with industry standards.
Proper piping design is fundamental to ensuring the safe transport of fluids within a facility. Despite the critical nature of piping design to health, safety, well-being, the environment, profitability, better operations and minimization of maintenance, piping system design is often discounted, sometimes even overlooked altogether.
The investment in design can yield returns as early as installation — reduction in material volume and in fabrication costs — and lifetimes later by way of decreased inspection and maintenance cost, both of piping and connected equipment.
Piping designers need to understand the specific requirements of the industrial process, including the type of fluids (liquids or gases), flow rates, pressures, temperatures and any special handling or treatment requirements. This information forms the basis for designing the piping system. They choose materials for pipes and fittings based on compatibility with the transported fluids, corrosion, environmental conditions, durability and cost.
A streamlined system design can minimize operational costs and contribute to the effectiveness of the entire production cycle. A well-designed piping system allows for flexibility in accommodating future changes, expansions or modifications, thus leading to lower costs down the road. This adaptability reduces the need for extensive overhauls and
facilitates cost-effective adjustments to meet evolving operational needs.
Proper piping design also minimizes the risk of equipment failures and unplanned downtime. By ensuring the integrity of the piping system, industrial facilities can operate reliably, meeting production schedules and avoiding costly disruptions. This reliability is critical in industries where continuous operation is essential to profitability.
One example of this is pump reliability and the relationship with pump nozzle stresses. A piping
Objectives
• Learn about different approaches to various process piping project drivers.
• Understand how to design a process piping system with focus on overall project goals.
• Know the items that need to be considered in the design process.
FIGURE 1: Proper piping design focuses on the equipment layout and all connections for optimal access for operation and maintenance. Courtesy: Matrix Technologies Inc.
ENGINEERING SOLUTIONS
‘
The piping engineer should work with the structural team to design appropriate supports and restraints to prevent excessive movement or vibration of pipes.’
design that has flexibility built in, rather than the shortest route from A to B will reduce nozzle stresses resulting in increased impeller life, fewer pump seal failures, decreased vibration and overall, longer pump life leading to monetary savings that are typically not quantified in this way.
Thoughtful piping design considers the total cost of the system, including initial installation costs, maintenance costs, inspections and energy consumption. By optimizing the piping design for cost-effectiveness, industries can achieve long-term savings and enhance their competitive edge versus looking to save on engineering by “just hooking up the lines.”
Process piping design and engineering
The piping engineer should work with process engineers to properly size pipes to ensure optimal fluid flow by providing preliminary sketches on routing options. Consider factors like velocity, pressure drop and friction losses. Plan the routing of pipes to minimize bends, elbows and obstacles that could impede flow and create pressure drops.
Efficient pipe routing can also facilitate maintenance and accessibility. Account for the pressure and temperature conditions that the pipes will experience. Select materials and design features capable of withstanding these conditions. Ensure
FIGURE 2: Process pipe designers allow for flexibility in their designs, like adding stress loops, pipe guides and anchors when needed to absorb or control pipe movement. Courtesy: Matrix Technologies Inc.
that pressure relief devices and thermal expansion considerations are integrated into the design.
Further, access to devices, valves, control valves, expansions joints, can lower future expenses for operations, maintenance, inspection and replacement.
Adhere to industry standards and codes to ensure the design meets safety, quality and regulatory requirements. Compliance with these standards is essential for obtaining necessary approvals and certifications. Conduct a thorough safety analysis to identify potential hazards associated with the transported fluids. Implement safety measures, such as relief systems and isolation valves, to mitigate risks. Consider the consequences of leaks or spills and design with safety in mind.
The piping engineer should work with the structural team to design appropriate supports and restraints to prevent excessive movement or vibration of pipes. Proper support is essential for preventing stress on the piping system and ensuring its long-term integrity.
Design the system to facilitate ease of maintenance and inspection. Consider accessibility for maintenance personnel and incorporate features such as isolation valves and spacers for easy removal or replacement of components. Integrate instrumentation and control devices into the piping system to monitor and regulate the flow of fluids. This includes valves, flow meters, pressure gauges and other instruments essential for process control and safety.
Maintain thorough documentation of material specifications used in the piping system. This traceability is crucial for quality control and ensures that materials meet specified standards.
Consider budgetary constraints and optimize the design for cost-effectiveness. Balance the upfront costs with long-term operational efficiency and maintenance considerations, for example, layout equipment to minimize pipe runs in designs with high-cost materials when possible.
Three types of process piping project drivers
1. Cost driven: Cost-driven design is an approach in engineering where cost considerations play a central role in shaping design decisions. The primary focus is on optimizing the design to minimize design, fabrication and installation costs while meeting minimum specified performance and quality requirements. This approach is particularly relevant in industries where lower upfront costs are a critical factor, such as manufacturing, construction and food and beverage industries as opposed to long-term, overall costs.
Long-term maintenance costs or superior materials are often traded for reduced upfront costs.
“Nice-to-have” features are often eliminated early. Reduction in automation and a heavier operator presence are often seen with cost-driven projects.
Process piping designers have options on approach to cost driven projects, starting with developing the quality plan and evaluating the risks, then adjusting the project level of detail and design to meet project needs, without over or under delivering. The level of design refers to the amount of detail in the 3D model and the level of detail refers to the amount of detail in the construction drawings. This is broken down into four levels with one being very low detail and four being highest level of detail.
Many times, there are embedded contractors that continually work in the plant. They are very familiar with the plant’s details, preferences and need minimum guidance with low level detail sketches and drawings. This level of detail needs to align with the construction team, providing direction without any extras. This approach dials in level of engineering effort to support the field contractors’ expectations to construct the project.
Routing and layout designs are scalable and can range from basic sketches to detailed fabrication drawings, the latter typically being scaled back to save on capital expenditures upfront. This can be effective but does expose the owner to risk of cost overruns during construction. The higher risks of requests for information to clarify gray areas while constructing, so planning for post issued for construction site assistance is typically warranted.
2. Schedule driven: Conversely, schedule-driven design refers to an engineering approach where
the schedule is the primary driver for decisionmaking during the design process. In other words, the design process is structured and guided by the need to meet specific deadlines or milestones. In some cases, this may necessitate larger than typical engineering or construction teams resulting in lower efficiencies to meet those dates. Obviously, those lower efficiencies come with higher design costs, higher construction costs and increased contingency.
These projects have tight deadlines that are daisy chained with minimal relief. Planning work packages in strategic order, usually timed with construction planning is paramount. Laying out the process units, along with equipment placement and orientation, focusing on the first areas to be built, can be an effective strategy for shortening timelines. Staging is a popular design and construction technique where installations such as deep foundations can be constructed, while detailed piping design finishes and long lead items await arrival.
Where shutdowns are necessary for installations, process piping designers can separate packages into pre- and post-turnaround designs. This allows for small, accelerated work packages to be demolished and installed in short windows of a swoop down or shut down if needed. The remaining work can be connected to the pre-turnaround design and installed without affecting the operation of the existing facility. This is done with careful planning in the design process for minimal components to be installed in a minimal construction window,
Insightsu
Process piping insights
uThe value of process piping design lies in the ability to identify specific project drivers, meet the specific needs of the industrial process while ensuring safety, compliance and reliability.
uThorough planning and attention to detail during the design phase contribute to the success of the project and longevity of the piping system while meeting all needs of operation, construction, maintenance, accessibility and safety.
FIGURE 3: Plant or unit layout focus will minimize distance between tethered process and equipment, with consideration for minimizing long runs of costly high alloy pipe. Courtesy: Matrix Technologies Inc.
ENGINEERING SOLUTIONS
FIGURE 4: The acronym “LOD” can be used in different ways throughout the industries we serve and needs clarification when discussing. Level of design refers to the amount of detail in the 3D model. Level of detail refers to the amount of detail in the deliverable drawings. Thes are both common scales used to dial into project expectations. Courtesy: Matrix Technologies Inc.
while creating a bolt-up connection between the two phases for quicker install.
Another approach is modular/prefabrication design. Design predetermined shippable units and skids to minimize field time and reduce construction costs. This is favorable in remote work sites or where there is limited skilled labor and in schedule-constrained projects. Built in a shop within a controlled environment with high level of accuracy, these skids and pipe spools can be bolted up in the field or at least minimize field welds. This also allows for clear project scheduling, repeatable construction that lends itself to duplication and being easily replaceable. This method typically extends engineering design to allow for a well-thought-out plan to construct during a compressed outage.
There can be design sacrifices when executing a schedule driven project plan. Because of the project pace there are higher risks for design or construction conflicts to arise. The right quality planning needs to take place for proper focus on the highrisk items versus lower acceptable risks. Understanding the owner’s goals is key to preparation and preparation is key to successful construction.
3. Design driven: Design-driven projects refers to where the design process takes a central role in shaping the project's goals, decisions and outcomes.
When the project requires an optimal output, is targeting a firm operational threshold or needs to consider multiple options, the design-driven engineering approach is typically employed. An example of this might be a very specific product in the
spirits distillation industry where there is also a visual centerpiece to the project such as the façade and the shiny process equipment. These projects tend to have finite engineering, while needing more schedule to work through and consider all project drivers.
These types of projects typically have very defined details and code-driven parameters. This could be cleanroom design, food and beverage or semiconductor projects that require specific design practices and adherence to codes. Other common examples would be cryogenic or super-heated lines that require strict finite element analysis to account for all stress needs of contraction and expansion of piping systems without overloading equipment connections while containing the process fluids safely.
In summary, the value of process piping design lies in the ability to identify specific project drivers, meet the specific needs of the industrial process while ensuring safety, compliance and reliability. This value extends to operational efficiency, compliance with standards, cost-effectiveness, adaptability and the overall integrity of industrial processes.
Thorough planning and attention to detail during the design phase via piping system engineering and design contribute to the success of the project and longevity of the piping system while meeting all needs of operation, construction, maintenance, accessibility and safety. PE
Robert Hunt is the Senior Discipline Manager at Matrix Technologies Inc.
Education and personal development are vital to the advancement of the engineering community.
We invite our readers to explore and utilize the educational efforts of this year’s participants in our annual Educating Engineers program.
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SP4 is ABB’s solution for a more sustainable future, driven by the need to reduce energy consumption. The idea is simple: Take a proven AC induction motor design and make it better by reducing motor losses by an average of 20%. With most industrial electric motors operating without a drive, SP4 allows customers to improve performance and efficiency without the need to invest in additional components. As a standalone unit, SP4 achieves NEMA Super Premium
efficiency; however, when paired with a variable speed drive, even higher efficiency levels are attainable.
SP4 motors run cooler, reducing energy losses, extending component life and lowering energy consumption, resulting in reduced operating costs. They comply with current U.S. Department of Energy standards as well as anticipated medium electric motor regulations, which take effect in 2027 and mandate that motors up to 100 HP maintain NEMA Premium efficiency, while motors between 100 and 250 HP must achieve NEMA Super Premium efficiency.
A proven AC induction motor design made better
Forty-five percent of the world’s electricity is converted by electric motors into motion, and there are more than 300 million industrial electric-driven systems in operations worldwide. As the cost and demand for electricity grows, ABB’s commitment to energy efficiency will help ensure a greener future for industrial electric-driven systems worldwide.
Scan the QR code to learn more.
A
utomationDirect provides free online PLC training to anyone and everyone with no purchase necessary.
As the world around us becomes more and more automated, an understanding of electrical control systems becomes more and more vital. Because of this, the demand for training in industrial controls has grown exponentially over the years.
Luckily, AutomationDirect has decided to meet this demand head-on by offering absolutely FREE online PLC training –no purchase necessary!
This online video training course encompasses various levels of training from entry level programming to advanced PLC functions, and is available 24/7/365 so you can learn at your pace and at your convenience.
Some of the general topics covered include:
• Logic circuits
• Basic switches
• Sinking and sourcing
• PLC scan time
• I/O fundamentals
• PLC memory addressing
Scan the QR to view video about training opportunities.
A
wide variety of free training videos can be found at automationdirect.com.
Also available are over 200 videos specifically covering AutomationDirect PLCs and include topics on how to use their rung editors, logic instructions, internal control relays, subroutines, communication, data view windows and many other functions.
• CLICK PLC Family Video Library
• Do-more\BRX PLC Family Video Library
• Productivity PLC Family Video Library
This training is provided by AutomationDirect’s education and training partner Interconnecting Automation who has been training automation professionals for more than 20 years. Interconnecting Automation’s instructors pride themselves on providing a “no hype”, “no sales pitch” type of instruction and aim to thoroughly help others learn about PLC products so they are ready to use these products to their fullest potential.
To get unlimited access to the FREE online PLC training or to see more about what is provided, head on over to www.automationdirect.com/plc-training.
When an opportunity for being better or the best at what we do is available, why wouldn’t we take it?
As Engineers, Technicians etc., we should and, need to know what we are doing. Having a better understanding of our role is something that we can accumulate as we perform our jobs, but sometimes things come along that are ‘out of the norm’, just different or more complex than we can educate ourselves on, or perhaps related to a subject you may have only briefly covered during your formal education.
On the job training is only as good as those we are learning from, sometimes we need to seek additional help especially with much of the newer technologies we see today. While we could read books, manuals and these days even watch videos on the subject they often lack the ‘hurdle’ component, that’s the bit where we need additional guidance when something just didn’t make sense.
Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist.
While finding time to take advantage of these opportunities may be a challenge, we should take them when we can. Companies such as DEWESoft offer opportunities both in-house and a variety of locations around the country to provide that training from beginner to expert in a variety of different subjects, consider the advantage and ultimate time saving as well as possibly creating local experts so the future on-the-job trainings you give will truly cover the needs of the role.
“ Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist. ”
Training session with Dave Gallop, Business Development Training Manager — Dewesoft
Cli Ck or scan QR to learn more
Achieve sustainability goals and lower total cost of ownership with a holistic flow control approach
To help businesses rise to the challenges of decarbonization and energy reduction targets, Flowserve has developed the Energy Advantage Program (EAP), incorporating proven engineering expertise, innovative data-driven optimization of flow loop operations and mutually-agreed-upon actions to reduce efficiency costs and/or achieve carbon and efficiency goals.
Within the EAP, Flowserve performs engineering analysis, project management, and execution of aftermarket upgrades, tailored to the industry, application, and other site variables. The plant operator’s commitment is the collaboration on data, process information, and implementation.
Flowserve partnered with a petrochemicals plant operator to optimize energy usage of a cooling
Implementing the EAP allowed the petrochemical operator to reduce combined power consumption for substantial cost reduction while increasing redundancy and reliability levels.
water system with five parallel VS3 pumps (rated 600 kW each) connected to a cooling tower in an open system. Flowserve’s EAP team implemented validation testing for open channel flow measurements to benchmark a dynamic system model for the different operating scenarios. This allowed new duty conditions to be defined for the pumps to achieve optimal energy efficiency at a system level.
Following a data-driven analysis on the complete flow loop, Flowserve recommended a retrofit of the CW pumps with a custom hydraulic end. Improvements were validated through CFD
analysis and factory tests prior to final on-site validation of the savings.
In addition to the petrochemical industry, Flowserve’s EAP is already helping companies realize measurable results in a wide variety of industries and applications: coalfired power plants, nuclear, pipeline, and steelworks, just to name a few.
CLICK HERE or scan the QR code shown below to get in touch with Flowserve’s EAP engineering team and learn how your company can achieve sustainability goals and lower TCO with an enhanced holistic flow control approach.
RedRaven is ready for predictive maintenance. Are you?
As a plant operator, you already understand the increasing need to monitor, analyze and predict the performance of pumps, seals and valves These components make up a large part of the collective lifeblood of your plant’s operations, and RedRaven can help you run your business at peak levels — as close to full capacity as possible.
RedRaven, Flowserve’s predictive maintenance solution for pumps, seals and valves, is a connected platform of smart products, software and services including:
• Condition monitoring, enabling you to capture asset performance data for analysis
• Predictive analytics, applying data analysis software and algorithms to help you diagnose equipment problems
With access to advanced analytics and trend data, you can often detect even the slightest changes in
your equipment’s performance — variations that can indicate a problem is looming. You won’t just receive data, you’ll also get real insights needed to make more informed decisions for improving your plant’s efficiency, productivity and bottom line. RedRaven is helping a diverse set of operators across the globe in this way.
Most Flowserve fluid motion and control equipment is RedRaven Ready designed and built to accept RedRaven wired or wireless sensors, using cloud architecture for condition monitoring and predictive analytics services. RedRaven Ready equipment securely connects to an IoT platform that includes hazardous area-certified equipment sensors, secure communication, performance analytics and trend reporting tools — all tailored to your plant’s unique needs.
For more information on RedRaven, contact your Flowserve representative or visit www.flowserve.com/redraven
In addition to oil and gas applications, recent deployments include aerospace fueling, pulp and paper, municipal water suppliers, and more.
Webinar:
How to Choose Oil-Free or Oil-Lubricated Rotary Screw Air Compressors for Your Application
This webinar provides a comprehensive comparison between oil-free and oil-lubricated rotary screw air compressors to aid professionals in selecting the optimal compressor for their specific needs. Covering essential factors such as performance, maintenance requirements, environmental impact, and cost considerations, this webinar offers insights into the advantages and disadvantages of each type of compressor.
Attendees will better understand the operational differences between oil-free and oil-lubricated rotary screw air compressors, enabling them to make informed decisions based on their application requirements and operational constraints.
The KROF is a two-stage oil-free rotary screw air compressor that provides high-quality, ISO 8573-1 Class 0 oil-free, compressed air.
Whether for industrial or commercial applications, this webinar equips participants with the knowledge needed to navigate the complexities of compressor selection, ensuring optimal efficiency, reliability and performance in their systems.
Learning objectives:
• Differentiate between oil-free and oil-lubricated compressors in design, performance, maintenance needs, environmental impact and cost considerations.
• Evaluate the operational advantages and disadvantages of oil-free and oillubricated compressors to determine suitability for specific applications.
• Discuss applications that commonly require high-quality, oil-free air.
• Apply knowledge gained from the webinar to confidently select the most appropriate compressor type based on application requirements and operational constraints.
Click here or scan the QR code below to watch the webinar!
Log on to our website and find all the information you need about industrial lubricants. From mineral based greases and oils to the latest high grade synthetic fluids, the data is compiled in our Lubriplate Lubrication Data Book that you can download at no cost to you.
Also available in digital format are important specification and product information sheets on H1 Food Machinery Lubricants, Environmental Lubricants and more.
Complete data on drop points, cold tests, viscosity indexes, ISO grades, AGMA numbers, etc. is included. There is lubricant information available regarding compressor fluids, hydraulic fluids, bearing lubricants, power transmission fluids, specialty lubricants, high grade greases and more.
If you have a specific question you may also talk with one of our lubricant representatives at 1-800 733-4755 or e-mail lubeXpert@lubriplate.com
Develop Engineering Talent for Top-Level Customer Service
A key aspect of developing engineering talent is to involve them in the process.
A common trait among successful companies is providing a superior customer experience. To do that, companies must invest in good systems, processes and people, especially regarding engineering talent. Continuous improvement generally occurs to maintain the preferred customer experience even with changes in customer demands and the overall economic environment. Most companies routinely invest in upgrading systems and processes based on programs like Lean Six Sigma, but not everyone takes the same approach with upgrading their engineers’ skills.
One key aspect of developing engineering talent is to involve them in the process rather than making assumptions. Development decisions made because “that’s how we’ve always done it at XYZ Corporation” are likely to fall short of the needs and expectations of today’s workforce. Generations Y and Z demonstrate a greater desire to participate in learning
and development opportunities, having navigated education systems that taught them to establish a roadmap for success.
Have managers conduct sessions with their employees to discuss their interests and create learning and development paths. Some will want to become subject matter experts in a specific area; others will want a broader range of responsibilities. Some from each category may desire to become a formal leader someday. Each path has overlaps but distinct differences. By listening to your engineering talent, you can create individualized development
plans that require little effort yet keep your crucial talent engaged in their current roles. They will be prepared to take on more while delivering that allimportant level of customer service.
This article was written by Billy Hamilton, Senior Vice
President
of Human Resources for Motion. He has over 30 years of experience in human resources with companies such as Overhead Door Corporation and Lockheed Martin. He is passionate about talent management and data analytics.
Click here or scan QR to learn more.
For more information, visit Motion.com/learning-development/
Want to learn about engineering topics pertaining to gearmotors? We have the information at your fingertips!
Tired of looking up multiple sources for answers to common engineering questions about gear units or gearmotors? We have the solution.
SEW-EURODRIVE’s online Technical Notes can be a real life-saver when you need answers. Technical Notes provide quick access to many engineering topics such as how to properly mount a torque arm, how to determine and design for inertia, or how to properly design your machine to use a hollow shaft gear unit.
Need answers on how the speed, mounting position, environment, and duty cycle can affect the thermal rating of a gear unit and how to protect against too much heat? That’s one of many in-depth documents you can find by visiting www.seweurodrive.com and clicking Technical Notes.
Whitepaper
Our technical white paper, Maximize Gearmotor Speed Range shows you how to operate VFDs above 60Hz to widen speed range, improve stability and reduce cost.
In this white paper, you’ll learn why it can be a good idea to operate gearmotors above 60Hz. Through a common example, we will show you how to select the proper gearmotor that will significantly enhance performance in the following ways:
• Increase stability by reducing inertia mismatch
• Widen the available speed range
• Eliminate a costly ventilator fan at low speed
• Eliminate motor overheating at low speed
• Enable the use of a smaller motor
Visit https://lp.seweurodrive.com/wp-vfd to download the PDF.
Scan QR code to access Technical Notes on your smartphone.
cslyman@seweurodrive.com
+1 (864) 439-7537 www.seweurodrive.com
Online Valve Configurators Streamline Design and Pricing for Engineers, Saving Time on Complex Solutions
Individuals tasked with specifying automated valves prefer integrated solutions combining the actuator and accessories with the valve into a cohesive assembly.
Assured Automation’s automated valve configurator uses advanced configuration and pricing management technology to deliver these solutions quickly and precisely.
The online configurator guides users through the build process, ensuring optimal pricing and area classifications.
After configuration, users can view the valve assembly in an interactive 3D viewer and download CAD models in over 150 file formats. A user specific PDF datasheet with a 3D model viewer, construction drawing, part numbers, and key specifications is also generated.
HERE to try it now
sales@assuredautomation.com 800-899-0553
How Do You Protect Your Lone Workers and Workers at Heights?
Grace Lone Worker and Grace Fall Safety Pendants monitor the personal safety of a worker by offering a manual panic alarm button, motion sensing, fall detection and suspension trauma prevention.
Fixed facility solutions are subscription free, work in facilities where cellular signals do not, and integrate with SCADA and other external notification systems.
As an add-on to any fixed facility system, Grace Connected Safety™ offers Grace Cloud Connect™ ; a web and APP based monitoring alerting portal as a subscription-based safety solution for “anywhere-anytime” monitoring with email, text, text-to-voice call alerting via a Grace Wi-Fi/ethernet, cellular and satellite Gateways.
Click here or scan QR code to learn more Phone: 724-962-9231 GraceLoneWorker.com
SCAN QR TO LEARN MORE
Knowledgeable employees are essential to successful lubrication reliability program. LE can help with convenient training options.
When you raise the lubrication standards at your operation, start by investing in the knowledge of your employees. The success of any lubrication reliability program depends on personnel being able to understand and apply lubrication best practices.
Lubrication Engineers offers convenient opportunities for lubrication training and certification with a variety of options to fit your schedule and budget. Our Xpert MLT I training classes are available multiple times throughout the year in a convenient online format. In addition, our LRF, MLT I, OMA I and CLS classes can be scheduled as private onsite training.
CLICk HERE or scan QR to find out more info@le-inc.com • (800) 537-7683 www.LElubricants.com
pe202407_eduENGhalf_lubricEng.indd 1
Washers for Every Bolted Connection: Wedge-locking washers for critical joints and customized solutions for unique specifications
Nord-Lock’s original wedge-locking technology is truly a high point in engineering. Every detail matters in keeping bolts tight and secure, even under extreme vibration and dynamic loads. To ensure outstanding performance, we rigorously monitor production and use patented processes with top-quality materials.
Our washers secure bolted joints with tension instead of friction. The system is composed of a pair of wedge-locking washers with cams on one side and serrations on the other. It uses cam-geometry to efficiently prevent the bolt from loosening. Our washers are available in five different materials: steel, stainless steel, 254 SMO, alloy 718 and alloy C-276.
bolting@nord-lock.com • +1 412 279 1149 www.nord-lock.com CLICK HERE OR SCAN THE QR CODE TO LEARN MORE
Raymond Corporation .4 .www .raymondcorp .com/POY2024
ROYAL PRODUCTS .56 .www .mistcollectors .com
SEW-EURODRIVE, Inc .2 .www .seweurodrive .com
WELDBEND . . .18, 19 www .weldbend .com
Workbenchmarket .11 .www .workbenchmarket .com
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The ultimate in power density just got better. When space is at a premium, the Baldor-Reliance RPM AC motor is the answer. RPM AC features a power-dense laminated steel frame with custom power and speed ratings to match demanding variable speed application requirements.
