HELPING TO KEEP YOUR BUSINESS FLOWING
Issue 6 Volume 5
NOVEMBER/DECEMBER 2017
The future of upstream oil Transfer solutions for the ‘new normal’
Pipeline nerves
Fibre optics are finding leaks before they start
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COMMENT & CONTENTS
Contents 2
November/December 2017
Latest news
10 Creating a nervous system for pipelines How a Canadian company is utilising fibre optics for preventative leak detection in major pipelines
ISSUE 6 • VOLUME 5
Woodcote Media Ltd Marshall House 124 Middleton Road, Morden, Surrey SM4 6RW, UK www.fluidhandlingmag.com MANAGING DIRECTOR Peter Patterson Tel: +44(0)20 8648 7082 peter@woodcotemedia.com EDITOR Daryl Worthington Tel: +44 (0)20 8687 4146 daryl@woodcotemedia.com DEPUTY EDITOR Liz Gyekye Tel: +44 (0)20 8687 4183 liz@woodcotemedia.com ADVERTISING SALES MANAGER Fraser Owen Tel: +44 (0)20 8648 7092 fraser@fluidhandlingmag.com PRODUCTION Alison Balmer Tel: +44 (0)1673 876143 alisonbalmer@btconnect.com SUBSCRIPTION RATES A one-year, 6-issue subscription costs £160 (approximately €225/$270 depending on daily exchange rates). Individual back issues can be purchased at a cost of £30 each Contact: Lisa Lee Tel: +44 (0)20 8687 4160 Fax: +44 (0)20 8687 4130 marketing@woodcotemedia.com
Join Fluid Handling International on Linkedin to discuss important issues Follow us on Twitter: @FluidHandIntl No part of this publication may be reproduced or stored in any form by any mechanical, electronic, photocopying, recording or other means without the prior written consent of the publisher. Whilst the information and articles in Fluid Handling are published in good faith and every effort is made to check accuracy, readers should verify facts and statements direct with official sources before acting on them as the publisher can accept no responsibility in this respect. Any opinions expressed in this magazine should not be construed as those of the publisher.
12 Beating bubbles to measure flow New technology handles entrained gas in wellhead hydrocarbon fluid transfer applications 14
Creating oil transfer solutions for the ‘new normal’ Why long-term efficiency and flexibility are the future in upstream oil fluid transfer
17 Are your pumps counterfeit? A major pump manufacturer is taking action against Asian brand and trademark infringements 20 22
Innovations in safety for chemical transfer Getting the best AODD pump for handling hazardous materials Keep your pumps flowing Insight into preventative maintenance practices to keep productivity flowing for submersible dewatering pumps
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27
Ten considerations for better gate valve operation Sound utility operations are as vital as the product itself when it comes to reliable gate valve operation A single solution for shutdown valve failures Benefits of automated safety instrumented systems that meet IEC 61508, IEC 61511 and ISA 84.01 standards
29 Lots of data – a single language How standard formats for data communications are simplifying logistics between petroleum companies 31
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A smooth path to drive coupling selection Engineers and designers can often face a daunting task when it comes to specifying the most appropriate drive coupling for the task in hand Brexit and the pump industry Pump sector engagement is vital to meeting both the challenges and the opportunities of Brexit
HELPING TO KEEP YOUR BUSINESS FLOWING
Issue 6 Volume 5
NOVEMBER/DECEMBER 2017
Don’t miss out on future editions. Head to www.fluidhandlingmag.com to subscribe to Fluid Handling International, and read a free copy online
The future of upstream oil Transfer solutions for the ‘new normal’
Pipeline nerves
Fibre optics are finding leaks before they start FC_FH_nov-dec_2017.indd 1
10/11/2017 16:37
Comment Dear reader, On 27 August 1859, Edwin L. Drake struck oil in northwestern Pennsylvania. He had studied the techniques used for drilling salt wells, and was inspired to apply them to the search for oil. Initially, loose rock and soil just below the surface meant it was impossible to maintain a borehole, a problem Drake overcame by driving sections of pipe into the ground until bedrock was struck. Drake is considered by many to be the first person to have devised a way to drill a practical oil well (it should be pointed out that this is open to some debate, with others, such as the Canadian James Miller Williams, credited with creating the first oil wells). Whoever was really responsible, the breakthrough came at a pivotal time. Prior to the mid-nineteenth century, oil from the ground had been collected from naturally occurring seeps. The first oil wells set the foundations for the global industry that has evolved over subsequent decades. Fast forward to 2017, and a massive infrastructure now exists around the handling and transfer of oil. Innovative new ways have been created to extract oil from the ground, to refine it, and to transport it. Environmental questions have risen surrounding the oil industry and its impact, and companies are under more pressure than ever to handle the precious black fluid as safely and efficiently as possible. This issue of Fluid Handling International takes a look at the present, and the future, of oil handling. On page 14, an expert from Trelleborg discusses the importance of long-term efficiency and flexibility in upstream oil transfer. Moving along the process, page ten presents an introduction to Hifi Engineering’s innovative use of fibre optics to detect potential pipeline leaks before they happen. On page 30, an expert from Implico explains why standardised formats for data communication will simplify logistics between oil companies. A century and a half after crude oil was first drilled from the ground, the industry is still striving for new innovations and technical solutions. Best wishes, Daryl
ISSN 2399-5602 1
PUMP NEWS
Stainless steel AODD pump for the semiconductor industry launched by Almatec A stainless steel, air-operated diaphragm pump for transferring pure solvents in the semiconductor industry has been released by Almatec. Part of PSG, a Dover company, Almatec has just announced that its Futur S and SH pump series are now available in 316 stainless steel with a high surface finish. The Futur S/SH series air-operated double diaphragm (AODD) pumps incorporate what Almatec dubs a ‘straight-through flow pattern’, with only one wetted housing part (the centre housing). The air control system and air chambers are located in the side housings. According to a statement from Almatec, the design ensures that only one part of the housing comes into contact with the liquid, reducing the number of flow bends, minimising the surface area, eliminating sliding parts in the product chambers and
Almatec Futur S stainless steel
making it possible to eliminate gaskets. The AODD pumps are self-priming with dry run capabilities, and come equipped with the PERSWING P Air Control System to optimise air consumption and production rates. The pumps are available in two pump sizes: 20 50lpm (5.3 and 13gpm). Both feature diaphragms and valve bodies made of solid PTFE without inner
elastomer or metal parts that increase the risk of contamination. Wetted seals are also available in solid PTFE. The non-wetted side housings on the Futur S Series pump are constructed of PE conductive material and can be used for temperatures up to 80°C (176°F). The side housings on the Future SH series pump are constructed of 316 stainless steel for temperatures up to 130°C (266°F). z
Hydraulic Institute launches personnel certification programme The Hydraulic Institute has launched its new Pump Systems Assessment Professional (PSAP) certification programme, designed to provide pump end-users and other stakeholders with a means to assess complicated systems with qualified and certified pump system assessors. With pumping systems accounting for 40% of industrial energy usage, the PSAP programme aims to help meet the need for more reliable and energy efficient systems, according to a statement from the Hydraulic Institute. “The PSAP program addresses a key market need in the industrial and commercial marketplace,” states Michael Michaud, executive director of the Hydraulic Institute.
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“Energy and maintenance costs combine to represent some 65% of the total cost of ownership of a medium sized industrial pumping system. A thorough system assessment often identifies energy efficient upgrade opportunities that usually pay for themselves in less than a year, lowering overall energy costs while increasing reliability, reducing downtime and maintenance costs. The key to unlocking the savings starts with a holistic assessment from a professional who can assess and optimise the overall system.” The Hydraulic Institute argues that corporations can gain a competitive edge by employing PSAPs and performing more
pump system assessments. “PSAPs are professionals who distinguish themselves as true experts in assessing all types of pumping systems,” said Edgar Suarez, technical programme manager at the Hydraulic Institute. “Examining system interactions means looking beyond the individual components to identify inefficiencies. Flow requirements are often overstated when specified and components can be oversized to ensure requirements are met. These inefficiencies add up to a lot of potential waste in a system and create opportunities not only to improve the overall system performance, but lower maintenance costs and increase uptime and overall system reliability.” z
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
RELIABLE IS ONLY WHAT WORKS IN THE LONG-TERM
In everything we do, we never lose sight of what is essential to you: cost-efficient processes and needs-based solutions. As the inventor of the elastomer-coated rotary lobe pump and a driver of innovation in the field of pumping highly viscous media with high solids content, we see it as our mission at Vogelsang to keep up the good reputation of the German mechanical engineering industry. Since our company was founded in 1929, we have been supplying extremely compact, robust machines that are highly-praised by our customers all over the world for their functionality, quality, and reliability.
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Vogelsang‘s intelligently designed, compact rotary lobe pumps meet the demands of the oil industry largely owing to their great performance, resistance and maintainability. Since they are self-priming and reversible in their flow direction, they are also the perfect solution for many areas of the petrochemical industry. Whether tanks need to be filled, drained or cleaned, the pumps are ideal because they are resistant to dry running too. vogelsang.info
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FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
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PUMP NEWS
Andritz to supply €60 million of irrigation pumps to India
Andritz, an international technology group, is set to supply a range of irrigation pumps to India as part of a €60 million agreement. The recently signed agreement with Megha Engineering and Infrastructures of Hyderabad, India, will see Andritz equip three pumping stations with a total of 27 vertical volute pumps near the village of Kaleshwaram in the Indian state of Telangana. Start-up of the pumps is scheduled for June 2018. According to a statement from Andritz, a single pumping station conveys 660 cubic metres of water per second from the Pranahita River and then through other pumping stations into a reservoir. This reservoir will ensure a sustainable supply of water for agricultural irrigation in the cities of Karimnagar, Medak, Nizamabad, Nalgonda and in the Ranga Reddy district. Andritz vertical volute pumps boast a low energy consumption, a result of their hydraulic efficiency of 90%. Headquartered in Graz, Austria, Andritz operates in 250 sites across more than 40 countries, employing approximately 25,400 people. The company is an international supplier of plants, equipment and services for a variety of applications and industries. z
Yokogawa to conduct PoC test of remote pump monitoring service Japan-based Yokogawa Electric Corp. has announced that it has begun working with pump equipment manufacturer Iwaki Co. on a proof-of-concept (PoC) test for a remote pump monitoring services. This service will use an Industrial IoT (IIot) architecture that is currently under development by Yokogawa, according to a statement supplied to Creamer Media Engineering News. The PoC test will examine the market potential for such a service and investigate means by which it may be offered. According to a statement from the two companies, Yokogawa and Iwaki will jointly conduct a PoC test of a service for remotely monitoring the operating status of Iwaki magnetic drive pumps, which are widely used in chemical, pharmaceutical, and food plants for the transport of various types of fluids. With this service, operating data such as the current being drawn by a pump, pump discharge pressure and flow rate, temperature of the conveyed liquid, and tank empty/not empty status will be collected via an Iwaki pump protector DRN and transferred to a cloud using the IIoT infrastructure that Yokogawa currently has under development. z
Landia delivers pumps to Chinese sludge treatment facility Three new Landia Chopper pumps have been introduced at the Dalian Xiajiahe sludge treatment project in north-eastern China. They join 13 Landia pumps which have already been in use at the facility for over a decade. According to a statement, the treatment plant in the Liaodong Peninsula in north-eastern China has seen Landia’s chopper pumps only once require replacement of an external knife system despite operating 12 hours per day in a difficult application for almost ten years. All mechanical seals and bearings continue to work without any problems for the treatment plant, as Landia’s Danny Zhang commented: “I am very proud to represent Landia in China, knowing that upon inspection at Dalian, for example, our near ten-year old pumps looked like new, sounded like new, and also performed like new pumps – despite so many years of very hard operation.” Landia’s Export Sales director, Thorkild Maagaard, added: “The Dalian Xiajiahe Sludge Treatment Project is a shining example of just how seriously China is about treating its wastewater properly. Our pumps are an integral part of an operation that every day handles several hundred tonnes of trucked-in dewatered sludge from wastewater treatment plants all over the city of Dalian.” The three new Landia chopper pumps that have gone into operation are for the recirculation and pumping of restaurant waste. Due to the low pH-level of this food waste, stainless steel pumps are mandatory. In central China, Landia has also previously supplied 22 pumps and mixers for the Matougang sludge handling facility in Zhengzhou. Four Landia submersibles mix sludge before dewatering, while each of the plant’s 16 digesters utilise an MPTK-I Landia sludge circulation pump (with two further units on standby). Both the Dalian and Matougang facilities have tanks and digesters supplied by leading tank manufacturer Lipp, whose acclaimed construction method is recognised worldwide for the storage of solid, liquid and gaseous substances. z 4
Landia Chopper pumps at Dalian, China
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
VALVE NEWS
Valve management system reduces tank storage provider’s risk A valve management system has significantly reduced the operational and financial risk exposure for a major tank storage provider. Valve operation specialist Sofis installed the solution to reduce the risk of incorrect valve line-up at Oiltanking Malta. “Everyone in the oil and gas industry is aware of the risk of incorrect valve line-ups,” commented David Muscat, assistant technical manager at Oiltanking Malta, in a statement. “I really appreciate the help of the whole Sofis team in finding us a good solution to accommodate our needs and getting this project ready on time.” Miscommunication or accidental operation of the wrong valve or valves during tank storage operations can lead to substantial risk exposure for the terminal operator. Oiltanking Malta identified the potential risk and cost associated with incorrect valve line-ups in its operation, and set out to find a customised solution. Valve interlocks and a key management system from Sofis were combined with Oiltanking Malta’s existing distributed control system. This mitigated the risk of incorrect valve line-ups “to the maximum possible extent”. An additional benefit of the new system is that operators can now perform multiple valve line-up procedures simultaneously. According to a statement from Sofis, the new system also means that valve changeovers are carried out more efficiently. z
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FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
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VALVE NEWS
Steel ball valves help eliminate 20,000 tonnes of CO2 a year Ultravalve, a process valve and RPZ valve specialist owned by Bonomi, has supplied valves for a ground-breaking district heat project in Greenwich, London. Based in the Midlands, Ultravalve is the exclusive UK partner for Vexve, a Finnish valves manufacturer specialising in district heating and cooling valves. Ultravalve has supplied the project with Vexve Full Bore Steel Ball Valves Flanged PN16 sized from DN80 to DN500. The ambitious, innovative project is expected to eliminate 20,000 tonnes of carbon dioxide emissions per annum. The Greenwich Peninsula Low Carbon District Energy Centre (Greenwich Energy Centre) is situated in one of London’s major urban development zones, serving 15,700 new homes and over 300,0002 of office space in what is the largest residential new-build district heating system in Europe. The centre houses boilers and a combined heat and power plant. Heat energy is distributed via a district heating network from the energy centre to each plot across the development. “Ultravalve and Vexve have worked with specialist UK district heat consultants on numerous other projects, but this is our most significant project to date, both in terms of magnitude and value,” said Ultravalve managing director Bill Brach. “In addition to our high performance Vexve valves being virtually maintenance free, the fact that we could supply them in a wide range of sizes; from DN 15mm right up to DN 800mm backed up by Vexve’s renowned fast delivery, played a significant part in the project consultants
Vexve flanged ball valve
choice of valve supplier.” The Paris climate agreement and funding announced by the UK government in 2015 have led to a strong demand for environmentally-friendly and efficient heating in Britain. A report commissioned by the Department of Energy & Climate Change showed that heat networks have the technical potential to supply as much as 43% of heat demand for buildings by 2050. “Ultravalve’s ability to offer the services of a global manufacturer, combined with
our proactive and local service were also important, and we were quickly able to fulfil any additional requirements for parts or specification changes as the project progressed,” Brach added. “We anticipate that this will be the first of many such projects as cities throughout the UK investigate the feasibility and long term benefits of district heating. The suitability of our products in this type of environment and the experience we have gained working on the Greenwich project makes us the ideal choice of supplier in this field.”z
Valve pioneer and Velan founder passes away Karel Velan, founder of major Canadian valve manufacturer Velan, has passed away. Born in Poland in 1918, Mr Velan’s death came just a few months before his 100th birthday. According to a statement from the company, Mr Velan peacefully passed away in his sleep while being treated for complications related to pneumonia at Montreal General Hospital. Mr Velan grew up in Zywiec, Poland. Following the Second World War, he completed his Master of Engineering
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studies at the University of Brno in what was then Czechoslovakia. When communists seized power in Czechoslovakia in 1948, Mr Velan, his wife Olga and their two sons fled the country, initially settling in Switzerland before immigrating to Canada in 1949. In 1950 he founded Velan Engineering in Montreal, soon patenting an innovative bimetallic steam trap. In 1954 Mr Velan oversaw the establishment of the company’s first overseas manufacturing plant, while
in 1956 he began travelling extensively to establish the company’s network of overseas distributors. Since then Velan has grown to become a major international company for the construction of industrial valves, employing over 1900 people and manufacturing in nine countries on three continents. A statement from Velan describes how Mr Velan remained involved in company operations late into his life, continuing to regularly visit the office until he was 96 years old. z
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
FLOWMETER NEWS
Liquid flow capability added to Honeywell’s remote terminal unit Honeywell Process Solutions (HPS) has announced a new release of the company’s ControlEdge Remote Terminal Unit, which now offers measurement of both gas and liquid flow. The new version of the ControlEdge also offers expanded HART support, allowing for easier device commissioning and diagnostics. The new electronic flow metering capability supports liquid custody transfer per the American Petroleum Institute (API) 21.2 guidelines in North America. The new release aims to boost the efficiency of remote asset management by doubling as a flowmeter while also allowing operators to automate loop check and commissioning, reduce hard-wired input/output devices, and extend device diagnostics. “As we continue to add even more capability to our ControlEdge RTU, our focus is constantly on allowing our customers to more effectively operate their distributed assets,” explained Paul Vellacott, HPS solutions marketing manager. “We continue to expand the idea of what can be done via remote asset management, and the ControlEdge RTU is leading the way.” ControlEdge RTU is part of Honeywell’s next generation family of controllers, which aim to take advantage of the power of the Industrial Internet of Things (IIoT). The RTU is able to withstand harsh environments and is designed for easy deployment at remote sites, in applications such as wellhead monitoring and control, data concentrators, gas flow metering, block-valve automation, and pump and compressor control, as well as in water distribution and wastewater treatment. z
Krohne launches ‘highest capacity’ Coriolis flowmeter Krohne has announced the introduction of new large line sizes as standard for its OPTIMASS series of flowmeters, including an addition which the company claims is the “highest capacity” Coriolis flowmeter on the market. For the OPTIMASS 6400, diameters DN150/6” and DN200/8” have been added, while the OPTIMASS 2400 is now available up to DN400/16”. According to Krohne, the new large line sizes are targeted at the oil & gas and petrochemical industries. Typical applications for the new large line sizes include bulk hydrocarbon loading and bunkering as well as LNG/cryogenic or high temperature applications. Significantly, the new additions to the OPTIMASS series feature gas and liquid MID and OIML custody transfer approvals and compliance with API and AGA guidelines, SIL 2/3 functionality and NE 107 diagnostic functions. The new large line sizes also feature Entrained Gas Management (EGM), offering continuous and repeatable mass flow or density measurement over a wide range of gas fractions and complex flow conditions. The meters indicate and maintain operation with 2-phase flows such as liquids mixed with gas, slurries with gases of highly viscous fluids with gas entrainments. The OPTIMASS 6400 DN150/6” and DN200/8” share the dual bent tube design of their smaller sizes, while OPTIMASS 2400 DN400/6” is actually a completely new design. The dual straight tube has been extended to a four straight tube design for flowrates up to 4,600t/h/169,021lb/min, which Krohne is claiming makes it the highest capacity Coriolis flowmeter on the market. The flowmeter’s accuracy is 0.1% with a turndown of 20:1, and an optional 0.05% “flat” accuracy with a turndown of 10:1. Krohne states that the OPTIMASS 2400 flowmeter is suitable for field proving with small volume prover. In-situ calibration, verification and documentation with the OPTICHECK verification tool is also possible. z FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
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OTHER NEWS
Oil and gas industry expecting to create more jobs The oil and gas industry expects more new jobs to be created than lost over the next twelve months, according to newly published survey results from recruiters NES Global Talent and oilandgasjobsearch. com. If true, it’ll be the first time since 2014 the industry has had a net increase in jobs. It is estimated that 440,000 jobs have been cut in the oil and gas sector worldwide since oil prices crashed in 2014. Since July 2017 however, the price of oil has stabilised, and the new survey shows that almost 90% of employers expect staffing levels to either increase or remain the same in 2018. In total, almost 60% of employers expect to recruit significantly over the
next year, according to the survey results. Almost a quarter of those employers expect to increase their workforce by 5%, while 19% expect to increase staffing by between 5% and 10%. 17% expect to increase their staff by more than 10%. According to the survey results, 30% of employers expect staffing levels to remain the same while just 11% are expecting to make job cuts. “Globally we are now increasingly confident that the market supports increased investment in the energy sector. Energy companies with the support of their partners have right-sized their organisations for the current levels of activity,” said Tig Gilliam, CEO of NES Global Talent.
“With a stabilised price environment and lower cost profile more and more assets offer attractive returns on investment and operations. This increasing activity is leading the higher performing companies to refocus on quality people to lead and deliver value.” “While this activity is being led by a sharp increase in investment in US shale, there has also been an uptick in capital projects being approved which will positively impact the industry across all regions. With our own staff operating in over 60 countries, the increasingly positive tone of our clients and contractors is a welcome signal of the turnaround in the market and the participants in this survey echo that sentiment.” z
Emerson acquires oil and gas UK Gasket maker opens software solutions provider ‘state-of-the-art’ new facility Paradigm for $510 million Emerson has acquired Paradigm, a software solutions provider for the oil and gas industry, for $510 million (€434 million). The acquisition is expected to close within the next 60 days, subject to various regulatory approvals. Combined with its existing Roxar software business, Paradigm will allow Emerson to offer an ‘end-to-end’ exploration and production software portfolio with offerings spanning seismic processing and interpretation to production modelling. According to a statement, Emerson hopes that Paradigm’s technology offerings will enable it to ‘better help’ oil and gas operators increase efficiency, reduce costs and improve return on investment. “This acquisition is a significant technology investment that meets our customers’ growing demand for an independent, global provider of E&P software solutions,” said Emerson chairman and CEO, David N. Farr. “Paradigm broadens our leadership in the upstream oil and gas market by adding a range of subsurface software tools that complement our growing Automation Solutions portfolio.” Headquartered in Houston, Texas, Paradigm has more than 500 employees globally. The company provides an array of tools that help customers to gain insight into the subsurface, reduce uncertainty and support responsible asset management. “When combined with Emerson’s Roxar Software Solutions portfolio, Paradigm expands the global upstream oil and gas capability of our Plantweb digital ecosystem, creating a more comprehensive digital portfolio for our customers from exploration to production,” said Mike Train, executive president of Emerson Automation Solutions. “Our offering can now help customers better maximise the value of their existing investments and reach Top Quartile performance.” According to Emerson, Top Quartile performance is defined as achieving operations and capital performance in the top 25% of peer companies. z
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A leading UK gasket manufacturer has opened a new hi-tech production facility designed to supply the water treatment industry with innovative sealing products. J.A. Harrison’s new, £2.8million (€3.2 million) installation houses the technology, machinery and manufacturing processes to create specialised sealing products for water treatment plants. It also incorporates a tightly controlled supply chain that ensures the facility meets the industry’s stringent safety and quality requirements. Located in Oldham, Manchester, the new facility backed by the Department of Trade and Industry through the Growth Company opened on 10 November. The 38,000 square foot (3530 square metre) design incorporates computerised industrial presses, lathes, ovens and cyber-safe security systems, as well as significant efficiencies to cut lead times and down-time at water treatment plants. Enhanced handling, packaging, storage, cleaning, waste control and review methods are also in place to ensure J. A. Harrison supplies uncontaminated products. J.A Harrison’s new production plant has recently obtained ISO 9001 -2015, ISO 14001 and OHSAS 18001 accreditations, meaning it can start to supply products directly to water treatment projects around the world. The company already counts major chemical and medical organisations, such as Siemens, Dow Chemicals and the NHS (UK National Health Service) among the clients for its range of bespoke and standard-dimension gaskets. “Contamination, safety of products and security of systems are big issues for customers in the water treatment industry. This facility addresses them all and many more,” said Keith Sheperd, managing director of J.A. Harrison. “It is a flagship facility for our industry and gives us the scope to produce gasket and seals for the biggest water treatment projects in the world. We’re delighted it is now operational.” z
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
OTHER NEWS
Pipelines safer than rail for fluid transportation Concerns remain over the safety of rail to transport energy liquids and gases, according to a newly published report. The research from the US National Academy of Sciences, Engineering and Medicine argues that both pipeline and maritime transportation have a more comprehensive safety system in place than rail road transportation. Long-distance transportation of domestically produced crude oil, ethanol and natural gas has increased sharply and unexpectedly since 2005, according to the report. This has led to a number of concerns arising about the safe transport of these hazardous materials, especially in relation to railroad track defects, rural communities’ emergency response preparedness, and the older tank car designs that will continue to be used in multi-car unit trains.
It is argued in the new study that pipelines and barges have accommodated major portions of the growth in domestic energy liquids and gases without significant new safety problems and within the basic framework of their longstanding regulatory and safety assurance systems. A significant conclusion of the report is that railroads have an opportunity to create a more robust safety assurance system for moving crude oil and ethanol, one which is similar to those used by pipeline and maritime carriers. It’s noted by the authors that prior to 2005, railroads had very little experience in carrying ethanol and crude oil in large quantities. This meant that after the surge in domestic production, a situation arose where
railroads were called upon to transport hazardous energy liquids in tank cars that had not previously carried them in bulk. The committee found no new safety problems have emerged from the increased use of pipelines transporting larger amounts of domestic oil and gas. It does note however, that substantially more pipeline mileage and higher traffic volumes may result in more pipeline releases over time, simply because of the increase in exposure. The safety impact of this is likely to depend on the extent to which new pipeline technologies, leak monitoring systems, and more vigilant and capable integrity management programmes are effective in protecting the newer pipelines and the older ones that connect to them. z
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PIPELINES
Creating a nervous system for pipelines Hifi Engineering are a Calgary, Canada-based company who utilise fibre optics for preventative leak detection. Fluid Handling International spoke with company founder John Hull about the potential of this innovative technology
by Daryl Worthington By the time a pipeline operator detects a leak thousands of litres of fluid could have already escaped. To solve this issue, Hifi Engineering has developed a technology which monitors pipelines with no restrictions of space or time. “It’s based on a concept called interferometry, which is a method of comparing two signals,” company founder John Hull explains. “You send pulses of light down the length of a fibre and then these light pulses reflect back and carry information about the environment around that fibre, it’s similar to how your nerves work. “Like a nerve the fibre optics can sense vibration, that is, dynamic energy. Dynamic energy in its very highest frequency is called acoustic, in a lower frequency it’s called vibration and even lower frequencies it’s called strain. The fibre optics can also measure temperature. “Often the leak will give off clues before it actually happens. The key is that this technology allows us to perform preventative leak detection and detect those signs, for example ground shifting and movement or earthquakes.” Fibre optic technology has a range of uses: in security, in well monitoring in upstream oil and gas applications, and in pipeline leak detection and security. In 2012, Hifi Engineering won an investment from the Canadian government to hone and optimise the use of fibre optics for leak detection and prevention. 10
Over the last four years, the company has been using its technology in controlled tests with a wide range of third parties, including major oil companies. Hull tells Fluid Handling International that these tests have been going extremely well, achieving a 100% success rate with no false positives on fluids such as liquid petroleum, wastewater and oil. “The zero false positives is important. If you’re hearing false alarms all day the system becomes useless,” Hull continues. The Hifi team are now developing their technology to get the best results possible. It is currently being tested on a number of different active pipelines as part of a research project in collaboration with TransCanada, Enbridge and Kinder Morgan. This includes the Keystone oil pipeline in Houston, Texas, and Kinder Morgan’s Trans-Mountain pipeline, which transports heated bitumen. “We’re striving for 100% accuracy, we think it’s possible. It’s like a human brain. Does it work when you’re born? Yes, but as life goes on you learn things and become more intelligent, it’s a continuous process.” Monitoring all of the pipeline, all of the time According to Hull, fibre optics are distinguished by their potential to monitor a pipeline constantly through both space and time. This is a capability rarely found in alternative methods of leak detection. “Traditional methods usually rely on point sensors which are placed periodically along the pipeline. They may not be in the right place at the right time so if something happens in between those sensors, you may not detect it,” explains Hull. “One time surveys, like drones flying overhead or people walking the pipeline may also not be in the right place at the right team. A leak could be going for 50 days before a survey finds it. “The reason fibre optic technology is getting a lot of interest is it offers 100% coverage in space and time. The problem with current sensors is they’re not sensing every metre and they’re not always there. With a mass balance sensor for example, you’ll have a point sensor every 10km and if something happens in between that, you’ll miss it.” “To get close to 100% leak detection we have to solve the problem of space and time. Full coverage in space and full coverage in time. Fibre optics can do that.” FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
PIPELINES Hull is quick to point out that fibre optics are not necessarily a replacement for existing leak detection technologies, noting that Hifi Engineering’s main competitors are other companies working with fibre optics, rather than alternative leak monitoring methods. He believes that fibre optics can form part of an ever more comprehensive level of protection against pipeline leaks. “It’s not about replacement, it’s about layers of protection. Every time another technology comes out, it’s just an added layer of safety and security to what exists already. Fibre optics will never replace mass balance sensors because mass balance sensors are in the majority of the systems around the world. “The new technology that’s coming on is drones, but those are still just a one-time survey. In addition, a pipeline could be leaking below the ground and a drone wouldn’t see that. Fibre optics and drones could work together. If a fibre optic sensor detects something, you could send a drone out straight away to inspect that.” Preventing and detecting leaks across a full range of fluids Much of Hifi’s work so far has been connected to the oil industry. However, the company states that fibre optics could be applied to any fluid. “When I say a fluid, I include natural gas. The pipeline monitoring is all the same, we’re looking for the same things, intrusion, seismic shifts, ground movement, it doesn’t matter what’s in the pipeline we can still measure that,” Hull explains. “If an actual leak happens, compressed air or compressed gas gives off a lot of the same dynamic energies as jet fuel, heated bitumen or even wastewater. With LNG (Liquefied Natural Gas) we might have to use different software, because an LNG leak would have more of a cooling effect than heated bitumen. Temperature is temperature though, we’d just need to adjust the algorithm.” According to Hull, multiphase fluids also present little trouble for Hifi’s technology. Indeed, it’s already been tested at both onshore and offshore facilities run by Exxon. “Any pipe that carries a fluid that has an undesirable effect when it leaks (whether loss of money or environmental damage), we can monitor it.” Report card In July 2016, a pipeline operated by Husky Energy leaked into Canada’s North Saskatchewan River, spilling 225,000 litres of heavy oil mixed with diluent onto a riverbank. About 40% of the leaked oil managed to reach the river. According to Husky’s own analysis, the pipeline leak was caused by ground movement. The Saskatchewan government announced in October 2017 that the pipeline would go back into operation. It was reported that a range of measures were installed to improve its safety, and these include Hifi’s fibre optic technology to measure stresses and strains on the pipeline. Hull suggests that this could become increasingly common in the future. “We’re working with our partners on providing a monitoring score, a report card if you will. One client in particular is gearing the test in this report card to make it acceptable to a regulatory body. “The regulatory bodies will check the report card to see if the pipeline is clear to operate. Will this affect the pipelines’ licence to operate and insurability? I can’t answer that but the writing is on the wall that it has the potential to one day. The regulatory
bodies will ask to see a report card to check if a pipeline is cleared to operate. This could eventually allow a monitoring system.” High fidelity Hifi Engineering is not the only company using fibre optics for preventative leak detection. Hull believes that it’s the fidelity of the data Hifi uses that distinguishes them. “What differentiates us from everyone else who does this is data quality. In the sensing world we call that fidelity, the ability to sense environments or reproduce a signal with quality and confidence. We realised when we formed the company that existing technologies were out there but they were designed as a telecoms diagnostics tool. We liked the idea of fibre and we saw there was potential there, so we redesigned it so it had high fidelity. That’s what drives our performance and success. “Everything we do, from hardware to software, is designed to get the best fidelity possible. Fidelity means intelligence,” Hull concludes. z
For more information:
John Hull is the founder of Hifi Engineering. Visit: www.hifieng.com
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FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017 11
Beating bubbles to measure flow
FLOWMETERS
New technology handles entrained gas in wellhead hydrocarbon fluid transfer applications Wherever hydrocarbon fluid is transferred, there is a risk of gas entrainment at the beginning or the end of a process. Gas entrainments are a challenge for accurate measurement with all flowmeter technologies. Accuracy of information at the well site is critical, since royalties are based on what is loaded there. The old standard mechanical meters and even newer mass flowmeters simply cannot provide accurate measurements with entrained gas. Now, new technology is available with synthetic drive control that ensures continuous accurate measurement – even with high entrained gas conditions. The new technology also has an extremely low pressure drop, which greatly increases the liquid transfer speed. Entrained gas in fluid transfer applications At a typical wellhead, oil flows into a separator that separates the water, gas, and oil. When it does, gas may be entrained in the fluid coming out of the separator. The presence of entrained gas (gas bubbles) can disturb the sensitivity of mass flow measurement of liquids, decreasing accuracy – or even stopping measurement completely.
Row of separators, each with an OPTIMASS 6400
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Gas entrainment can occur for many reasons. Air voids may creep in when hoses are filling or tanks emptying. There can be de-gassing (off-gassing); leaks upstream of (or in) a negative pressure area; excessive cavitation and levels falling below the minimum in supply containers, as well as agitators in tanks; or long drop distances for media into tanks. Entrainment can Real world entrained gas conditions are dynamic based on a variety also occur due to of factors as shown here for horizontal or vertical installations status transitions in process control, such as when starting, displacement (PD) meters. They are shutting down, or cleaning the system. relatively inexpensive, have been used for decades, and people are familiar Available technologies for with them. Since they require no power, fluid measurement mechanical meters are often used in remote locations that lack access to In the past, many operators used power. They are also used wherever mechanical meters for fluid transfer operators unload tanks using only the applications, like turbine or positive force of gravity. One disadvantage of mechanical meters is that they require a filter or strainer in front of the meter to protect the measuring element from slugs of wax or gravel that could otherwise enter the meter and cause it to jam. Using a filter adds to the pressure drop and reduces transfer speed. In addition, mechanical meters lack diagnostic capabilities to demonstrate accurate metering. The user might never know that accuracy has been compromised unless the meter becomes completely blocked. In recent years, new mass flow metering technology has come on the market that FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
FLOWMETERS
OPTIMASS 6400 in a separator doghouse
enables faster flow with no pressure drop and no risk of obstruction. These meters do not lose accuracy and require little or no recalibration. Information from diagnostics provides insight into any problems with the meter, which can be dealt with quickly and before accuracy is affected. For example, the new OPTIMASS Coriolis mass flowmeter with entrained gas management (EGM), developed by Krohne, detects and signals gas entrainment. The technology offers reliable indication of gas bubbles in a process by using a combination of various measurements to detect a two-phase flow. The meter maintains the active measurement in all measuring conditions with gas content from zero to 100% by volume. It maintains continuous mass density measurement and provides measured values at all times. At the same time, it can report the two-phase status and output a preconfigured alarm, in accordance with NAMUR NE 107 requirements. Case study: Increased throughput, improved efficiency and process optimisation Bonanza Creek is developing a major oil and gas field by drilling horizontal lateral wells and multi-stage fracture stimulation. They needed an accurate and reliable way to measure how much oil and water each well was producing. Tank gauging is the standard method used to measure the volume of production at each well. While simple and relatively accurate, tank gauging is time consuming, costly,
and entails safety risks. To account for the production variations among the wells and provide accurate well allocation measurement information, each well on a pad had to flow into a separate tank. They were looking for a cost-effective way to provide an accurate oil meter at each wellhead. They anticipated there would be gas entrained in the fluid coming out of the separator, so they needed an option that could handle entrained gas. They eventually opted for the OPTIMASS Coriolis mass flowmeter with the EGM feature. In this application, the OPTIMASS meters are installed on the crude oil leg of the oil/water/gas separator. Less expensive metering technology is used to meter the water, since it is of lower value to investors. Gas is metered using DP devices. After purchasing the first 30 meters in 2013, Bonanza Creek compared the tank volume versus the metered volume over a 24 hour period and found only minor differences in the measured values. They have since installed more than 400 OPTIMASS meters, which they use to accurately manage wellhead allocation and provide stakeholders critical production data. The new meters are now being used at other exploration and production companies working in the Wattenberg Fields. After a head-to-head demonstration and evaluation comparing OPTIMASS meters to a competitor meter without EGM, one major energy company purchased and installed about 180 OPTIMASS meters, and expects to purchase at least 60 more in the near future. Maximise efficiency for oil and gas loading and unloading Approved for custody transfers of both liquids and gases, the new mass flowmeter with EGM helps maximise efficiency and optimise processes. It uses proven, patented flow splitter technology that provides minimum pressure loss, making it an excellent option for oil and gas loading and unloading operations. z
Many options, fast choice. ELAFLEX hose assemblies, rubber expansion joints and couplings reflect the decision for premium quality. They ensure safe operation and long-term optimisation of the total cost of ownership. Due to the large number of product options we have complemented our catalogue with online configurators. These configurators offer a fast and efficient overview or can be used for your enquiries.
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For more information:
This article was written by Steffen Baecker, Business Development – Flow at Krohne. Visit: www.krohne.com
ELAFLEX - Gummi Ehlers GmbH Schnackenburgallee 121 · 22525 Hamburg, Germany Tel. + 49 40 540 005-0 · info@elaflex.de FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017 13 www.elafl ex.de/en
UPSTREAM OIL
Reeline submarine line
Creating oil transfer solutions for the ‘new normal’
Why long-term efficiency and flexibility are the future in upstream oil fluid transfer For many, 2017 will go down as a year in which the oil industry has had to adapt to a ‘new normal’. The winners in this climate are those adapting their business practices to become leaner, more flexible, and more efficient in the long-term – rethinking approaches from the bottom up and instilling practices for the long term, rather than employing cost-cutting measures as a quick fix. Speaking at the beginning of the year, Tom Ellacott, senior VP of corporate analysis research at Wood Mackenzie, commented: “Overall 2017 will be a year of stability and opportunity for oil and gas companies in positions of financial strength…strengthening finances will still be a top priority. Capital discipline, cost reduction and deleveraging will frame corporate strategies in 2017.” This has largely turned out to be prophetic. According to research from classification society DNV-GL, 85% of oil and gas professionals saw cost management as a top or high priority for 2017, and a 14
majority (63%) saw current cost-efficiency measures as marking a permanent shift towards leaner ways of working. This has affected a significant shift in how oil companies are thinking about their long-term operations. A report from Trelleborg’s offshore operation found that many companies are striving to learn lessons from the last few years and future-proof their businesses in the face of the ‘new normal’. Although over half of engineers expect installation and commissioning costs to be a major challenge when making ‘shelved’ projects more viable, 61% of facilities are willing to spend more on a project upfront to ensure longevity and reduce the need for future upgrades. Nowhere is this more important than in the field of oil transfer. This is one of the most technically challenging areas that the industry faces, and one in which the costs of failure – environmental, financial and reputation – have the potential to be most detrimental. Oil transfer requires
highly precise, engineered solutions that must often operate in harsh conditions for lengthy periods of time – up to a decade in some cases. It is vital that, whatever the conditions for the market in the future, that the significant safety gains made in recent years are not lost. Managing these projects requires not only specialised technology and products, but specialised expertise as well. As the search for marginal gains intensifies, oil companies can benefit from examining the relationships they have with their suppliers to analyse whether they are getting the most value in terms of consultation and knowledge exchange. A report from FPSO Network outlines the importance of this approach from the very beginning of a project. 55% of operators list ‘poor selection of contractors and subcontractors’ as one of their top three causes of cost overrun and delays. Later down the line, 42% see unforeseen production issues that are not picked up at the design and execution stage
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
UPSTREAM OIL and strain databases for fatigue analysis. For hoses qualified to GMPHOM 2009 standards, hydrodynamic analysis is conducted as necessary, considering how a qualified hose design will function in conjunction with its specific properties, performance expectations, and its environment. It’s important that those involved in procurement are aware of the testing and research that goes into each project, and the value added at this stage. Research and testing at this stage can also lead to innovations that have wider operational benefits throughout a product’s lifecycle. For instance, our engineers identified that in high-traffic areas, hoses may need to switch between floating and submerged modes to allow traffic to pass. Secondly, it is often necessary to adjust the shape of a submarine line. For example, this could be under a Calm Buoy to accommodate density
Satisfactory bending test 1.5x ID of a Reeline nipples hose after 7 years in service
changes in the conveyed fluid. To address these issues, Trelleborg developed adjustable buoyancy modules that can be placed along the hose line at any point, maintaining the ideal shape and configuration of the hose to minimise loads and fatigue and improve safety and service life. This is one of several innovative solutions that can come out of carefully examining the environment in which a solution will function.
as the main causes of downtime. At Trelleborg, we have been working on making oil transfer safer and more efficient for over 40 years. We recommend a three-stage approach to ensure that we, as suppliers, can add value at every point throughout the lifecycle of a solution. 1. Analysis and discovery Understanding the environment in which a hose will function is a crucial first step in safe hose management. This is why, at Trelleborg, our R&D teams become involved at the earliest stage of any project to ensure that the environment is properly understood, and that we create appropriate solutions. Our teams will usually begin by using prototypes, which undergo rigorous chemical and mechanical testing, in addition to hydrodynamic analysis. This allows the creation of models that match real-life service conditions, while granting researchers a detailed analysis of performance under fatigue. This testing process will vary according to whether the product in question is a qualified hose designed to meet GMPHOM 2009 (Guide to Manufacturing and Purchasing Hoses for Offshore Moorings 2009) requirements, or API Spec 17K, which is typically used for customised, one-off projects for which the requirements are harder to standardise, typically in extreme operational or environmental conditions.
Tanker connection – floating hose, connection to tanker – Angola
If the API Spec 17K is selected, high fidelity finite element (FEM) and finite element analysis (FEA) models for each specific hose construction are created, enabling a precise prediction of hose behaviour, including its specific characteristics and performance limits. Following this, the fluid properties of the product to be transferred, including temperature, pressure, and viscosity – as well as the necessary standards and their specific requirements – are all scrutinised under hydrodynamic analysis. This allows for a detailed comparison report on the limitations of each hose to be developed. As the number of off-loadings will also affect the strain placed on the hose – particularly in more extreme environments – nippleless hoses, more commonly used in these conditions, are also tested against stress
2. Selection Having completed an analysis of the environment, the next stage is to select an appropriate solution. Trelleborg offers a wide range of oil hoses, recognising that one size does not fit all for the sheer variety of environments and projects that exist throughout the industry. In most cases, the most suitable solution for non-harsh, low-cost extraction environments will be a single or double carcass nipple hose. The design uses binding steel wires fixed on the nipple flange to attach the hose body structure made with textile layers and reinforced with a steel helix. This type of hose is the most commonly used in today’s market, in both floating and submarine configurations. Key factors to consider at the selection stage are mechanical characteristics, such as the minimum bend radius (MBR) of an oil hose. This determines how much movement a hose will be able to withstand without affecting its performance (see fig. 1). This is a crucial metric of performance for products that
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017 15
UPSTREAM OIL will either function for extended periods of time, or in particularly harsh environments. Other key properties include tensile, torsion and bending stiffness, as well as bending and axial load resistance.
Minimum bend radius against internal diameter
A nippleless hose excludes the stiff metal connector used in nipple hoses, to increase flexibility. Instead, it carries a flange, which is embedded in the rubber itself. This reinforced flange design, combined with an integrated bending stiffener, can then be used to create a hose that survives harsher conditions for longer. When it comes to selection, this is another area where a supplier’s guidance, based on extensive technical knowledge, is invaluable. Different levels of specialisation will be necessary depending on each project, and suppliers need to act as trusted advisors to recommend the best solution. 3. Maintenance The role suppliers play in oil transfer does not end at the delivery of a product.
Connection of Reeline hoses with hydraulic wrenches
Suppliers must support projects throughout their execution to ensure that the highest safety standards are upheld, as well as guaranteeing the benefits of proper lifecycle management. This approach includes on-site inspection and testing for requalification, hose maintenance and inspection programmes, and on-site repairs to ensure that hoses are not only performing correctly but are meeting the required standards in safety and quality. This may need inspections, tests on site or in the factory such as OCIMF (Oil Companies International Marine
Forum) and burst tests, or ageing analysis of the components such as adhesion tests or elastomer property analysis. Looking ahead Earlier this year, Trelleborg asked professionals what they deemed to be the most important factors when selecting an oil hose. Respondents listed ‘quality and durability’ as ‘vital’ over 80% of the time, while ‘price’ was listed as vital only 19% of the time. The next most ‘vital’ factors were ‘aftersales support and service’, and ‘ease of installation’ at 32% and 28% respectively. In 2018 and beyond, the onus will be on suppliers to demonstrate how their expertise, research and know-how can add value by understanding the job that needs to be done, selecting the right tool, and supporting it throughout its operations. It’s clear that the industry understands how increased capital expenditure can reduce operating expenses over the course of a product’s lifecycle – which bodes well when contextualised within the ‘new normal’ of prioritisation given to capital discipline, cost reduction and deleveraging. z
For more information:
This article was written by Nicolas Landriere, product manager, Oil Applications, Trelleborg Oil and Marine. Vertical connection of floating hoses in Angola
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Visit: www.trelleborg.com
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
PUMPS
How KSB Group is taking action against Asian brand and trademark infringements
Are your pumps counterfeit?
by Bryan Orchard
It is a commonly-held view that counterfeiting and patent infringements predominantly happen in the consumer goods markets where large global organisations go to extreme lengths to protect their brands and corporate identities. The global market in counterfeit goods costs companies many billions in lost revenues and in fact goes way beyond high profile consumer products. Manufacturers of capital goods are affected significantly by the illegal activities of enterprises that go to great lengths to copy their products and distribute and sell them as genuine items. The international pump industry is no stranger to counterfeiting and the challenges that many of the leading brands face in trying to fight what is termed ‘low-end disruption’. Cynics may say that the global leaders in pump technology would want to close down any competition in order to maintain their profit margins, and there may be an element of truth in this. However, the use of counterfeit pumps across all areas of fluid handling puts the end-users at the risk of damaging their production equipment, producing sub-standard products that do not comply with international regulations, contributing to environmental pollution and putting employees and the public at risk. End-users that knowingly purchase counterfeit pumps and components are equally complicit in this pernicious trade. Many German industrial enterprises are complaining about soaring problems with counterfeit products from China. The VDMA (Verbund Deutscher Maschinenund Anlagenbau) Mechanical Engineering Industry Association represents
The scale of the problem – an online advertisement for a counterfeit KSB pump
more than 3,200 mostly medium-sized companies in the capital goods industry, making it the largest industry association in Europe. In its 2016 Product Piracy Study, 70% of its participating companies indicated that they were victims of product or brand piracy. Its findings indicated that the damage to Germany’s mechanical engineering sector was an estimated € 7.1 billion every year1. Internet expansion While the rapid growth in the internet has brought huge benefits, it has also created opportunities for unscrupulous individuals and organisations to conduct illegal operations that can seriously harm legitimate businesses. Within the framework of the globalisation and digitalisation of business models, largesized and high-priced investment goods are now also sold over the internet. This
is leading to a sharp increase in brand and trademark infringements regarding offers made on online platforms. Over the last few years, the German based pump and valve manufacturer KSB has been closely monitoring this situation. The KSB Group is among the world’s leading suppliers of pumps, valves and related services, with applications ranging from building services, industry and water transport to waste water treatment and power plant processes. The company has a presence on all continents with its own sales and marketing organisations, manufacturing facilities and service operations. The success of the company is based on innovative technology that is the fruit of its own research and development activities in hydraulics, materials development and the automation of pumps and valves. According to Franz Bosbach, KSB Technology Foresight, a significant number
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017 17
PUMPS of Asian manufacturers are using KSB’s well-established reputation to market their products. “Under protected KSB brand names, they offer pumps and valves as well as spare parts for sale on international trading platforms,” comments Bosbach. “In particular, the names of well-known products such as Etanorm, Omega and BOA, are frequently used. The umbrella brand ‘KSB’ is also often misused to maliciously deceive the targeted buyers.” Not content to sit back and let this situation continue, KSB is being proactive in tackling both the manufacturers and the on-line shops selling the counterfeit products through a newly established taskforce. In cooperation with Italian project partner Convey, KSB is reporting these infringements to the platform operators and instructing them to take down the offending offers. If necessary, legal action is also brought against the brand and trademark infringers. It is
KSB stands for reliability, quality and know-how, especially in Asia. Our policy is to continue identifying counterfeits on Chinese trading platforms in order to defend KSB’s brand and trademark rights more vigorously,” continues Bosbach. Global challenge Clearly counterfeiting is a serious global problem for all pump manufacturers, but it is also a problem for would-be pump buyers. Many of the counterfeiters use sophisticated techniques to replicate the OEM’s website and this makes it very difficult to check product authenticity. Buying pumps that claim to be from the OEM (Original Equipment Manufacturer) and then fail because they are counterfeits can do major harm to the user’s business, not to mention the OEM’s reputation. Counterfeiters will go to great lengths to replicate
The pump industry is probably one of the most exposed to counterfeiting worth many billions of dollars proving to be highly successful, in its first year, starting in July 2016, the KSB Group identified 420 marketers on eight different online platforms who had been illegally misusing its product names. Between April and August 2017 it uncovered 4,000 illegal offers and had them removed from the associated trading platforms. “This is a great success for KSB since
the true product, employing reverse engineering techniques. This low end disruption is of major concern not only to KSB, but many other global brands. “KSB has many brands that are several years old, well-established and regarded as a premium product,” says Bosbach. “We are constantly upgrading these brands to meet our customers’
KSB goes to great lengths to protect its brands and reputation around the world and has set up a task force to combat and shut down illicit activities
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requirements and to offer improved operation, but this adds costs to the purchase prices and end-users are not always willing to pay more. We are aware of one Chinese manufacturer that has built up a considerable customer base selling a copy of one of our established brands. The quality is not the same as the KSB product, but some customers are willing to accept the risk because it is cheaper than the true KSB pump. By taking down these manufacturers before they get too big we protect our brands, quality and sales reputation.” Convey cooperation Franz Bosbach says that KSB is highly active in tracking down counterfeiters and getting them closed down. “The problem is that it can take a long time to take them down. For a single company like us, it is difficult to get a platform to take down a counterfeiter’s site. That’s why we teamed up with Convey,” he reports. “They have established connections with all the major platforms and this gives them considerable influence.” Italian-based Convey is an internet brand protection agency that hunts down fakes. The internet is probably the cornerstone of the counterfeit industry, so Convey has a dedicated team of engineers to develop new products to detect counterfeiters, alongside multi-lingual experts in international property rights. Once a counterfeiter has been tracked down, Convey take the appropriate action to defend its clients’ brands. While China leads the world in the manufacture and sales of counterfeit products, the irony is that some Chinese manufacturers are turning to the resources of companies like Convey to protect their own products. “Throughout the world there are a great many platforms which make it easy to set up an online shop,” says Michele Provera, vice-president IPR Protection Convey SRL. “In the pumps and valves industries there are the manufacturers who make counterfeit products and traders who sell counterfeit products. Many of these traders sell any number of pump and valve brands and not all customers are end-users. Thus the counterfeit sales chain is complex. The internet provides counterfeiters with a world-wide market and anonymity. Then there are spare parts, where the number of units purchased can run into thousands.” Provera continues: “In our first year
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
PUMPS of working with KSB we concentrated on manufacturers selling in China and South East Asia as they are the starting off point in the trade. It is very difficult to shut down the manufacturers, but we can take steps to reduce and shutdown their sales over the internet. We have sophisticated technologies called ‘crawlers’ designed in-house that can analyse hundreds of thousands of web pages on the internet each day. We are able to detect all the shops selling KSB products and we can see the products that they are selling, the prices, suppliers and where they have come from.” KSB recognises that counterfeiting has been a problem for a long time, but identifying rogue sellers has been difficult and taking them down is time consuming and involves considerable resources. With the expansion of the internet and growth in counterfeiters setting up websites, the incidents of counterfeiting have a higher visibility so it is possible to take them down more effectively. However, as soon as KSB takes a site down which has been selling counterfeit products, the site re-emerges, often selling competitors’ products. Convey has been checking twenty online trading platforms and eight social media channels for KSB to root out counterfeits. In future, patent and design rights are to be added to the monitoring of brand and trademark rights. It is also possible that the number of trading platforms to be checked will be increased and the project further expanded globally. “KSB has a great many registered trademarks and patent rights so we can see if the products being offered are registered,” says Provera. “If they are not then we can instigate enforcement procedures to take the offending websites down. The seller receives a warning and if they fail to respond we alert their service provider to the violation of intellectual property rights via their network. This involves issuing Take Down notices to the website hosting providers informing them of infringements, for they are legally obliged to cease transmission in such instances. If they do not take action, then they become liable to prosecution by KSB. This approach is very effective. Most sellers remove their offers after the first warning.” Many websites operate a penalty points system, so when a first notice of infringement is issued they will be served a penalty point. If they ignore this, a second penalty is issued and again if this is ignored then the site is shut down with immediate effect. Within the pumps
and valves industry, it is highly probable that the trader is selling any number of manufacturers’ brands, so by shutting down the website the trader loses its entire portfolio of products. This approach is more effective than instigating legal procedures which are expensive, complicated and take a long time – giving the seller a chance to move their trade elsewhere or continue under a new name. Convey makes sure an offer is taken off the internet within days and that the seller is removed from the market place. The China connection In China, arresting the people behind the counterfeits is one of the central elements of the work with KSB. It is not enough to merely delete a counterfeiter’s offer. The goal must be to shut down this shop on the respective trading platform and ensure through constant checks that the trader does not open a new shop. This requires close cooperation between the parties involved. Due to the excellent contacts between Convey and the platform provider Alibaba and their IP complaint systems, these infringements of law can be quickly eliminated. This is also in Alibaba’s interest since the company does not wish to find these infringements of law in the wider Chinese e-shopping marketplace either. According to Michele Provera, those responsible at Alibaba want to ensure that Western companies have secure access and are able to examine the associated legal bases. Convey takes care of that for KSB as its team includes law enforcement specialists who are qualified in trademark and patent law
and speak Mandarin Chinese fluently. In close cooperation with its subsidiary in Shanghai and local lawyers, KSB takes legal action against serious violations of law. Summary The pump industry is probably one of the most exposed to counterfeiting worth many billions of dollars. For KSB, and for a great many other companies, the major problem is what happens when a company buys what it believes to be a genuine product and it turns out to be a fake. The failure of a pump or valve can have very serious consequences, so should such a situation arise then the user will usually take issue with the manufacturer. Problems can also arise when a counterfeit component is fitted as a replacement in a genuine KSB pump and then causes damage to the pump. Investigating claims for compensation can be complex and costly, with the onus on the manufacturer. Some courts will argue that it is not sufficient to prove that the product is a counterfeit, and demand proof that the manufacturer has taken action against the counterfeiter. If it can be shown that efforts were not undertaken then the manufacturer can be charged with negligence. What KSB is doing by working with Convey is to show that it is taking all possible steps to eliminate counterfeiters internationally and protect its patents and trademarks. z Reference
VDMA Product Working Group on Product and Know-How Protection. www.protect-ing.de
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For more information:
This article was written by Bryan Orchard, a freelance journalist. Contact: bryan@bryanorchardpr.co.uk Visit: www.ksb.com
The KSB Etanorm pump series is an international best seller, but has been the subject of counterfeiting
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017 19
PUMPS
Innovations in safety for chemical transfer Getting the best AODD pump for handling hazardous materials
Two steps forward, one step back. That’s what it feels like to run an operation with a leaky pump. Leaky pumps inevitably lead to unscheduled downtime and increased maintenance needs. This stalls productivity and costs the average company hundreds of thousands of dollars per hour of downtime. Now add hazardous chemicals into the equation. Aggressive acids and slurries can cause pumps to leak much faster, and they create an unsafe work environment. While these chemicals are necessary for the production of pharmaceuticals, printing inks, steel production, ceramic finishing and more, they are also a huge liability. Selecting and maintaining the proper equipment to control hazardous materials is crucial to the long-term success of a business, but it isn’t easy. With so many different pump designs on the market, end-users are having a tough time distinguishing between the pumps that will cost them and the pumps that will save them.
Sodium hypo transfer
means that end-users must select their pump carefully. The crucial factors of the AODD chemical pump selection process are chemical containment capabilities, corrosion resistance, and icing prevention.
AODD chemical pumps Air-operated double diaphragm chemical pumps (AODD) offer many benefits to manufacturers who require the use of hazardous materials. Most other pump designs rely on mechanical seals for chemical containment, which are known to be prone to chemical erosion and leaking. AODD chemical pump designs eliminate the need for mechanical seals by using bolts to secure the pump together and create an effective seal. In addition, the AODD pump’s diaphragms move in gentle cycles to minimise turbulence and protect the liquid from shearing. In many instances, these chemicals can be as fragile as they are hazardous, and any mild turbulence can alter their chemical properties, wasting the material and 20
Leaky AODD chemical pumps
Graco’s family of ChemSafe pumps
costing money. Lastly, because AODD pumps are powered by compressed air rather than electric motors, they can dry run and deadhead without the risk of burning, seizing, or harming internal components. The problem with AODD chemical pumps is that their designs can vary in quality and effectiveness, which
Safety is the primary concern when moving dangerous chemicals. Chemicals must be properly contained in order to fulfill their intended purpose without harming employees. This requires a pump with a leak-free design. Unfortunately, even some of the best AODD pumps struggle with leaks over the course of the pump’s lifespan. Although leaking may seem natural or unavoidable, costs of employee injury and wasted materials are too great to ignore. A few design features stand above the rest to address certain factors that lead to leaking. In the case of plastic AODD pumps,
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
PUMPS leaking is often a result of cold flow and creep, which are caused by high temperatures, amount of time under load, and level of torqueing stress. While metal pumps are rarely damaged by loads at low temperatures, plastic pumps can be damaged by continuous loads at fluctuating temperatures, which is termed, “cold flow.” As temperature increases, the effects of cold flow on a plastic AODD pump escalate. Cold flow causes deformation of the plastic pump over time, causing its components to release against compression points and begin to leak. Creep refers to the total deformation of the pump beyond the immediate strain of loading and can cause significant leakage. PTFE is one of the most chemically compatible materials for resisting corrosion, which would make it a desirable pump material if not for its susceptibility to cold flow. PTFE is so susceptible to cold flow because it tries to escape the load as it gets warmer. UHMWPE is second to PTFE in terms of chemical compatibility, but it is similarly susceptible to cold flow leaking, although at a lower rate. In addition, the violent forces of operation and continuous loading can eventually loosen the AODD chemical pump’s bolts and create leak paths. End-users are recommended to re-torque bolts regularly. Some AODD pump designs require even further leak prevention steps, such as the use of reinforcing metallic plates in an attempt to evenly distribute the load from the housing bolts. While these quick fixes may work in the short term, constant checkups and reinforcements are far from ideal when controlling hazardous fluids in a fast-paced work environment. Solution to creep and cold flow A proven solution for leak prevention is a machined body reinforced with a dual force, tie-bolt design. Overall, machined housing components are an essential feature to provide a precision fit that will distribute the load evenly and greatly reduce leaking. With this design, components made with PTFE and UHMWPE, which are highly susceptible to creep and cold flow, are held securely by
tie-bolts that are resistant to the effects of cold flow and violent forces. This allows the pump design to make use of these chemically compatible materials without allowing leakage due to cold flow.
maintenance needs. One possible feature of an AODD pump for icing resistant air systems includes parallel pilot shifting valves. This stall-free design reduces icing and maintenance needs while keeping production moving.
Corrosion resistance Summary Pumps that have exposed metal or wet parts composed of metal are highly vulnerable to corrosion. Therefore, AODD chemical pumps designed with metal-free exteriors will be more durable in corrosive environments. Similarly, interior corrosion can be prevented using PTFE and UHMWPE fluid paths to ensure chemical compatibility. This means that the entire
Several visual clues can indicate whether it is time to replace an old or deteriorated pump with current technology. These include a corroded pump exterior, leaks around the manifolds, worn internal fluid bowls, and discolouration on the floor caused by severe leakage. Premature deterioration can be prevented by
With so many different pump designs on the market, end-users are having a tough time distinguishing between the pumps that will cost them and the pumps that will save them fluid path – from entering the inlet, passing the first check ball, leaving the fluid chamber through the second ball, and finally exiting the outlet of the pump – is either PTFE or UHMWPE, so there is no need to worry about incompatible chemicals eating away the pump’s interior. Air motor icing stalls production Because AODD pumps are operated by compressed air, they are subject to rapid changes in temperature. The air is very hot when it’s compressed and cools rapidly as it expands. Air motors operate compressed air at about 20 to 180 psi (1.4 to 12.4 bar) and exhaust air at atmospheric pressure, approximately 14.7 psi (1.0 bar). This is an extremely high percentage of pressure decrease occurring in a short time span. Since the exhaust air will be below freezing temperatures when it exits, moisture in the air freezes and crystallises inside the air valves. This buildup of ice can cause the air valves to stall, creating unplanned downtime and increased
carefully selecting the best quality pump for operational needs. A dual force, tie-bolt design and precision machined components offer a leakfree precision fit for effective chemical containment and safe operations. Wherever harmful chemicals are present, business owners must be mindful of the proper safety precautions and continue to educate themselves on current trends for chemical handling. z
For more information:
This article was written by Michael Sandlin, Global Product marketing manager, Graco. Visit: www.graco.com
Chemical transfer applications demand maximum performance and superior chemical containment. Graco ChemSafe pumps feature 100% PTFE and UHMWPE fluid paths and are chemically safe. You can use these pumps with a variety of materials, plus they deliver unmatched chemical compatibility with challenging corrosive acids and destructive slurries. The precision-machined body features a tie-bolt design that ensures reliable sealing surfaces free of leaking.
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017 21
Keep your pumps flowing
PUMPS
Maintaining your dewatering pumps goes a long way
Submersible dewatering pumps have one clear goal – to move water, whether it’s to another location for reuse or to simply remove water from a low-lying area. For the most part they require minimal maintenance. Before you set and forget your submersible dewatering pumps though, there are some preventative maintenance practices you should follow to keep them operating day in and day out so productivity keeps flowing in the right direction. Some of the most important practices start long before your submersible pumps hit the jobsite. A pump that sizes up
Double mechanical seals provide a consistent, water-tight seal and play an important role in protecting the pump’s internal components
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Electric submersible pumps are the most commonly used pumps for dewatering construction sites. They are small and lightweight and when it comes to maintaining the pumps, choosing the right one for the application is one of the biggest decisions you’ll make. Using a pump that isn’t sized for the application can lead to issues down the road, like a broken shaft, dislodged seal or thrown impeller, any of which will mean costly downtime. To avoid this, there are three things to consider: the material you are pumping, how far you need to pump it and the elevation to which it will be pumped. If the pump is moving materials like sand, gravel or clay, rather than just water, you’ll need a model that is rated for that application and is equipped with impellers made of a durable material, like cast iron. Other materials, like polyurethane, can handle water, but abrasive materials can cause them to wear out quickly. Electric submersible pumps rated for these applications can typically move materials as large as 1 inch in diameter with minimal wear to components. From there you will want to confirm the pump can move water as far as you need it to go. Generally, the further the pump
is from the water site, the greater the gallons per minute (gpm) it will need to move the water to or from that location. If the water has to move uphill, the pump will also need more head capacity. In other words, how high the pump can raise water. Electric submersible pumps operate with as much as 5,300 gpm and can pump water as high as 275 feet (84m). Outputs can be as wide as 10 inches in diameter for even greater flow capacities. Get immersed in the details Once you’ve determined the right size, make sure the pump is built with durable materials and has features that will withstand long run times and the harsh conditions of construction applications. The pump’s wear plates and seals play an important role in that since they help protect the internal components. Choose pumps with double mechanical seals, which provide a consistent, watertight interface. Some manufacturers offer stainless steel seals, which last longer than rubber seals and are more durable, making them great for use on jobsites. Also, look for mechanisms that stop the unit if it overheats or the electric current overloads the pump. On most models the pump will automatically restart after it has cooled. This helps protect the motor from damage and extends the life of the pump. If your pump will be unattended, consider installing a float that automatically shuts the pump off when the water level becomes too low, then restarts it as the level rises. This prevents damage to the seal and premature motor failure. In addition to pump components that keep damage from occurring, there are others that make maintenance faster and easier on the jobsite. For example, some pumps offer access to their interiors with the removal of just three bolts rather than up to several more on other
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
PUMPS
WEDA+ pumps feature a unique sealing that system makes it possible to carry out maintenance on site
models. Some pumps also don’t require users to remove additional components, like the seal, to access the interior. For even faster maintenance on the jobsite, many manufacturers offer a complete replacement package that includes a seal, shaft and impeller and everything users need to install them. Also consider where you can get parts and how long you might have to wait for them. Now you’re ready to get things moving, but once you have your pump in place, don’t forget to pay it a visit once in a while. A little goes a long way While every piece of equipment with moving parts needs regular, preventative maintenance, it’s particularly important for equipment used in rugged applications like dewatering construction sites. Electric submersible pumps have three main wear parts: the impeller, seal and shaft. A drop of preventative maintenance goes a long way with all of them.
Choose a pump that’s sized for the application and is rated for the type of material it will be pumping. This will help reduce costly downtime
Since the seal is one of the most critical parts of a pump, it’s important to check the seal oil as often as once a week in heavy-use applications and refill it as needed. This will ensure the seal remains properly lubricated and watertight. Inspecting hoses and cables for damage should be on your weekly checklist too, especially if they are exposed to the elements or in areas where traffic could cause damage. Typically, a damaged pump hose is easy to spot as you’ll see water flowing from the hose. A damaged cord, on the other hand, might not be as noticeable, and if left unrepaired could be a danger to personnel or short the motor. If your pumps will be in use for extended periods, you’ll also want to take them out of service about every four months to thoroughly inspect internal components like the impeller and shaft. Damage to these areas can allow water to leak into the pump and damage components. This is also a good opportunity to change the seal oil as it can become thick and gummy over time
and cause the pump to burn out. Don’t forget to shut down the power supply before performing any maintenance to eliminate the risk of injuries. Finally, keep a backup pump on hand to keep water flowing if your pump needs maintenance or when you take it out of service. Go with the flow The longevity and performance of your pump all trickles down from the preventative maintenance practices you perform. From the time you purchase a pump to the last day it’s on site, a clear preventative maintenance plan will keep water moving and productivity flowing in the right direction. z
For more information:
This article was written by Joe Moser, pump product manager, Atlas Copco Construction Equipment. Visit: www.atlascopco.com
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017 23
VALVES
Ten considerations for better gate valve operation Reliable gate valve operation isn’t dependent solely on the product itself. In fact, it’s more accurate to say that reliability is the product of sound utility operations Valves are arguably the most critical components of a water system. They are necessary for supplying water for residential and commercial use, allowing operators to control flow, isolate sections of pipeline systems for maintenance and repair, or to isolate pressure zones. They may seem simple, but valves come in all shapes and sizes, containing complex components tailored for different uses. Of all the various types, gate valves are the most common within water distribution systems – and perhaps the most important. Certainly, they must work when called upon. AWWA (American Water Works Association) describes their basic operation, which utilities know well: “The gate, disc, or wedge of the valve is raised and lowered by a threaded operating stem, which is operated by a handwheel or valve key. When fully open, gate valves provide almost unrestricted flow because the gates are pulled fully up into the bonnet.” Utilities also know that gate valves improperly selected, installed, or maintained are prone to failure, which can have significant health, cost, and convenience repercussions for both the utility and the public. Fortunately, future issues can be avoided if the following considerations are made during the decision-making/ specification process and while installing and maintaining your gate valves. The tips were provided by a trio of valve experts – John Petito, PE and associate VP with AECOM, along with Virgil Diaz and Mark 24
Snyder, district engineers with Mueller Co. These considerations are applicable for metal-seated gate valves adhering to AWWA Standard C500, as well as resilient wedge (RW) gate valves adhering to C509 (cast iron/ductile iron) or C515 (ductile iron). They are classified in linear
fashion to denote tasks recommended before, during, and after installation. Before installation 1. Create a robust spec Start by having a robust specification (or “performance spec”) that covers epoxy linings and coatings, stainless steel fasteners, grade of rubber, type of seals (e.g., flat gaskets or O-rings), torque requirements, gear ratio, etc. Be specific not just on AWWA Standards, but also on NSF/FM/UL certifications and approvals to ensure quality materials in accordance with your specific application and unique conditions such as corrosive soil or high- temperature water. This will make sure that you don’t end up with an inferior product, which Diaz warns ‘will come back to bite you’. “The only thing you can really do is invest up front by putting together a solid specification. If you can’t shut down your system with minimal interference to your customer base because you have a poor product in the ground, then you probably didn’t invest the appropriate amount of time on your spec,” he said. “If you’ve got a four-page spec, chances are you spent some time developing that. The
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
VALVES There is often natural sediment in the pipeline, however, that is unavoidable. If the debris accumulates in the bottom and solidifies, it will create an obstruction in the travel of the wedge of the valve and make it harder to operate, requiring more torque and causing the actuators to break. To make sure the debris doesn’t solidify, exercise your valves on a regular cycle. [see #8].
guy who has half a paragraph is going to get a bottom-of-the-line product and will probably see that once buried valve again in the very near future.”
not even of the required specifications, quality, or brand,” Diaz warns. “The inspectors need to be very educated and know what they’re looking at.”
2. Guard against corrosion Defend your gate valve against corrosion and debris by specifying not only an NSFapproved epoxy system, but thickness as well. Whether via liquid or fusionbonded epoxy (FBE), the interior coating should conform to AWWA C550, while the industry standard for exterior coating (not governed by C550) is 8 to 12 mils. Quality components should also be specified to keep out debris. Debris leads to corrosion, which ultimately leads to galling or binding – when you can barely move the valve, or even not at all. “Providing proper stem covers, dirt seals (also known as wiper rings), O-rings, and gaskets are the most important issues to help keep out debris,” says AECOM’s Petito.
During installation
3. Verify that manufacturer documentation matches your spec Having worked to make the perfect spec, be sure that the documentation for the gate valve matches your specifications prior to its installation. It is often overlooked or taken for granted that the right product is onsite. “Your inspection team is really your last line of defense. If you have no one there to receive it, the contractor could be installing something that’s
4. Favour vertical installation over horizontal “Gate valve installation in the vertical [stem] position is always preferred,” advises Petito. “Provision for efficient and easy manual operation of the valves is also critical.” Installing on a horizontal line with the stem and wedge vertical, especially for larger valves, allows gravity to do some of the work. Mueller Co.’s Snyder acknowledges, “You cannot always do that, if you don’t have the clearance due to the depth of the water main. You’ve got to lay them over (horizontally) sometimes.” 5. Avoid internal pipeline debris Sediment and debris can be naturally occurring within a pipeline, but the advice here is to ensure that no outside debris is allowed into the pipeline during installation or repair of the valve by municipal staff or contractors. There are even instances, conveyed by the Mueller Co. district engineers, where kids might throw rocks into an open pipeline. Proper oversight and careful execution are the keys to keeping foreign debris – rocks, dirt, etc. – from getting into the pipeline.
6. Consider a larger size valve box, valve can riser, or concrete vault It’s very simple upon installation, but using a larger size valve box concrete vault for access to the stem – 9” instead of 6”, for example – can save considerable time, effort, and money later by allowing you to do stem change outs without excavation. “Especially if you’re in the middle of some street with heavy traffic, the last thing you want to do is have a backhoe, traffic control, and shutdowns to fix a problem. But if you can do it through the valve box, it’s a much faster fix if you just think ahead,” explains Diaz. 7. Open left/open right? Some gate valves open left and some open right. Ideally, all the gate valves in a distribution system will open the same way, but at minimum you want to know which ones might be backward (i.e., opposite the majority). During installation, note the colour of the operating nut; a red nut indicates that the valve opens to the right, while a black nut indicates that it opens to the left. After Installation 8. Cycle once per year (at a minimum) Valve cycling is exercise for your valves – the practice of opening and closing each valve to not only verify operation, but to ensure that they remain running smoothly by clearing out debris. Once per year is acceptable, and twice per year even better, but short-staffed operations may find any cycling programme difficult to schedule. Some utilities may, therefore, outsource the task to contractors. AWWA M44 Distribution Valves is the go-to field manual, offering “updated information on valve selection and installation, as well as the importance of location, condition, and frequency of operation,” according to AWWA’s description.
If you’ve fixed a similar problem on six out of 30 valves, that’s a pretty good indication that the standards need to be changed FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017 25
VALVES 9. Document all issues If you’ve been burned by a bad valve or a bad spec, make sure it ends there by documenting issues discovered during cycling, then updating the current spec to meet the new standard needed for success. If a valve fails, note the year of the valve, the manufacturer, the type of failure, etc. “If you’ve fixed a similar problem on six out of 30 valves, that’s a pretty good indication that the standards need to be changed,” Diaz related hypothetically. At specification review, leverage that knowledge and consult your documentation to uncover the underlying issues and create a better spec; don’t just “kick the can” down the road. 10. Make valve box adjustments as necessary Oftentimes the fault of paving crews, but something municipalities should venture to avoid and correct, is a situation where the water utility is forced to break through blacktop to reach the valve box because it was paved over. The valve box needs to be raised
to grade for continued accessibility – typically a contractor requirement per the repaving contract. However, oversights (or attempts to save money) by the contractor do happen, and it behooves the utility and municipality to have an inspector on-site to ensure that valve boxes don’t get buried in asphalt. With continuous diligence – before,
during, and after installation, aided by these ten recommendations – utilities can all but guarantee reliable gate valve operations when called upon. z For more information:
This article was provided by Deron Austin, senior director of Marketing for Mueller Water Products. Visit: www.muellercompany.com
Have you done your homework? Research gives you a clear advantage over your competitors. You can get the very latest information on new plants, projects, innovations and legislative updates all from one source… www.biofuels-news.com Get an A* and get online today.
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FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
A single solution for shutdown valve failures
VALVES
Benefits of automated safety instrumented systems that meet IEC 61508, IEC 61511 and ISA 84.01 standards Employing best practices and complying with international industry standards simply are not enough to prevent incidents within plants that can cause serious injury, loss of life, damage to facilities and equipment, or consequences to the environment. Why is this so? Despite rigorous risk assessments and SIL analyses in accordance with International Electrotechnical Commission (IEC) I61508 and IEC 61511 Safety Instrumented System standards, emergency shutdown valve (ESDV) failures continue to occur at a high rate and are often attributed to systematic failures. Data from the Health & Safety Executive based in the UK (see Figure 1) reveal that 44% of failures in safety shutdown control systems are due to insufficient specification. Studies such as this have resulted in the development of new safety instrumented system standards ISA84.01/IEC61511 and IEC61508.
rather than prescriptive and involve multiple components from various manufacturers that are assembled into a system by third-party integrators. Adopted and documented in 1998, IEC 61508, Functional Safety of Electrical/ Electronic/Programmable Electronic (E/E/PE) Safety-Related Systems, defines functional safety as “part of the overall safety relating to the EUC (Equipment Under Control) and the EUC control system that depends on the correct functioning of the E/E/PE safety-related systems, other technology safety-related systems and external risk reduction facilities.” IEC 61508 covers the entire safety life cycle. IEC 61511, “Functional Safety – Safety Instrumented Systems for the Process Industry Sector,” outlines best practices in the engineering of Safety Instrumented Systems. (See www.iec.ch for more information.) The first version of IEC 61511
84.01 (ISA 84.01) gives requirements for the specification, design, installation, operation and maintenance of a safety instrumented system, so that it can be confidently entrusted to place and/ or maintain the process in a safe state. This standard has been developed as a process sector implementation of IEC 61508 (see www.isa.org for more information). Limitations of these standards IEC 65108, IEC 65115 and ISA 84.01 establish a performance or goal-setting approach that allows the user to select an appropriate performance target for an SIS function and, thus, design the system accordingly to achieve that level of performance or safety integrated level (SIL) rating. These standards do not provide a set of rules that define in detail how an SIS should be designed. Instead, the standards lay out a framework that allows each individual user, designer, and owner to determine what is appropriate for their specific situation. This performance-based approach, however, does not provide guidelines defining the engineering processes required to design and integrate the automated emergency shutdown valve nor is it addressed in the Safety Lifecycle Model found in IEC. This has resulted in diverse approaches to engineering and designing the final element often leading to overdesign and decreased reliability. SIS purpose
Figure 1: Data from Health & Safety Executive found that 44% of safety shutdown control systems are due to insufficient specifications
Best practices and IEC standards do not address many types of systematic failures. Here are some reasons: IEC 61508 is component-oriented and focuses on validating component reliability while IEC 61511 is process-orientated. Typical solutions have been performance-based
was released in 2003, and the United States version was approved in 2004. In 2015, the United States Chemical Safety Board suggested additional reforms were needed to ensure compliance with process safety standards such as IEC 61508 and 61511. International Standards Association
An SIS prevents or reduces hazardous events by taking the process to a safe state when predetermined conditions are violated. An SIS typically includes the design and implementation of a variety of shutdown and/or blowdown valves. Key components of an SIS include: • Sensors or initiators that detect process conditions; • Logic solver that processes an
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017 27
VALVES input from the sensors to an output to the final elements; and, • Final elements that perform corrective actions by bringing the process to a safe state. An emergency shutdown valve (ESDV) is the SIS final element. The valve/actuation package (also known as the SIS final control element) is the weakest link in the safety instrumented function (SIF), contributing greater than 50% of total probability of failure on demand (PFD) for an SIF. The reliability, safety, and design of the final element has a significant impact on the overall risk reduction factor.
Figure 2: According to the ARC Advisory Group, valve and valve actuation packages are the weakest link in the safety instrumented function, making the reliability of the final elements crucial to risk reduction
Benefits to end users End users around the world typically want to achieve the same results – improvements focused on reducing capital expenses and operational expenses, increasing safety and reliability, and minimising environmental impact. Plant owners and operators can derive extensive benefits from implementing a complete, sole source original equipment manufacturer (OEM) solution that harmonises the IEC 61508, IEC 61511 and
ISA 84.01 standards through control over the engineering, design, and manufacture of the entire emergency shutdown valve package. A comprehensive approach such as this has been available from Emerson Automation Solutions for more than ten years. Emerson Automation Solutions has a proven track record for improving ESDV reliability within refineries, chemical and petrochemical facilities, and power generation plants in virtually every region of the world. As a sole
source provider, Emerson’s final element solution is optimised to boost efficiency and increase operating margins, while also mitigating risks and reducing disruption to processes and production. z
For more information:
This article was written by Shawn Statham, Global Business development director, Emerson Automation Solutions Visit: www.emerson.com
Don’t miss your chance to appear in the January/February 2018 issue of Fluid Handling International For editorial suggestions contact: Daryl Worthington, daryl@woodcotemedia.com, +44 (0) 208 687 4146 For advertising information and prices contact: Fraser Owen, Tel: +44 (0)208 648 7092, fraser@fluidhandlingmag.com Next issue features include: Oil industry focus in conjunction with StocExpo 2018 Spotlight on North America A close look at seals and leak detection
Advertising deadline: 24th January 2018 28
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
TECHNOLOGY
Lots of data – a single language Standard formats for data communication simplify logistics between petroleum companies About ten years ago, a group of pioneers in the German petroleum industry embarked on an important mission: they began collaborating on the development of IFLEXX, an open standard format for exchanging data within the downstream industry. Nowadays, in a world dominated by big data and tightly linked supply chains, standardised data communication has become missioncritical. Fluid Handling International spoke to Kay-Peter Buhtz, Implico’s managing partner and the co-founder of IFLEXX. Mr. Buhtz, why is standardised data communication so important in today’s downstream industry? Business structures in the industry have changed. In the past, the major oil companies had larger stocks of their own products and did not exchange products with each other so often. More recently, however, they have reduced their inventory levels and bartering transactions have taken on a more important role. There are also many more players in the market – such as, for example, independent tank storage companies
and large trading companies with no service station networks of their own. What is more, we are living in a fastpaced world in which standards are higher. In some companies, monthend closing is supposed to have been completed three days after the end of the month; and dispatchers need to know in real time which filling service stations the driver has delivered to. Typing out lists manually or sending delivery notes via fax is no longer acceptable. As companies become increasingly integrated, proprietary data formats are growing obsolete: companies can only process the data they receive from their business partners quickly and accurately if they all share a common standard. How long have you been involved with the subject of standardised data communication? Since the late 1980s. Back then, we introduced the first MPKS (Mineral oilPartner Communication System) standard in Germany in collaboration with a number of large oil companies. Unfortunately, it no longer complies with currents standards and does not meet today’s needs. For this reason, about ten years ago, we got together around a table with the most important players – petroleum, software and consulting companies – and started working on the new IFLEXX standard, which stands for International File Exchange XML. At around the same time, there was an organisation in America called PIDX, which had also standardised the old data
formats. When the PIDX organisation expanded in the direction of Europe, a modern PIDX format was needed. At this time, we had already gained a lot of experience with IFLEXX, so we made our standard available, and that is why IFLEXX and PIDX are now virtually compatible. Which parties in the downstream industry exchange data with each other? All the companies in the supply chain. That means the refineries or the tank terminal operators where the goods are collected and the results passed on. It also means the customers who collect the goods. Then there are the forwarding agents who deal with the transportation and who need to import the data into their scheduling systems. In some cases, the authorities are also involved, especially when oil or gas is being shipped free of duties or taxes, or when it is being moved across national borders (EMCS). And what data is involved? Mainly logistics data, that is, order and loading data. The PIDX standard supports the “planned movements” process for order data, which involves customers placing their order electronically with the tank terminal or refinery. The data is then stored directly in the IT system. The loading terminal therefore knows which customer wants to collect what quantity of which product during a specific time window. Both IFLEXX and PIDX support the BOL standard for providing information about the loaded quantities. The actual loaded
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TECHNOLOGY quantities, which can often deviate slightly from the planned quantities, are transferred from the IT system of the tank terminal or refinery to that of the business partner. The bill of lading description contains the various units of measure, the product, the place of loading, the vehicle and all reference numbers. A third area of application is transferring loading data to on-board computers in the tank trucks. This enables the dispatcher, for example, to know what quantity of fuel is being shipped to a service station. After making the delivery, the driver can enter the actual delivery quantities and conclude the process. Ideally, the electronic measuring equipment in the vehicle transmits the delivery quantities directly to the on-truck computer.
specific field. IFLEXX and PIDX are different. Firstly, each field has a clear description of its contents, and secondly, you can write as much in the fields as you like. There are also many more fields available; so IFLEXX can transmit much more information and in greater detail. MPKS was only developed to handle loading results, and really only for the tank truck business. IFLEXX, on the other hand, supports all modes of transport, including ships, pipelines and railcars, and supports not only physical stock removal from terminals and refineries but also the storage and transfer of stock – in other
Are companies under any obligation to introduce the new standards? No, there is no legal obligation to do so. But when two partners sign a contract, the use of a standardised data communication format is often taken for granted. Many companies no longer have the manpower needed to record and verify data manually. They also don’t like to wait several days after the end of the month before issuing invoices. In view of demands currently being placed on logistics, modern data communication is indispensable. Kay-Peter Buhtz, managing partner of Implico
How widely used are IFLEXX and PIDX in the marketplace? The industry is currently going through some dramatic changes. Many companies are still working with outdated standards. In Germany, for example, all the major oil companies have stated quite clearly that they intend to replace the old MPKS with modern communication standards. Some have already implemented projects aimed at replacing MPKS; some are busy working on it and others are about to do so. We have seen a surge of activity over the past two years, which will probably be maintained for the next two years. I am confident that MPKS will be replaced almost entirely by 2020. What benefits does the new standard have to offer? The old MPKS system used a data format with fixed-length records, whereas IFLEXX and PIDX, being based on XML, are much more flexible. The fields in MKPS had a fixed character length, which was limiting. You also needed a template – or the relevant technical knowledge – to identify what information was contained in any 30
words, all types of goods movements. MPKS was designed to transfer data once a day. IFLEXX transmits data as often as necessary – up to once every second. It can also send data in two different directions: to the tank truck’s on-board computer and to the business partner’s accounting system, such as SAP or Oracle, for example. The XML files may be exchanged in different ways depending on user requirements: by e-mail, by SFTP (Secured File Transfer Protocol) or as a web service. How difficult a task is it to introduce IFLEXX or PIDX? The process is neither painful nor particularly time-consuming. It is a perfectly normal IT project. The challenge, however, is that no petroleum company can compel all of its customers to switch at the same time. Clearing houses – companies that take responsibility for the conversion for a certain period – offer a possible solution. A tank terminal could then carry on sending its loading data in the normal format, and the clearing house would
convert the data into an IFLEXX or PIDX format and send it to the oil company. Although this does not increase the level of detail, the data arrives in a modern, XML-based format. This provides the basis for conversion at a later date. Which ERP systems can work with the modern data formats? IFLEXX and PIDX are independent of the ERP solution. For example, many companies use SAP systems, which offer “connectors” that enable integration into the system. But we also have experience with customers who use Oracle-based installations such as the JD Edwards system. These are also increasingly using XMLbased message data. There are even companies with their own very exotic ERP solutions – and even they support XML-based data communication. XML is a neutral format that allows anyone to share data – which is what makes it the ideal basis for a standard. How is the standard being developed? The IFLEXX community has been meeting regularly for almost ten years to discuss how to further standardise data communication. The IFLEXX community in Germany now comprises 17 companies, including refinery operators, tank terminal operators and IT service providers. At the meetings, the companies suggest, discuss and often adopt enhancements to the IFLEXX standard. The fact that the most important market players regularly gather around the same table ensures that we remain fully aware of the needs of the industry. What is the IFLEXX community currently working on? At IFLEXX meetings we always come up with new ideas. We have already standardised the most important thing, which is the description of the volume movements exchanged between partners. The next thing we would like to do is to standardise the permitted attributes, such as loading points and product names, so that everyone knows and uses the same product code for, say, diesel. We will carry on collaborating with the industry to further develop the standard and to open it up to new fields of application. z
For more information:
Kay-Peter Buhtz is a managing partner of Implico and co-founder of IFLEXX. Visit: www.implico.com
FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
A smooth path to drive coupling selection
COUPLINGS
Engineers and designers can often face a daunting task when it comes to specifying the most appropriate drive coupling for the task in hand Drive couplings vary greatly in their design and capabilities, so for any given application engineers must ensure that they specify the drive coupling correctly to ensure reliable, efficient, and in the more challenging applications, safe operation. A detailed review of what the coupling will be subjected to in use is an essential starting point. Factors such as torque transmission, speed ranges, running start/ stops and potential shock loadings are just some of the key elements in the selection of the coupling. However, engineers must also consider alignment between the various components, the environmental operating conditions that could include high temperatures or moisture etc., and any maintenance requirements or restrictions. There may also be potential limitations on available space, size and/ or weight, which will have to be taken into account. The prime mover, diesel or gas engine, hydraulic or electric motor will also be influential in the specification and selection of the drive coupling. Get it right, and the coupling will provide
Torsionally flexible claw coupling, fail safe design
years of uninterrupted service, requiring little or no maintenance in its own right while ensuring that mating components are protected from undue stresses and downtime is kept to a minimum. Torsionally stiff flange couplings for pump drives
Common mistakes can be costly There are a number of common mistakes which result in the wrong coupling being specified. This can have serious consequences both for the coupling and the other elements in the drive train. Often, it does not take long before these issues rise to the attention of maintenance engineers in the form of a catastrophic failure of the coupling and hours of unplanned downtime. Other less visible effects will be undue wear on bearings, shafts and gears, which will ultimately impact motors or gearboxes. Before making a final decision on selecting the drive coupling the specifier must fully evaluate and understand the forces and loads that will be applied to the coupling in use. Making an “educated guess� at these values is not an option and could result in either a coupling being specified which is not fully up to the job, or design overkill, which would result in an unnecessarily larger and more expensive solution to the application. The specific application will dictate whether the coupling required is a disc coupling, shaft to shaft coupling, auxiliary coupling or other variant, however, it is essential that consideration is given to factors such as the torque rating and torsional stiffness required for the task. Generally, couplings with a higher torque rating will be larger and less flexible. In addition, the degree of axial, radial or angular misalignment that the coupling will be required to compensate for will influence choice, and it is essential that the coupling to be used is able to meet these criteria, but has the capacity to accommodate a level of unexpected deflection while in service without failing.
Another contributing factor, which will influence success, is how the coupling is mounted. In applications where there are minimal shock or reversing loads, keyways and taper bushes will be a reliable solution. For applications where there may be high shock loads it could be preferable to avoid a keyway solution and instead opt for a taper bush fixing, or couplings with shrunk discs, which will also provide backlash free operation. From a maintenance perspective, the time required to remove or replace a coupling or any change parts is a major consideration. Therefore, the selection of a coupling which not only meets all of the technical and application requirements, but is either maintenance free, or has the ability to have change parts replaced in-situ will bring significant benefits to uptimes and efficiency. If there is any doubt on the part of the individual responsible for specifying and selecting the coupling, seeking expert advice from the manufacturer will both eliminate risks and ensure longevity and reliability in operation. With a history spanning more than 70 years, Reich Kupplungen has built up unrivalled expertise in the design and manufacture of drive couplings for use across a wide range of industries and applications. The company also embraces a D2C (design to customer) principle, which allows the creation of customised high-quality and long-lasting products in collaboration with the customer and their specific requirements. z For more information:
This article was written by David Proud, general manager of Reich Drive Systems UK. Visit: www.reich-uk.com
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OPINION
Brexit and the pump industry
As Britain prepares to leave the European Community, Shaun Hampson, managing director of Flowserve SIHI and chairman of the BPMA (British Pump Manufacturer Association) Marketing Committee, encourages pump sector engagement to meet the challenges and opportunities
Shaun Hampson, managing director of Flowserve and chairman of the BPMA
At the moment nobody really knows for sure what Brexit means for the UK, but it is our time to come together to capture the opportunities while managing the threats, through unified lobbying of government. A vast amount of UK legislation contains references to EU treaties, and the government will be seeking to stabilise UK law and regulations as fast as possible. These regulations, laws and directives contain material which can directly tip the buoyancy of the UK’s pump industry. Basic practises like CE Marking and Declaration of Conformity, for example, will need to be reviewed for inclusion into UK legislation. Other legal directives which we all take for granted may also be reviewed with respect to Import & Export Compliance, movement of employed staff, transfer of machinery, cash pooling, trade-barrier taxation, and hundreds more. How many companies have non-UK EU citizens working in critical roles within their businesses – will they decide to go home, and why? What about the paperwork needed to import a simple gasket from France? Let’s not even discuss the implications with exotic alloys and PTFE which have dual use. On the flip-side, there are ‘once-ina-lifetime’ opportunities which could outstrip the threats, with examples being a wider global market, boosted domestic manufacturing and production, elevated skills and talent pools, plus of course good old fashion British innovation and motivation. Much of these will be the product of
apprenticeship schemes and easy access to technically-driven education. Hedging the threats and capturing the opportunities however, is heavily dependent upon the eventual deal agreed between the British government’s single seated negotiator and a twentyseven strong seated opposition. At what point will the pumping industry be discussed - before or after the automotive, banking, and military sectors? Will it ever get any specific consideration? Now is our time to find the common thread among the UK pump industry and its front-line supply chain. It is vital that we fight to preserve beneficial laws, eradicate other bureaucratic nonsense, and forge strong apprenticeship schemes. Right now – at the still relatively early stages BPMA is working for the good of the pump industry through member and non-member engagement. The aim of the BPMA is to construct an agenda of “go” and “no-go” aspects of forthcoming legislation, while demanding the re-balance of skills, and ultimately voicing our unified position loudly with all appropriate governmental bodies. Not many pump companies will escape some form of change to their business model after Brexit has finally matured. If you have unanswered questions about future legislation, and would like be included within the BPMA escalation discussions, you are encouraged to engage with the BPMA in the not-too-distant future. Recently, the BPMA has been collecting thoughts and prescriptions from its membership through a simple questionnaire. This is a critical path to ensure that we cover every angle on this topic without leaving any business – small or large – exposed and all alone. If you are a member and have not completed this short assessment, please give it the benefit of your team’s vast experience. Non-members, who understand that this subject will affect their company, and/or distributor network, should contact Steve Schofield – director of the BPMA at s.schofield@bpma.org.uk. By doing this, we can all work together to guard against threats and identify opportunities for the collective good of all pump companies, internationally. z For more information:
This article was written by Shaun Hempson, managing director of Flowserve SIHI and chairman of the BPMA Marketing Committee. Visit: www.bpma.org.uk
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FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017
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FLUID HANDLING INTERNATIONAL l NOVEMBER/DECEMBER 2017