HELPING TO KEEP YOUR BUSINESS FLOWING
Issue 5 Volume 5
SEPTEMBER/OCTOBER 2017
Petrochemicals, millennials and automation How the industry is changing
Building a smarter future
Water technology’s vital role in cleaner, greener, cheaper living
COMMENT & CONTENTS
Contents September/October 2017 ISSUE 5 • 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 £150 (approximately $240/€185 depending on daily exchange rates). Individual back issues can be purchased at a cost of £30 each Contact: Lisa Lee Tel: +44 (0)20 8687 4160 Fax: +44 (0)20 8687 4130 marketing@woodcotemedia.com
Join Fluid Handling International on Linkedin to discuss important issues Follow us on Twitter: @FluidHandIntl No part of this publication may be reproduced or stored in any form by any mechanical, electronic, photocopying, recording or other means without the prior written consent of the publisher. Whilst the information and articles in Fluid Handling are published in good faith and every effort is made to check accuracy, readers should verify facts and statements direct with official sources before acting on them as the publisher can accept no responsibility in this respect. Any opinions expressed in this magazine should not be construed as those of the publisher.
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Latest news
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Petrochemicals, millennials and automation A major energy sector recruiter discusses the changes facing the petrochemicals workforce
12
Chemical resistance How an algae biofuel producer in Portugal beat the erosion and corrosion chemicals can cause to impellers
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Brexit’s implications for chemicals regulation The implications of Brexit on the regulatory framework in which the UK chemical sector operates
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Reducing the variables For a manufacturer of membrane materials, producing consistent quality meant finding a pumping solution which worked reliably with a host of different chemicals
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Building a smarter future How smart technology is driving smarter living
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WEFTEC preview The water industry heads to Chicago
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A modern alternative A new, clean and safe way to lift raw effluents through direct-in-line pumping with no wet well
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Taking the stress out of piping design The benefits of more advanced rubber joint arrangements
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Arresting the danger of flames in plant piping An in-depth look at regulations and best practice for flame arresters in plant piping
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Sealing the standards for LNG Developing a new generation of seat-to-body seals for cryogenic trunnion mounted ball valves to exceed LNG industry leakage rate standards
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A positive choice for multiphase fluids Progressing cavity pumps for pumping multiphase fluids in oil
HELPING TO KEEP YOUR BUSINESS FLOWING
Issue 5 Volume 5
SEPTEMBER/OCTOBER 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
Petrochemicals, millennials and automation How the industry is changing
Building a smarter future
Water technology’s vital role in cleaner, greener, cheaper living FC_FH_sept-oct_2017.indd 1
15/09/2017 13:07
Comment Dear reader, “Automation has been heralded as the biggest change to the workplace since the Industrial Revolution,” Janette Marx, COO of energy sector recruiter Airswift, says in an interview on page 10 of this issue of Fluid Handling International. “Maybe that’s so, maybe that’s a touch of hyperbole.” Exaggeration or not, it’s undeniable that industries involved in fluid handling are having to adapt if they’re to seize opportunities in a world that is constantly changing. A fact made clear by the UK Chemical Industries Association’s discussion on the implications of Brexit for the UK chemical industry, on page 15. This need to adapt also means finding solutions for new applications. As part of our petrochemicals and chemicals industry focus, we learn on page 12 how a Portuguese company producing cutting-edge algae biofuels, seen by many as the next stage of renewable energy, turned to composite materials specialist Belzona to protect machinery from corrosive chemical reactions. These changes and challenges are not limited to chemical handling. On page 18, water specialist Xylem explains how water pumps, perhaps the most traditional example of fluid handling technology, will play a vital role in developing the “smart” buildings of the future. For engineers and specialists, keeping abreast of changing standards and regulations is of course just as important as keeping on-top of the latest technological developments. On page 26, an expert from KITO gives a thorough run-down of the latest regulations and best practices when it comes to flame arresters in plant piping, while page 28 sees SaintGobain share their innovative work in developing seals that exceed industry leakage rate standards. Those involved in fluid handling might not be experiencing a second Industrial Revolution, but the need to provide solutions to cutting-edge industries, adjust to a changing world and meet stringent regulations means they have to cope with constant evolution. If there are any topics you’d like to see covered in a future issue of Fluid Handling, or any industries or innovations you feel we need to pay attention to, please feel free to contact me at daryl@woodcotemedia.com Best wishes, Daryl
ISSN 2399-5602 1
PUMP NEWS
North American diaphragm pumps market energised by demand for AODD
The North American double diaphragm pumps market is undergoing a resurgence, according to new research from Frost & Sullivan. In recent years the market has endured subdued growth, a consequence of low oil prices and a “sluggish” North American economy. However, a “robust” need for air operated double diaphragm pumps (AODD) and metering pumps in the water and chemical industries, as well as greater investment in infrastructure development, are stimulating the market, according to the Frost & Sullivan report. “Growth will be augmented by strong sales of diaphragm pumps in the oil and gas, food and beverage, power generation, and pharmaceutical sectors,” claims a statement from Frost & Sullivan. “Original equipment manufacturers (OEMs) and suppliers will need to expand channel, distribution, and partnership initiatives, and consider acquisitions to
drive product line expansion, customer base and market share in a competitive and fragmented ecosystem.” The strength of the market combined with new regulations will have a significant effect on the pump manufacturing industry. “Demand for energy-efficient pumps, catalysed by new government mandates and regulations, will result in the development of advanced pumps with smart, electronic features that will also enable better system integration,” said Frost & Sullivan Industrial Automation & Process Control Research Analyst Shilpa Mathur Ramachandran. “Investment in constant innovation is imperative to diaphragm pump manufacturers’ success as the convergence of automation with the process equipment industry looms large.” A number of trends are highlighted by the report. Significantly, it’s suggested that in the short term Canada will
Armstrong’s new pumps hit ‘highest’ standard for motors
Armstrong Fluid Technology has announced that its recently released Design Envelope Generation 5 Pumps meet the IE5 efficiency standard for motors. This includes Armstrong’s Design Envelope Tango parallel pumps and Design Envelope Vertical In-line pumps up to 10hp. IE5 is the highest efficiency standard currently available for motors on the market. Armstrong’s Design Envelope pumps were already operating well above established North American efficiency standards. The new Generation 5 iECM motor technology means the pumps now also meet the more stringent IE5 standard for European markets. “Design Envelope Generation 5 pumps with iECMTM motor technology deliver both the lowest installed cost and unmatched efficiency over the operating life of the pump,” said Neil Cooper, Armstrong’s director of Global Sales Enablement. “Meeting the IE5 efficiency standard represents a 20% reduction in motor energy losses from IE4.” Armstrong Fluid Technology has more than 1000 employees worldwide, working in seven manufacturing facilities on three continents. The company is a specialist in designing, engineering and manufacturing intelligent fluid flow equipment, including HVAC, fire safety and plumbing technology. z 2
dominate the diaphragm pumps market in North America thanks to the country’s focus on infrastructure development. After 2019 however, that dominance will begin to decline. International competition will also start to have a greater effect on US manufacturers. “Low-cost competition from European and Asian pump manufacturers is likely to affect North American pump sales and lead to a gradual, yet definite, reduction in local manufacturing and sales business,” noted Ramachandran. “To beat competition on this front, local companies must provide competitive pricing, improve operational efficiency and longevity of pumps, and invest in technological advancements and research and development.” The report, titled ‘North American Diaphragm Pumps Market, Forecast to 2022’, is available now from Frost & Sullivan. z
Atlas Copco adds high flow models to dewatering pump portfolio
Atlas Copco Portable Energy has “vastly expanded” its dewatering pumps range with the launch of over thirty heavy-duty, high-capacity pumps. Among the new additions are three high-flow models to the PAS range of centrifugal dry prime pumps, capable of accommodating flows of up to 1400 cubic metres an hour. “Since acquiring Varisco we’ve established a consistent presence in the dewatering market,” said Wim Moors, vice-president of the Pump division at Atlas Copco Portable Energy. “The new single brand portfolio provides our customers with the best choice and widest flexibility when selecting a high-quality for their application.” For the dewatering pump market, Atlas Copco is offering wet and dry prime centrifugal pumps for construction, drainage and emergency applications, as well as specialised models for well point applications and pumping abrasive liquids and bentonite mud. Included in Atlas Copco’s new offerings is a piston positive displacement pump especially designed to run dry without damaging internal components. According to Atlas Copco, it is ideally suited to well point applications where the volume and depth of water is low. z
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
PUMP NEWS
Atlantic gets new European pump distributor
Netherlands-based Bakker & Co. has joined Atlantic Pump’s list of European distributors. The company, which has offices in both the Netherlands and Belgium, will distribute Atlantic’s SlurryPro and Audex pumps. Mark Attride, Atlantic Pumps European business development manager, said: “Bakker & Co are a long established distributor based in Zwijndrecht in the Netherlands. They supply and offer service for various types of pumps and process equipment, and have added SlurryPro and Audex from Atlantic Pumps to enhance their offering for slurries and abrasive applications. Bakker & Co also have an office in Belgium. Bakker & Co will be offering SlurryPro and Audex pumps and spares to existing and new customers in the Netherlands, Belgium and Luxembourg.” Bakker & Co provides equipment for a host of different industries. The company’s range includes precision tubes, measuring equipment, industrial high pressure cleaning, meteorology and climate equipment and elevator technology. UK-headquartered Atlantic Pumps specialises in industrial dewatering pumps and pumps for handling abrasive applications. The company uses a number of pump distributors in Europe, including Öko Tect Kft in Hungary, Romania and Slovakia; Pump Expert in Poland; and Cramix in Spain and Portugal. z
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Rotork receives big actuator order
Rotork will supply 220 of its pneumatic actuators to the NASR Phase II Full Field Project in the UAE. Awarded by Hyundai Heavy Industries, the order includes spring-return pneumatic actuators to operate 30” and 36” class 1500 ball valves. Specifications state that the maximum actuator output torque at a design pressure of 9.4 bar should not be in excess of 90% of the valves’ maximum allowable stem torque (MAST). The huge force required to compress the spring means the above requirements are actually beyond the performance limits of the standard range of Rotork GP pneumatic actuators. This pushed Rotork’s R & D department to create an innovative solution. “Rotork engineers added a second pneumatic cylinder, mounted between the GP scotch yoke centre body and the spring-return cylinder,” according to a statement from the company. “Both cylinders are pressurised in the same direction at the same time, so one delivers torque for valve movement, satisfying the valve MAST requirement, whilst the other independently applies the torque to compress the spring.” The subsequent actuator is the largest GP350 actuator built so far, with a total length of 8.5 metres and a weight of 19 tonnes. The NASR Phase II Full Field Development project aims to increase the oilfield’s production capacity from 22,000 barrels per had (BPD) up to 65,000 BPD. z
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
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VALVE NEWS
Schubert & Salzer opens ‘hands-on’ valve training centre Schubert & Salzer Control Systems has announced the opening of a new training centre at its premises in Ingolstadt, Germany, aimed at new customers and current users of the company’s products. At the heart of the building is a fully functional valve test bench. Here, customers, partners, plant designers and end users from around the world will have the opportunity to expand their knowledge of modern valve technology. The centre offers training courses for the entire range of Schubert & Salzer’s valve technology. Water is employed as a test medium in the new facility. The system uses four highperformance centrifugal pumps which deliver high-pressure water through the pipes to the test components. The centre is also equipped with a pressure regulator system, which demonstrates how different pressure regulators from Schubert & Salzer function. z
Yokogawa acquires TechInvent2 as it presses ahead with oil and gas push US electrical engineering firm Yokogawa Electric Corporation has announced the acquisition of TechInvent2, a Norwegian enterprise that holds the rights to FluidCom, a chemical injection metering valve (CIMV). According to Yokogawa, FluidCom prevents blockages and corrosion in oil wells, pipelines, and other facilities and employs a patented technology for thermal control. It incorporates the functions of a mass flowmeter, control valve, and valve controller and has very few moving parts. FluidCom has already been delivered to several international oil and gas majors. With TechInvent2 joining the Yokogawa Group, Yokogawa will now target delivery of this solution to the oil and gas upstream and midstream sectors,
thereby helping to improve operational efficiency, reduce operational costs, and enhance HSE (health, safety and the environment) performance. In a statement, Yokogawa said: “Based on its Transformation 2017 mid-term business plan, Yokogawa will continue to focus on the oil and gas industries, and will strive to strengthen its solutions targeting the upstream and midstream sectors, in addition to its forte downstream sector businesses. “Following its April 2016 acquisition of KBC Advanced Technologies, a provider of consulting services that are based on its own advanced oil and gas simulation technologies, the company has been striving to work with its customers to create value through the provision of solutions that address every aspect of their business activities.” z
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Visit thematic hotspots such as the Industrial User Experience, Smart Water Networks Pavilion and Desalination Pavilion. Review the latest developments and innovations in the InnovationLAB and the BlueTech Research Innovation Pavilion.
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FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
VALVE NEWS
Bonomi unveils new floating ball valves
Italian manufacturer Bonomi has announced the expansion of its Valpres ball valve range with the introduction of API 608 Floating Ball Valves. API 608 is a standard which exceeds the requirements set by ASME B16.34, meaning the ball valves can comfortably handle the rigorous requirements of the petrochemical, power, oil and gas and water treatment markets. The new Floating Ball Valves incorporate increased thickness and an oversized driving train which, according to Bonomi, makes them well suited to demanding environments and particularly reliable in actuation applications. Bonomi’s API 608 are built with a fire safe design which meets the API 607, ISO 10497 and API 6FA standards.
RPTFE seats and FKM seals are fitted as standard to the valves, while additional optional features include on-off/modulating and a comprehensive range of additional seat and seal material options. Bonomi’s API 608 Floating Ball Valves are available in a range of sizes from ½” to 6” Class 150 and ½” to 4” Class 300 and 600, reduced bore is also an option in sizes of 2” or above. Various extensions are also an option, including an extended stem, extended bonnet for high temperatures and extended bonnet for low temperatures. Soft or metal seats are also available. The valves are side entry constructed with a two piece bolted body. They operate in a temperature range of -196°C to 420°C. z
The better alternative
NEMO® progressing cavity pumps for the paint and coatings industry Even today, NETZSCH is bringing the future into your factories: NEMO® progressing cavity pumps as a better alternative to air-operated diaphragm pumps. greater cost-effectiveness through low energy demand increased production capacity through large pumping quantities better product protection through low-pulsation conveyance lower noise emissions through the elimination of compressors improved flexibility through integration into existing pipeline system Our application specialists will be happy to advise and assist you.
KSB launches butterfly for long distance water transport To round off its existing range of butterfly valves, the KSB Group has launched the new Aporis doubleoffset butterfly valve with elastomer sealing element. This product is designed for situations where huge volumes of water need to be transported and shut off reliably. Applications include systems for water transport, water treatment
or in large industrial cooling circuits. The valve is available with the face-to-face lengths specified in the EN 558/ISO 5752, Series 14 standard, and in nominal sizes DN 300 to DN 2000. The maximum permissible operating pressure is 16 bar. The standard fluid temperature should range between 0 and 85 °C. z
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
NETZSCH Pumpen & Systeme GmbH Business Field Chemical and Pulp & Paper Tel.: +49 8638 63-1020 info.nps@netzsch.com www.netzsch.com
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FLOWMETER NEWS
New multiphase flow facility will have world’s largest test range Construction has begun on NEL’s new, £16 million (€17.7 million) Centre of Excellence (CoE) for subsea development. According to NEL, a specialist in flow measurement research and development, its new high pressure multiphase flow test facility will have the largest test range in the world. NEL’s new facility is being built to allow a greater understanding of the impact of higher operating pressures on measurement equipment in extreme subsea environments. The testing range on the new facility includes single phase, multiphase and dry gas, at operating pressures up to 150 bar – double current capabilities – to replicate subsea
production conditions. The range and combination of operating pressures, temperatures, flowrates and metrology in the CoE will be unique worldwide, claims NEL. “The investment in the CoE marks a significantly positive step for the global oil and gas sector, which has faced increasing challenges over recent years,” said Brian Millington, NEL’s managing director. “This new world-leading facility will support the industry to address the crucial goal of maximising economic recovery and reducing fiscal uncertainty. Once complete, NEL will be operating the only facility to offer the full range of flow rates and high pressure capabilities.” z
A drawing of the inside of NEL’s new Centre of Excellence
Bürkert unveils new flowmeter
Fluid control systems specialist Bürkert has launched a new flowmeter for the food, beverage, pharmaceutical and cosmetics industries. The flowmeter, called FLOWave, operates according to the patented SAW process (Surface Acoustic Waves), which uses surface waves to perform measurements. According to the company, the primary advantage of this process is that there are no installed fittings or constrictions, which also means there are no empty spaces in the measurement tube. In addition, measurements are performed without any contact between the sensor elements and the medium; the liquid neither affects the sensor elements nor can the sensors contaminate the medium. In a statement, Bürkert said: “This is not only hygienic, but also simplifies the cleaning process (hygienic design). The fact that the measuring tube is identical to every other straight tube section in the system in fluidic terms it also avoids pressure drops. Furthermore, installation is extremely straightforward thanks to the compact size and low weight of the device. “FLOWave consumes much less energy than Coriolis flowmeters, for example, and can be mounted in any installation position. Measurements can be taken in standing liquids in fast-flowing liquids or in liquid flows that change direction. In addition, no maintenance work is required, which can significantly reduce the operating costs.” z
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OTHER NEWS
A fluid cooling system that doesn’t need electricity Stanford University researchers have demonstrated that a unique system can cool flowing fluid to a temperature below that of the surrounding air, without using electricity. “This research builds on our previous work with radiative sky cooling but takes it to the next level. It provides for the first time a high-fidelity technology demonstration of how you can use radiative sky cooling to passively cool a fluid and, in doing so, connect it with cooling systems to save electricity,” said Aaswath Raman, a scientist involved in the research. Radiative sky cooling is the natural process that everything and everyone does as molecules release heat. An obvious example of this is the heat that comes off a road as it cools after the sun goes down. “If you have something that is very cold - like space - and you can dissipate heat into it, then you can do cooling without any electricity or work. The heat just flows,” explained Shanhui Fan, senior author of the paper published in Nature Energy detailing the research. “For this reason, the amount of heat flow off the Earth that goes to the universe is enormous.” The main obstruction to radiative sky cooling is hot weather, where sunlight will warm faster than radiative sky cooling can cool. Fan and colleagues overcame this problem with their multilayer optical film which reflects about 97% of sunlight while simultaneously being able to emit a surface’s thermal energy through the atmosphere.
The material can enable cooling below air temperature, even on a sunny day. “With this technology, we’re no longer limited by what the air temperature is, we’re limited by something much colder: the sky and space,” said Goldstein, co-lead author of the paper. For their latest research, the team created a system where panels covered in the specialised optical surfaces sat atop pipes of running water. The test was performed on top of the Packard Building in 2015. With the water moving at a relatively fast rate, the team found that the 2-foot-long panels were able to consistently reduce the temperature 3-5 degrees below ambient air temperature over a period of three days. Data from the Stanford experiment was applied to a simulation where their panels covered the roof and contributed to the heating system of a two-story commercial office building in Las Vegas - a hot, dry location where the team believed their panels would be most effective. It was revealed that in the summer months the panel cooled system would save 14.3 megawatt hours of electricity – a 21% reduction in energy used to cool the building compared to a conventional air-cooled chiller. Electricity savings fluctuated from 18% to 50% across the entire period. Fan, Raman and colleagues have now founded the company SkyCool Systems to further test and commercialise their panel technology. z
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FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
OTHER NEWS
Trelleborg supplies ‘world’s largest’ offshore facility Trelleborg has supplied a suite of products from its marine systems operation to Shell’s Prelude FLNG facility, the largest offshore facility ever constructed. 488 metres long, 74 metres wide and constructed with more than 260,000 tons of steel, Shell’s Prelude will extract and liquefy natural gas from a site in NorthWest Australia. Trelleborg is supplying the facility with its gas transfer technology and SafePilot navigational and pilot systems. “We’re delighted that our SafePilot solution, SSL, ESL and radio ESD for tandem condensate offload have been used on Shell’s Prelude FLNG,” said Richard Hepworth, president of Trelleborg’s marine systems operation. “The products supplied fall under our SmartPort product range: they
represent industry leading technology that enables real time communications and information sharing during vessel approach and the LNG, LPG and Natural Gas Condensate transfer operations.” To support Prelude’s process operations, Trelleborg has supplied its Ship Shore Link (SSL) system for the transfer of LNG from the platform to visiting LNGC’s. For this, a full shore SSL shore system was supplied. In addition, Trelleborg also provided their Electrical Shutdown Link (ESL), known more commonly as the SIGTTO link, for liquefied petroleum gas (LPG) transfer, and a new radio ESD link developed with Shell and used in conjunction with floating hoses for the tandem transfer of natural gas condensate produced as part of the LNG production process. z
ABB launches new laser level transmitter ABB has bolstered its level measurement portfolio with the addition of the LLT100 laser level transmitter. According to a statement from the SwedishSwiss corporation, the LLT100 can “measure the level of any material, solid or liquid, in any condition”. The new product has been specifically designed for industrial applications and harsh environments. It can precisely measure any solid or liquid surface, including clear liquids from 40° to +60°C (–40 to +140°F), or up to 280°C (535°F) with a cooling tube. ABB’s LLT100 offers a resolution of 5mm,
an accuracy of ±20 mm and an eye-safe, Class 1 laser beam with a divergence of less than 0.35°m meaning it can be used in low visibility conditions. Its range spans from 0.5 to 30m for liquids, 0.5 to 100m for solids and 0.5m to 200m for positioning applications with a reflective target. Encased in an IP67/NEMA 4X explosion proof class 1/division 1 (zone 1) enclosure, the new laser level transmitter can be used in applications including mining, aggregates, oil and gas, chemicals, food and beverages, power, pulp and paper, pharmaceuticals and water and wastewater. z
Microsoft and Halliburton team up to transform the oil and gas industry Technology giants Microsoft and Halliburton have announced plans to enter into a strategic alliance to drive digital transformation across the oil and gas industry. “Halliburton is focused on delivering intelligent cloud solutions to drive the next generation of efficient oil and gas exploration and production,” said Jason Zander, corporate vice president of Microsoft Azure. “We are excited to bring the power of Azure’s hyperscale, hybrid and
global cloud platform technologies to this alliance to enhance the value chain for our mutual customers.” Through the collaboration, the companies will be able to apply voice and image recognition, video processing and AR/virtual reality to create a digital representation of a physical asset using Microsft’s HoloLens and Surface devices. Additionally, Microsoft and Halliburton will utilise digital representation for oil wells and pumps at the IoT edge using the Landmark Field Appliance V2 and Azure Stack. z
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
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PETROCHEMICALS
Petrochemicals, millennials and automation A major energy sector recruiter discusses the changes facing the petrochemicals workforce
Fluid Handling International spoke with Janette Marx, COO at Airswift, a global workforce solutions provider for the energy, process and infrastructure sectors, about how the workplace is changing for engineers in the petrochemicals sector. Airswift is currently carrying out surveys for the Global Energy Talent Index (GETI), the “world’s largest” recruitment and employment trends report. Can you introduce yourself to our readers, what is the GETI and what are its aims? I am Janette Marx, CEO at Airswift. I have been with the company for more than three years now and prior to Airswift, I held various leadership roles with Adecco over a 19-year period. The Global Energy Talent Index (GETI) is the world’s largest energy recruitment and employment trends report. The survey covers oil and gas, renewables, nuclear, power and petrochemicals, and aims to draw an understanding of the changing nature of the energy workforce. The 2018 report will take a deep-dive into the rise of automated technology and its potential impact on the future of energy workplaces. What were some of the trends uncovered in 2017’s survey? What’s changing for engineers and plant managers in the energy sector? Perhaps the most interesting finding from last year’s survey was the significant difference in expectations between hiring managers and candidates in the energy sector. We found that candidates are much more optimistic than hiring managers, with more than half of the workforce predicting an increase in salaries over the next 18 months – compared to just 23% of those hiring. This is something we will be keeping an eye on over the coming years.
Janette Marx, COO at Airswift
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A focus of the 2018 survey is automation. Is this the biggest change facing those currently working in the energy sector? Automation has been heralded as the biggest change to the workplace since the Industrial Revolution. Maybe that’s so; maybe that’s a touch of hyperbole. What is true though is that technologies such as data analytics, artificial intelligence and robotics are set to transform working practices forever. And some of these changes are already being seen in the energy sector. Automation is most useful in repeatable, programmable tasks, and tasks which
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
PETROCHEMICALS pose risks to humans – this is common in the industry. This is where the industry stands to gain immensely – in terms of personnel safety. There are thousands of high-risk tasks where human intervention can be eliminated. And what’s more, this could lead to $300 billion (€252 billion) in annual savings, according to the McKinsey Global Institute. Although we are seeing an increase in automation in the sector, it is probably not the threat everyone believes it is. Companies still need humans to work with the technology that is being automated and there is still a lot to be said for human intuition and logic. A machine may be able to handle a repeatable task according to a programmed routine better than a human, but when something goes wrong and it requires thinking on the fly, humans still have the upper hand. It’s more often specific tasks rather than entire jobs that are automated. Robots need a human touch. Are there any trends that distinguish petrochemicals from other sectors? Two-thirds of petrochemical professionals surveyed for the 2017 GETI report expected salaries to rise in the next 12 months, compared to just one in five hiring managers. This is a big disconnect and more than other sectors are showing. This could also be driven by the increased demand of talent in the petrochemical industry. How have the demands on petrochemical engineers and plant managers changed in the last 20 years? The engineering role has evolved over the past 20 years. In that evolution, the engineer is able to use different tools, research methods, speed in communication and the ability to work across disciplines and locations in a more efficient way. The demands on engineers and plant managers have continued to and will continue to evolve, change and increase as technology is enhanced and priorities tied to the business operations change. What are the current employment trends in petrochemicals? Is the industry in good health? Are their enough qualified workers? GETI 2017 revealed a significant skills shortage with two in three hiring managers agreeing that the petrochemicals sector is experiencing a lack of new talent coming through. Bringing in talent from other
related industries may be the answer, with three-quarters of hiring managers actually thinking the sector would benefit from this. The industry will need to continue to do more to attract and retain key positions to remain in good health. A number of recent reports have noted that industries connected to fossil fuels are having to deal with an aging workforce. In addition, they’re struggling to recruit ‘millennials’ who see industries connected to fossil fuels in a negative light. How are Airswift, and employers, approaching this challenge? While the hydrocarbon industries offer competitive salaries, millennials expect more from the workplace. Factors such as company culture, flexible working and the opportunity to work with cutting-edge technology are high on millennials’ agendas. Furthermore, the changing nature of the sector means it is now competing with the likes of Google or Amazon to attract tech talent. To attract and retain this new and different type of worker, companies are finding that they need to change their approach to talent acquisition and rethink their culture. They are broadening their recruitment searches beyond the traditional business and engineering graduates; connecting with and having a presence in some of the top tech universities, technical training schools and employment hubs. The same for any third-party workforce solutions providers they engage. A more socially and environmentallyfriendly company culture could also be a draw to these new workers. Robust corporate and social responsibility programmes will become more important. Working culture changes such as flexible and remote working arrangements, are also more likely to be in demand and dress codes may need to be less corporate and more Silicon Valley. From our vantage point in the workforce solutions industry, we’re already seeing these trends take root in the sector. Get that right, and a company stands a good chance of succeeding in an automated world. Those that adapt too slowly risk being left behind. z
For more information:
Visit: www.airswift.com
A copy of the 2017 GETI Report is available here: www.getireport.com/download-report/
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
rmation : Additional Info e/en/camlock w w w.elaflex.d
CHEMICALS
Chemical resistance How an algae biofuel producer in Portugal beat the erosion and corrosion chemicals cause to impellers
Among the renewable energy sources available today, generating biofuels from algae is a relative newcomer to the industry but one that has grown exponentially. In fact, the algae products market is anticipated to only increase further, with projections indicating a potential $44.7 billion (€37.6 billion) valuation by 2023. Algae-based biofuels make up approximately a quarter of this estimate and point to the vast possibilities of this aquatic organism for the energy industry. Because of its simpler compound structure and suspension in nutrient-rich solutions, algae can multiply rapidly in comparison to other traditional biomass crops, such as corn. This means that it can be continually harvested, with typical growth cycles for aquatic algae ranging between one and ten days. Meanwhile, it also benefits from a higher yield potential versus these other forms of biomass (in some cases as high as 20 times more) and requires a smaller surface area for cultivation. This makes algae production both highly sustainable and increasingly attractive in terms of future development and investment.
caused by the fluid handling had resulted in severe metal loss on the impellers. The damage reached such an extent that the company required a complete overhaul of three damaged impellers after just one year in service. Polymeric solutions maintain green energy progress To minimise downtime and avoid future replacement costs, the bioengineering company were in search of an alternative solution to their pump troubles. As a result, they contacted Belzona’s Portuguese distributor, Belzona Portugal, with regards to using their cold-applied, polymeric materials for the repair and protection of pumps. Belzona Portugal had considerable experience in the restoration of process equipment and therefore suggested suitable solutions to repair and protect the impellers. These systems would be able to not only rebuild the metal loss, but also enhance the pump’s longevity against chemical attack and erosion-corrosion. Following confirmation, all three pump impellers were cleaned
The process and its potential problems In order to cultivate this form of biomass effectively, there are several different stages of the algae’s development. These include algal ponds, as well as photobioreactors, between which the nutrient-and carbon-enriched fluid is transferred and exposed to necessary sunlight. As the fluid is transferred between each area, it is prevented from settling by maintaining a highly turbulent flow within the reactor, using either a mechanical pump or an airlift pump. This turbulent flow can exacerbate issues such as erosion and corrosion damage which traditionally trouble pumps, in turn resulting in faster rates of metal deterioration. In addition, the algal biomass requires a contaminantfree environment, rid of any microbiological matter which could affect the algae’s growth or quality. Many producers will use high-strength chemicals to eliminate any unwanted growth, as well as chemical cleaning agents to disinfect the process equipment. When combined, this can take a significant toll on the lifespan of the equipment. Disruption to algae production This problem had significantly impacted Portuguese bioengineering company A4F (Algae for Future), which focuses on the production of algae for a variety of different purposes, including biomass and biofuel generation. In 2014, their production process was continually being affected by the need to replace damaged pump components. With the pumps being cleaned on a weekly basis, the frequency of harsh chemical contact and erosion-corrosion 12
Grit blasted impeller highlights the extent of the damage
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
CHEMICALS
Impeller rebuit and coated in 2014
Impeller in excellent condition after three years in service
With the pumps being cleaned on a weekly basis, the frequency of harsh chemical contact and erosion-corrosion caused by the fluid handling had resulted in severe metal loss on the impellers and grit blasted to achieve the correct surface profile. This revealed the extent of the metal loss, which had resulted in complete deformation of the impeller blades. Fortunately, this could be rebuilt to its former design using a combination of wire steel mesh and Belzona 1311 (Ceramic R-Metal), a pastegrade metal repair material. Once the shape was restored, the impellers were coated using Belzona 1321 (Ceramic S-Metal) to provide additional protection. Together these materials provide enhanced erosion-corrosion resistance versus the original metal while also providing outstanding chemical resistance to combat the aggressive cleaning agents.
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Three years in service In 2017, the pump impellers were revisited and found to still be in exceptional condition after three years of service. Compared to the short lifespan and excessive damage when unprotected, the Belzona coating had improved the longevity of the component significantly, much to the satisfaction of the client. Versus the alternative, which involved replacement of the impellers and the associated shutdown costs during this time, Belzona’s solution offered a significant improvement in terms of cost-efficiency and uptime. As an additional precaution, the customer requested a further application of the coating, simply to ensure the successful protection was continued. Due to the overwhelming success of these applications, Belzona has been chosen to coat four new impellers in 2017. z
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This article was written by Thomas Belli, marketing assistant at Belzona Polymerics. Visit: www.belzona.co.uk
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 13
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CHEMICALS
Brexit’s implications for chemicals regulation On 30 March 2019, the UK is scheduled to leave the European Union (EU). The Brexit decision may have a profound impact on the future of the UK chemical industry, a sector that provides the vital building blocks of many other sectors including automotive, aerospace and pharmaceuticals and is also its own biggest customer The implications of Brexit for the regulatory framework in which the UK chemical sector operates should not be underestimated. The UK government intends to repeal the European Communities Act 1972 and transfer EU into UK law through the “Repeal Bill”. The Bill, currently being discussed in Parliament, will convert directly applicable EU legislation into UK law on the day the UK leaves the EU. While transposing much of EU chemicals legislation to a UK regime is not expected to create difficulties, there are several EU regulations permitting businesses to trade in Europe, such as the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH), which present a challenge and where a straightforward transfer is not possible – a key message already raised by chemical businesses and many other major sectors heavily relying on chemical products for their business. The government recognises a proportion of a converted law like REACH will not function effectively once the UK has left the EU unless additional action is taken to correct it. To overcome this challenge the Repeal Bill will provide a power using secondary legislation to ensure the UK has in place the necessary corrections before the day it exits the EU. Such powers are expected to allow technical changes rather than deal with any substantive policy issues. With the Repeal Bill, UK businesses will still be subject to the same regulatory requirements on exit day in order to manufacture and import chemical products in the UK. While the government’s efforts to provide certainty, stability and limit disruption to businesses are welcomed, there are concerns about duplication of costs UK exporters in particular may
potentially face and the consequent impact on the competitiveness of the UK chemical sector. The chemical industry is looking for regulatory continuity and to minimise any additional regulatory costs associated with Brexit. Earlier this year, the Prime Minister announced in a speech the UK’s intention to leave the single market and not pursue full membership of the Customs Union. This will not only be an important aspect for issues such as movement of people or customs systems but also critical for chemical policy. In this context, we should not forget that REACH is a measure of the single market. An immediate and by far one of the major concerns for industry in terms of the chemicals regulation is the uncertain future for all existing compliance efforts that continue to permit ‘market access’ across the EU. The REACH Regulation requires an EU manufacturer or importer to register substances to a central EU agency - ECHA (European Chemicals Agency). Under the existing regime, UK businesses are recognised under REACH as an ‘EU manufacturer or importer’ and therefore comply with the REACH registration obligations and continue to access EU markets. The UK’s exit from the EU would mean that UK manufacturers and importers would no longer be recognised under REACH and become “non-EU manufacturers”, automatically bringing into question whether additional measures and investment is needed to continue accessing the EU market. UK businesses have already made some 6,355 registrations (second after Germany) to ECHA and this number is expected to increase as we move to the
final May 2018 registration deadline. The European Commission’s 2012 review estimated that the average cost of registration per substance is approximately €70,000, although in reality this is a conservative figure with some companies indicating registrations costs in excess of €400,000 per substance, per registration. The cost of a registration per substance is therefore significant and will inform long term investment decisions for chemical businesses. One big issue is the time it could take if, for instance, under a worst case scenario – businesses are left to re-register via an EU representative in order to access the EU market. Supply chain disruption can be anticipated both in the UK and EU if a timely solution is not in place by day one of Brexit. The recent UK government position on goods on the market developed in the context of Article 50 negotiations makes explicit reference to chemicals as an example where businesses should not be required to duplicate compliance activities. Taking into consideration that for the chemical sector 60% of exports go to the rest of the EU and 75% of imports come in from the EU, the on-going activities taking place to negotiate the UK’s exit terms from the EU as well as to develop the future UK legislative framework in the area of chemical policy are absolutely critical to the future success of the chemical sector and the many others in the supply chains that are supported by it. z
For more information:
This article was written by Silvia Segna, REACH Executive at the Chemical Industries Association. Visit: www.cia.org.uk
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 15
CHEMICALS
Reducing the variables For a manufacturer of membrane materials, producing consistent quality meant finding a pumping solution which worked reliably with a host of different chemicals
Eino Kuronen, Surfactor Finland, has 30 years’ experience at the Kitee manufacturing plant
16
Process challenges involve numerous variables. Surfactor, a manufacturer of membrane materials, is not alone in facing the challenges of ensuring process quality. The biggest challenge for the industry is to produce consistent quality, as raw materials and process conditions are not homogeneous. Surfactor Finland has been manufacturing coating films since 1983. The special coating films are based on amino and phenol and manufactured in the company’s Kitee plant by coating the paper with rosin. The membrane film that is produced is suitable for coating veneer and other types of plywood. Surfactor supplies these membrane films for various applications within the construction and vehicle industries, which demand products that are durable and consistent in terms of quality. “Due to the variations in the quality of the paper, resin and additives, as well as humidity, the process must be monitored continuously. The fewer variables there are in the process, the easier the work of the operator becomes. The operators can then focus on overall quality control instead of worrying about the performance of the auxiliaries,” explains Eino Kuronen, operations manager at Surfactor Finland. To help ensure accurate and reliable operations, Surfactor ordered
Surfactor Finland is part of Surfactor Germany, which has three manufacturing facilities in two countries. The group is continuously looking to introduce best practices and process improvements. The company’s plant in Kitee, Finland, produces 40 million square meters of membrane film a year. The Finnish plant’s turnover represents 25% of the Group’s total, and it employs 33 people. Flowrox LPPD dosing pumps are suitable for the most demanding process conditions and applications. The membrane film produced by Surfactor is widely used in the transport and construction industries. seven new pumps from Flowrox. The purchase decision was made after three months of testing the Flowrox LPP-D pump for pigment dosing. Hose pumps also for rosin dosing The successful trial period with the Flowrox LPP-D pumps for pigment dosing encouraged Surfactor to extend the application to resin dosing. The diaphragm pumps that Surfactor used previously were hindering the process by jamming. The thickness of the pigments in turn caused inconsistent and inaccurate pumping. “We were not satisfied with the diaphragm pumps that used compressed air. It was quite challenging to adjust the rotation speed of the dosing. With the new hose pumps the dosing is very accurate,” Kuronen confirms. It was also challenging to obtain new diaphragms for the compressed air pumps. “The new hose pumps are very easy to maintain, as the hoses need to be changed only twice a year and spare parts are readily available and nearby,” Kuronen adds. “Spare parts for our hose pumps are manufactured by Flowrox Lappeenranta, so they are always available off the shelf,” explains Matti Saloranta, Flowrox area sales manager. As a responsible manufacturer, Surfactor also keeps its own spare parts in stock, but motors are not kept on the shelf.
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
CHEMICALS “We really do appreciate the fact that the spare parts provider is nearby, so if something major happened, the spare parts can get to us fast,” Kuronen states.
Flowrox LPP-D dosing pumps are suitable for even the most demanding and abrasive processes and conditions
Hose materials essential for durability Flowrox has more than 40 years of experience in elastomer technology. When delivering a solution to the customer, each process and application is reviewed on a case-by-case basis and the customer is given a quotation for the most suitable solution with the optimal materials. For the feed of the removal substance, an NBR hose was recommended to Surfactor. The pigment used in the membrane manufacturer’s process is almost pure oil, so a nitrite hose was the best option. Flowrox used its process expertise to make the optimal selection for hose material based on the pigment and the application. Surfactor has successfully extended the application of its new pumps into different process areas. “When we began working with Flowrox we had some issues with the rotation pumps and the durability of
the hoses, but we were able to resolve the issues quickly and the equipment is working very well. Recently we have ordered a new pump for the feed of lye. I can recommend Flowrox products, as they have worked very well in our application and process,” Kuronen says. The focus on operational efficiency
and quality at Surfactor reflect a positive trend in the company. Surfactor’s main markets are in Finland, where there is strong demand for its products. z For more information:
This article was written by Inka Tuononen, marketing manager at Flowrox. Visit: www.flowrox.com
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FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 17
TECHNOLOGY
Building a smarter future How smart water technology is driving smarter living
Across the world, more and more of us are living in cities and urban areas. According to the United Nations, 66% of the world’s population will live in urban areas by 2050. Currently, around half of all urban dwellers live in cities with populations between 100,000 and 500,000 people, and almost 10% of urban dwellers live in megacities – a city with a population of more than 10 million. This growing trend towards urbanisation is advancing the development of ‘smart’ infrastructure. As unprecedented population growth increases pressure on the systems and structures that support social and economic progress, municipalities and private technology companies are seeking smarter, more efficient ways of supporting Twenty First Century living. Governments and private companies are looking at how cities and their buildings can be more sustainable and ecological. In fact, global smart building technology spending is forecast to grow from $6.3 billion (€5.3 billion) in 2014 to $17.4 billion (€14.6 billion) in 2019, registering a compound annual growth rate (CAGR) of 22.6%, according to a report by IDC Energy Insights. The report notes that the most aggressive adoption will be in Asia/Pacific, North America, and Western Europe. What is a smart building? The vast majority of buildings today rely on multiple, independent systems for light, heat and other daily essentials, with these systems operating as if in silos. This is at the expense of energy, building use and cost-effectiveness. A smart building, however, houses systems that are inter-related and operate in tandem with each other to not only increase efficiency and reduce operating costs, but also enhance safety, productivity and quality of life for those who work and live in it. Essentially, smart buildings enable facility optimisation through the convergence of information technology and building automation. Smart buildings have been found to help save up to 30% of water usage, 40% of energy usage and 18
Burj Khalifa: Xylem’s specially designed variable speed booster sets distribute 1000m3 of water per day to the top floor of the Burj Khalifa
to help reduce building maintenance costs by ten to 30%1. As advancements in smart building technology continue, buildings are no longer seen simply as physical structures but rather as being central to citizens’ quality of life. To give an example, the 13-story San Francisco Public Utilities Commission building features a hybrid solar and wind turbine that generates up to 227,000 kilowatt hours per year, which equates to approximately 7% of the building’s annual energy needs. The building also contains a raised flooring system that reduces the building’s heating, cooling and ventilation costs by 51%. Similarly, the Bullitt Center in Seattle has a reputation for being the ‘greenest commercial building in the world’, designed to have a 250-year, instead of the more usual 40-year, life span. Smart features include net zero energy, net zero water, net zero carbon, composting toilets, toxic-free materials, and over 80% day light using high-performance windows. Another award-winning smart building, The Edge, a commercial office building in Amsterdam, the Netherlands, boasts a smart LED lighting system which has more than 30,000 sensors connected to the building management system through the Internet of Things (IOT). The lighting system measures motion, light levels, infrared radiation and temperature, allowing it to
automatically adjust energy use. When a floor in the building is unoccupied at night, for example, all lights are automatically switched off and heating and cooling can be set to minimum. As a result, when there is zero occupancy in the building, there is next-to-zero energy use. During the day when the building is occupied, individual occupants can also view their sustainability data and control and personalise temperature and light settings through a smartphone app. The Edge uses about 70% less electricity than the average commercial office building. Looking specifically at water, at the Levi’s Stadium in Santa Clara, California all of the pumping systems are equipped with variable speed drive technology to ensure optimum efficiency in the water supply system. Across the world, the Burj Khalifa hotel in Dubai has adopted a fully integrated system which controls the water levels in the hotel’s tanks as well as controlling flow, pressure and temperature. Regulations What is driving this trend towards smarter living? New European Union (EU) regulations aimed at increasing energy efficiency, as well as a global construction sector characterised by heavy cost pressures, is driving a ‘smart evolution’ across the commercial buildings
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
TECHNOLOGY services industry. In addition, consumers are demanding higher standards of living where comfort and sustainability go hand in hand. As urbanisation continues, city managers are looking for ways of running their building stock in a way that is cost efficient, while supporting sustainable living. The global building segment is highly focused on reducing energy consumption and operational costs as they relate to systems in a facility – whether it’s plumbing or HVAC systems. The Energy Performance of Buildings Directive requires all new buildings to be almost zero-energy by the end of 2020 while the Energy Efficiency Directive (EED) obliges EU countries to set minimum energy performance requirements for new buildings while encouraging extensive renovation of buildings. Water technology has a central role to play in the smart building agenda. According to a study by Navigant Research, global investment in water management technologies and services is expected to grow from $2.0 billion in 2016 to $2.8 billion in 2025 as water management becomes more integrated into smart buildings.2 A 2005 study estimated annual electricity consumption from pumps as corresponding to 50 million tons of CO2 emissions. Without efficiency measures, consumption was projected to increase by 25% in 2020 – equating to almost 12 million cars driven for one year. Recent EU regulations have led to significant advancements in heating systems, specifically in pumps and drives. The Energy-related Products (ErP) Directive, for example, requires new levels of efficiency from commercial building equipment, including motors, pumps and heating, ventilation and air conditioning (HVAC) circulators. The increasing use of variable speed drives (VSD) in water-related applications has led to the introduction of new standards
defining different classes of efficiency for individual components such as the drive, motor and pump. The EU’s forthcoming Extended Product Approach (EPA) is another step forward and complements the smart buildings agenda. Efficiency is no longer viewed as the sum of the efficiency of single components; rather, a specific standard is provided to define the efficiency of the whole system – the collective efficiency of the drive, motor and pump. ‘Industry 4.0’ refers to a new era in pumping whereby every component of a pumping system will have its own internet protocol (IP) address and will be able to communicate, through embedded intelligence, with every other component of the system. The deployment of IOT technologies and Industry 4.0 will increase operational efficiency by nearly 45%, escalate return on investment for manufacturers and widen application scope, according to a 2015 report by Frost & Sullivan. Xylem’s new Lowara Smart Pump range is an example of water technology that is helping to drive smarter living. The new range is equipped with builtin ultra-premium efficiency IE5 motors to achieve optimal performance in water supply and HVAC applications for commercial buildings. The IE5 motor delivers the highest level of performance, exceeding current IE3 legislative requirements. Embedded electronic drives dramatically extend the working area of the pump to maximise flexibility
Xylem’s Lowara Smart Pump range is equipped with built-in ultra-premium efficiency IE5 permanent magnet motors to achieve optimal performance in water supply and HVAC applications for commercial buildings
and enhance system performance by up to 20% as the pump system adapts to the user needs in real time, ensuring optimum performance at all times. The drive also enables the size of the motor to be reduced, resulting in a more compact footprint that is suitable for small spaces. This latest smart pump technology is simple to install and suitable for new and retrofit installations, a new level of flexibility provided by the system’s sensorless algorithm for closed loop systems. Pumps can also be linked via a multi-pump controller without the need for an external control panel, providing even greater flexibility and durability. The range comes standard with BACnet and Modbus capability for seamless building management system integration in all stand-alone configurations. Water is a precious resource requiring careful management. Technologies like Xylem’s new Lowara Smart Pump range will enable the development of more smart buildings that support the sustainable use of water and ultimately, foster smarter living. z
References:
1 http://www.forbesindia.com/blog/ business-strategy/smart-buildings-cantransform-a-city-and-its-citizens/ 2 https://www.navigantresearch.com/research/ water-management-in-intelligent-buildings
For more information:
Levi’s Stadium in Santa Clara, California
This article was written by Amedeo Valente, director of Innovation & Technology at Xylem Applied Water Systems (AWS) and managing director of Xylem Service Italy. Visit: www.xylem.com
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 19
EVENT PREVIEW
The water industry descends on Chicago from 30 September to 4 October Since 1928 the US’ Water Environment Federation has been holding an annual meeting to provide a forum for knowledge and technology exchange within the water and wastewater fields. Now, WEF’s Annual Technical Exhibition and Conference, aka WEFTEC, is a leading event for developments in water quality, research, solutions, knowledge development and cutting edge technologies. Attracting thousands of water and wastewater professionals from around the world, WEFTEC hosts a programme of technical sessions and workshops that address a diverse yet comprehensive list of water and wastewater issues such as plant design, operations and treatment; utility management, collection systems, the latest regulations, and much more. WEFTEC 2017 will be held at McCormick Place in Chicago, Illinois. The conference will run from 30 September to 4 October, the exhibition from 2-4 October. The exhibition will be attended by some of the biggest players in the water industry, including a host of manufacturers specialising in pumps, valves and other fluid handling equipment.
Singer Valve Booth #4451 Canadian company Singer Valve will be exhibiting its new Singer 106-2SC-PCO and 206-2SC-PCO Dual Solenoid Electronic Control Valves. The Singer Model 2SC-PCO is designed for use with Singer’s MCP Multi-Process Control Panel or the EPC Single-Process Control Panel. The flow into and out of the upper operating chamber is controlled by the two pilot solenoids. The electronic control determines whether the opening solenoid or the closing solenoid is operated. Virtually any hydraulic function can be achieved using the “openclose” output from the SCADA controller to the valve. This precision control valve is good for remote locations, The Singer Model 2SC-PCO requiring 20
minimal power with manual controls for emergencies and the ability to service in-line.
Netzsch Booth #1817 Netzsch Pumps North America will be showcasing a range of its pump technology, including the brand new N.Mac Twin Shaft Grinder, the FSIP version of its Nemo progressing cavity pump and the Tornado T2 rotary lube pump. The N.Mac Twin Shaft Grinder on display is designed to fragment a variety of materials and is ideal for wastewater treatment, biogas and biomass plants, food, animal N.Mac Grinders processing, and other waste and industrial applications. Netzsch’s FSIP Nemo progressing cavity pump provides full access to all of its rotating parts, allowing users to easily open the pump cavity onsite and dismantle all rotating parts, before simply installing them again without having to remove the pump or disconnect the piping. The iFD-Stator 2.0 being showcased features a two-part, reusable stator housing and replaceable elastomeric stator. The iFD-Stator 2.0 design strives to combine efficiency, economy and environmental safety in one unique system. Compatible with Nemo NM series progressing cavity pumps NM21 through NM063 and with larger sizes in development, the iFD-Stator 2.0 is designed to reduce energy and maintenance costs. Netzsch’s Tornado T2 Rotary Lobe Pump is a self-priming, valve-less, positive displacement pump ideal for any kind of liquid, including media containing gas, solids or fibrous matter. Boasting a low total life-cycle cost, the Tornado T2 pump can be used for almost any media on intermittent, continuous or metering applications.
Krohne Booth #916 Krohne will be presenting a range of its water and wastewater products, including the brand new biogas version of its Optisonic 7300 ultrasonic flowmeter, the Tidalflux 2300 for partially filled pipes, the Waterflux 3070 water counter with flexible power concept, and the company’s new generation of liquid and solids measurement products. The new biogas version of the Optisonic 7300 is well-suited to FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
EVENT PREVIEW methane gas applications in wastewater treatment facilities. The 2-beam ultrasonic flowmeter provides long term measurement stability and repeatability. It delivers high performance over a wide bi-directional flow range of ± 30 m/s (± 90 ft./s) with 1% accuracy. Krohne’s Tidalflux Krohne Optisonic 7300 2300 flowmeter can measure flows in pipes between 10% and 100% full, with a non-contact sensor that is unaffected by oils and fats floating on the surface. The flowmeter’s broad diameter range means it can fit pipes up to DN1600 or 64 inches (162.6cm). Krohne states that the flowmeter has a high chemical and abrasion resistance. The Waterflux meter provides precise measurement with no need for upstream or downstream piping, and has no moving parts, which Krohne claims makes the meter ‘maintenance-free’. The electromagnetic unit can be powered by a standalone battery, with solar power or even in-line power. It is a good choice for drinking water applications, or locations where power is unavailable. Visitors to Krohne’s booth will also have an opportunity to see the company’s latest radar level measurement devices, the Optiwave range. In addition, they will be able to see the company’s full product line for use in the water and wastewater industry.
efficiency and better fuel economy, among other benefits. As well as launching the Godwin smart pump, Xylem will be showcasing its range of solutions to address urban water resilience. This will include a comprehensive portfolio of proven, smart water technologies alongside the company’s deep application expertise - all geared towards helping communities tackle critical water challenges and support sustainable, resilient water management.
Watson-Marlow #3116 Watson-Marlow Fluid Technology Group is showcasing its Bredel line of heavy duty sludge pumps and Qdos range of peristaltic chemical metering pumps. The Bredel heavy duty sludge pumps on display are ideal for centrifuge and belt press feed. They feature only one wearing part – the hose – so there are no rotors, stators, or lobes to replace and no mechanical seals or packing to leak. Bredel pumps can handle flows to 475 gallons per minute (GPM) with suction lift to 30 feet (9m), while being dry running and reversible. Also on display will be the Qdos range of chemical metering pumps, suitable for disinfection, pH adjustment, and flocculation of drinking water, wastewater, and industrial process water. With accurate linear flow rates from 0.001 to 31.7 gallons per hour at 100 psi irrespective of fluid viscosity, Qdos pumps were specifically designed to reduce chemical metering costs compared to conventional solenoid or stepper-driven diaphragm metering pumps. z
Mueller Booth #1131 Mueller will be showcasing its H-306 Fabricated Steel Tapping Sleeve. Mueller’s H-306 is designed for hot tapping ductile iron pipe and thick-wall C900 plastic pipe. It features an integral bolt flange, Rilsan nylon coating, working pressures up to 300psi, and is available in sizes ranging from 4”-16”. The H-306 is an economical tapping sleeve ideally suited for use with Mueller CL-12, C1-36, and Mega-Lite drilling machines in less corrosive soil environments. It is made from A36 fabricated steel and meets the requirements of AWWA C223.
Xylem Booth #1248 In exciting news, Xylem will be launching the first in a line of Godwin smart dewatering pumps at their stand at 11am on 2 October. Details on the new series remain quite secretive, but Xylem claims the pumps will offer improved pumping
PUMP EFFICIENCY SOLUTIONS Belzona polymeric coatings can restore laminar flow rates and even increase pump efficiency levels beyond the original specification. REPAIR
Eliminate the cost of component replacement
PROTECT
Extend the pump’s designated life
IMPROVE
Reduce turbulent flow and increase efficiency by up to 20% on worn pumps
For more information on Belzona’s pump efficiency solutions visit: www.belzona.com/pumpefficiency
Xylem’s Godwin smart solution for water will be unveiled at WEFTEC
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 21
A modern alternative SPONSORED ARTICLE
SIDE Industrie has invented a new, clean and safe way to lift raw effluents through direct-in-line pumping with no wet well Traditional lift stations use submersible pumps in a wet well. The pumps are activated by float switches when the water reaches a preset level, and then run at full speed to empty the wet well. A primary issue with submersible pumps in wet wells is clogging with wipes and other flushable materials. The float switches are subject to fouling with fats, oils and grease and may require frequent cleaning to keep them operable. In addition, wet wells occasionally have to be cleaned out, typically with a vacuum truck. Another major issue is hydrogen sulphide gas, which can corrode electrical components, anything made of steel or iron, and even concrete, as well as cause odours that inevitably lead to complaints. These pump clogging issues, which are experienced in many countries today, were addressed and resolved years ago by French innovator Stephane Dumonceaux, general manager of SIDE Industrie and inventor of the DIP Systeme. The first DIP Systeme was patented, installed and proven successful in 2003 and since then there have been more than 1,500 of these systems in use in municipalities throughout France (for example in Disneyland Paris), as well as in the USA, Canada, Cambodia, Portugal, the Ivory Coast, and the Caribbean Islands. Based on practical expertise in the field, the development of SIDE’s product range (56 models with flowrate from 2 to 2000m3/h (20 to 10.000 gpm)/unit and head from 1 to 110m (3 to 300 ft)) is the result of 35 years of research, and listening to the daily concerns of its 1500 users worldwide, enabling the company to offer a modern alternative to wastewater lift stations that saves time and money by logically solving issues such as dangerous gases (H2S), odours, sand and grease accumulation, hazardous access, variable flow and clogging. How? Because the DIP Systeme lifts and boosts variable flows from the sewer line invert to the discharge pipe with no need of any wet well. By lifting gravity effluent directly at the point of entry 22
DIP Systeme: The only patented system to lift effluent directly at the point of entry, with no wet well
without water loading or a wet well, the DIP Systeme overcomes the drawbacks of retained volumes of effluent such as dangerous gases (H2S), smells, sand and grease accumulation, equipment corrosion, structural erosion and clogged floaters while also offering access safety. The absence of a collection tank eliminates the costly cleaning operations of traditional units and at the same time eliminates the complaints from residents living close to an installation that produces unpleasant odours. Additionally, it removes the risks for maintenance technicians. A change in direction In today’s global and throw-away society, the “enemy” is fibrous waste such as wipes, therefore in 2012 SIDE Industrie designed a special impeller called DIPCut, a patented impeller that becomes a “shredder” when it changes direction of rotation. DIPCut combines the
DIPCut: Automatic double function impeller for self-cleaning operation
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
SPONSORED ARTICLE Left: Norton’s lift station and its electrical cabinet fitted with remote management system OmniDIP
Right: Rehabilitation of Norton’s wastewater lift station with a DIP101
DIP Systeme in action At the end of 2015, SIDE’s distributor C&B Equipment won a tender from the state of Kansas to install a DIP101 at the Norton Correctional Facility in Kansas. The Norton project was a special one as it used a fibreglass tank with the pump preinstalled prior to shipment. The installation involved replacing an old dry pit system that continually clogged. The entire installation process was completed within only three days. The chosen contractor excavated, poured concrete footer, lowered the tank with the DIP Inside into the excavation, connected inlet and discharge, backfilled, connected cables to the provided cabinet and started up the DIP Systeme. One of the main reasons why the DIP Systeme was chosen for this project is that it is designed to make wastewater lift stations much less maintenance intensive while effectively dealing with the trash, wipes and clothing that clog pumps and sewer lines. The DIP Systeme automatically shreds these materials, allowing uninterrupted flow. This also eliminates the labour and costs associated with physically removing and disposing of the materials. With the “old dry pit system”, the maintenance team of the Norton Correctional Facility had to unclog the pumps every day. Municipalities and facilities converting
advantages of the conical Vortex impeller when pumping sand, gases or big solid wastes and a shredding function, cutting long fibrous materials into shreds. When the torque increases, the pump senses that it is becoming clogged. It then automatically slows down, stops and reverses direction. When it does that, knives on the impeller pop up and slice up any trash. When the pump senses that it is running free again, it slows down, stops and returns to the normal pumping direction. All this happens without operator intervention. Indeed, these self-cleaning pumps are connected and can be monitored and managed with a smart phone, tablet or desk top from anywhere in the world thanks to the included web assistance OmniDIP. OmniDIP is a self-monitoring system dedicated to the DIP Systeme. It checks
their existing wet well pumping stations to the DIP Systeme have obtained several key benefits. They include: • The system is self-sufficient and can adapt speed automatically to flow intake • The system can be managed remotely, eliminating the need to send a crew to the site • Reduced manpower is required to remove and reinstall clogged pumps • Rapid installation and less excavation needed for new construction. These benefits have all proven true for the Norton Correctional Facility in the five months since installation. “Our application here at our facility is a little unique. We never know for sure what’s going to get flushed down the wastewater system,” explains Joel Hrabe, deputy warden of the Norton Correctional Facility. “We absolutely have not had to shut our sewer system down to repair, pull pumps, to unclog pumps – none of that has happened since installation … I would recommend the DIP Systeme wholeheartedly.” A video by C&B Equipment detailing the results of the Direct-In-Line Pump System installed at Norton Correctional Facility is available on the Fluid Handling International website (www. http://fluidhandlingmag.com/videos)
automatically and continuously all the processes through 230 parameters per pump in order to guarantee optimal operation for as long as possible and avoid any needless intervention from a technician. It analyses so precisely that it allows forecasting and optimisation, and not just to inform when there is a technical fault or to log data. The factory service also checks and updates the system via OmniDIP and will automatically handle preventive alerts sent by the DIP Systeme. Thanks to the OmniDIP remote control system, the DIP Systeme solution brings comfort, safety and long term savings, including significant reductions in energy usage. Assuming that cleaning out a traditional pumping system costs on average $350 (€293.70) – equivalent to an electric
consumption of 3.500kW/h, DIPCut can prevent those clogs while using less power. Unlike grinders or shear and cut pumps, the DIPCut impeller keeps its high hydraulic pumping efficiency. Moreover, while shredding all the power of the motor is used only by the four “knives”, which use little energy. The result is double the efficiency of other pump systems, in turn preventing motor oversize. The DIP Systeme has many applications and is particularly suitable for treatment plants, sanitation, and public works, as well as for pumping washing water, industrial effluent, waste water and sea water in the stainless steel version L316. z For more information:
This article was written by Valerie Joguet, marketing manager at SIDE Industrie. Visit: www.side-industrie.com
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 23
Taking the stress out of piping design
PIPING
The benefits of more advanced rubber joint arrangements It is a fundamental principle that all piping systems require support and some degree of flexibility. Today’s pipe stress engineer must go beyond checking for just allowable pipe stresses, and check for load limitations on key equipment and/or support structure. This requires not just understanding general piping codes such as ASME B31.1 & 31.3, but also careful consideration of codes that address nozzle loading such as API 610 5.5.1 and ANSI/HI 9.6.2. Additionally, essential equipment suppliers have voiced their concerns relating to the damaging effects of high nozzle loading on their equipment. Unfortunately, this concern is often, and incorrectly, associated with rubber expansion joints based on an unacceptable pressure thrust force they could impose. Some equipment suppliers have even taken an extreme approach and recommended pipe stress engineers eliminate expansion joints, increase the rigidity of the piping system and tighten installation tolerances. This approach is both impractical and problematic because it does not adequately take into consideration the fundamentals of thermal growth and contraction of the piping system, ground settlement, vibration, realistic piping misalignment and other common external forces and displacements imposed on the piping system. This approach also hinders the efforts of owners and pipe stress engineers who desire piping systems with a smaller footprint, lower construction cost, improved energy efficiency, modular construction and less support structure. Systems designed without rubber expansion joints also lack the common benefits of absorbing all directional movements including ground settlement, reducing noise and vibration, having a cycle life in the tens of millions, 24
compensating for typical misalignments of 0.185”, providing access to piping and equipment, and having superior corrosion and abrasion resistance. An optimal approach requires understanding the imposing pressure thrust forces from some expansion joint arrangements, and when needed, incorporating more advanced rubber expansion joint arrangements that can facilitate both system flexibility and restraint. More advanced rubber expansion joint arrangements should not be confused with simply adding control rods to an unrestrained rubber expansion joint (Illustration 1). This is because setting control rods with gaps still imposes 100% of the pressure thrust force on the system and setting them without gaps will lack axial flexibility. This no-gap setting is effective in restraining the full pressure thrust force and
Illustration 1 Unrestrained rubber expansion joint
obtaining all common rubber expansion joint benefits excluding axial flexibility. Looking at the alternatives As a helpful exercise, the pipe stress engineer may look at several alternative solutions for the same application and compare the different end load results. Alternative solutions can include incorporating rigid pipe loops, traditional unrestrained rubber expansion joints, and/ or more advanced rubber expansion joint arrangements. Illustration 2 shows four solutions to an example application of a 36” diameter carbon steel pipe with a 100’ axial run under 90 psi with temperature fluctuation of 100°F (38°C). Each solution will restrain the pressure thrust forces, absorb the axial thermal movement of 0.8” and keep the piping system within allowable stresses. However, each solution will have very different end loads. For simplicity, load factors common to all solutions, such as pipe and fluid weight, are ignored, as well as the fact that actual pipe stress engineers will likely utilise FEA software including AutoPIPE or CAESAR II. SOLUTION 1 incorporates an unrestrained expansion joint installed between two main anchors with numerous guides at specific spacing. This is a good solution when there are no load limitations on the equipment and/or support structure. The common benefits of incorporating rubber expansion joints are also obtained. The consequence of an unrestrained expansion joint being installed axially in-line is the pipe no longer being able to carry the pressure thrust force in tension, and so the pressure thrust force must now be transmitted as a compressive load onto the systems ends, thus requiring main anchors. The end load can be calculated
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
PIPING and there is some value placed on reducing the system footprint, as well as saving material and energy costs. The common benefits of incorporating rubber expansion joints are also obtained. The end load can be calculated as the sum of the lateral spring rate loads of the two expansion joints and some minor friction loads from the pipe guides. The end load for Solution 4 extends to approximately 2,200 lbf; an extremely low and very manageable load. Illustration 2 Alternative piping solution
as the sum of the pressure thrust force, the spring rate load of the rubber expansion joint and some minor friction loads from the pipe guides. The end load for Solution 1 extends to be approximately 92,900 lbf (pounds force). This illustrates why many equipment manufacturers would not want their equipment to be treated as a main anchor and forced to carry such a heavy load. SOLUTION 2 incorporates a rigid piping loop installed between two intermediate anchors with a limited number of guides. This is a good solution when there are no space restrictions or a need to reduce material or energy costs, and there is no need for the common benefits gained from incorporating rubber expansion joints. The carbon steel pipe will carry the full pressure thrust force in tension and does not transfer that load on to the system’s ends. The end load can be calculated as the sum of the load deflection values from the solid pipe loop using the Kellogg method and some minor friction loads from the pipe guides. The end load for Solution 2 extends to approximately 105,000 lbf, a force greater than that of the pressure thrust force in the example application. Equipment manufacturers should be just as concerned with this heavy load as they are with eliminating pressure thrust forces. SOLUTION 3 incorporates an in-line pressure balanced rubber expansion joint installed between two intermediate anchors with a limited number of guides. This is the only effective solution for directly absorbing large axial thermal movements while continually selfrestraining the pressure thrust forces. This advanced rubber expansion joint arrangement consists of tie devices interconnecting its main joint section to its opposing balancing joint section
(Illustration 3). This is an optimal solution when there are load limitations on the equipment and/or support structure and there is a high value placed on reducing the system footprint, as well as saving material and energy costs. The common benefits of incorporating rubber expansion joints are also obtained. The end loads can be calculated as the sum of the spring rate load of the expansion joint and some minor friction loads from the pipe guides. The end load for Solution 3 extends to approximately 4,500 lbf; a very manageable load.
Illustration 4 Flexible pipe loop utilising universal tied rubber expansion joints
An optimal solution
Illustration 3 In-Line pressure balanced rubber expansion joint
SOLUTION 4 incorporates a flexible pipe loop installed between two intermediate anchors with a limited number of guides. This advanced rubber expansion joint arrangement consists of two universal tied joints for maximum lateral movement capability, interconnected in a compact pipe loop (Illustration 4). This is a very effective way to absorb large axial thermal movements from the longer adjacent pipe runs. It is also an optimum solution when there are load limitations on the equipment and/or support structure
When concerned about the load carrying capabilities of any essential equipment and/or support structures, an optimal solution is neither to increase rigidity into the piping system or ignore the imposing pressure thrust forces as an effect of some expansion joint arrangements; but rather to incorporate more advanced rubber expansion joint arrangements that can facilitate both system flexibility and restraint when needed. This approach is also very much in line with owners and stress engineers who desire piping systems with smaller footprints, lower construction costs, improved energy efficiency, modular construction and less structural support. z
For more information:
This article was written by Lloyd B. Aanonsen, president of General Rubber. With a BS in Mechanical Engineering, Aanonsen has more than 30 years’ experience in the design, development and application of rubber expansion joints. He currently sits on the board of the Fluid Sealing Association. Visit: www.general-rubber.com
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 25
PIPING
Arresting the danger of flames in plant piping
An in-depth look at regulations and best practice for flame arresters in plant piping Flame-transmission-proof devices have been used for decades as a key part of plant safety across the globe. With appropriate application they provide protection against combustion and explosion propagation that can infiltrate through openings or connecting pipes, in storage tanks for example, potentially destroying them. Wherever flammable gases or vapours could appear in combination with oxygen, flame-transmission-proof devices are incorporated as protection. Usually, all openings and pipelines are critically examined in the context of safety considerations, and a safety concept established and implemented if necessary. Protection measures should only be renounced when it has been ensured that no ignitable atmosphere will appear, and ignition sources can be completely avoided. This article will not only discuss typical gas-bearing piping such as vapour recovery pipes and gas displacement lines, but also liquid-bearing piping that is not permanently fluid filled. These could be tank filling and emptying lines for example, provided the tanks are fully emptied. Flame arresters in general can handle a wide variety of different risks. The effective range of end of line devices goes from simple atmospheric ignitions and explosions to resistance against flames which burn for an unlimited time and must be constantly contained. Inline devices too, can be laid out for different dangers: from so-called deflagrations to detonations which can propagate with supersonic velocity inside piping systems. 26
KITO BEH with flame
It is possible to obtain flame arresters for most standard substances. In order to choose the right device, it is not only important to consider plant safety, but to examine the fluid itself. Flammable gases and vapours have different properties in regard to the so-called Maximum Experimental Safe Gap (MESG) - a standardised measurement of how easily a gas flame will pass through a narrow gap bordered by heat-absorbing metal. These characteristics are used to classify fluids and gases into explosion groups. The IEC designates explosion groups IIA, IIB and IIC; while the US discerns between the groups A, B, C or D. Mind the gap Flame arresters predominantly utilise the flame extinction principle in tight gaps. This means that two metal strips (one flat and one corrugated) are tightly wound together, producing a gap of
triangular section which should not exceed a maximum dimension. This is called the flame arrester element and it is just one part of the flame arrester. High quality standards have to be applied for this production process: gaps that are too large might not stop the flames, too tight gaps are indeed safe but they cause an unwanted high pressure loss. In addition, there are models which are particularly applicable for piping which is predominantly liquid-bearing. In these instances, the medium itself can be used to stop flame fronts and explosions. For that purpose, siphon-like constructions are designed in which the transported medium constitutes a liquid stock. These so-called liquid seals or foot valves have proven their usability in practice in hundreds of facilities. High-speed valves too can be suitable as flame-transmission-proof devices for preventing flame and explosion propagation inside piping. As highspeed flame arresters they are also often
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
PIPING used for the protection of ship tanks, as they are suitable for the required higher pressure, and in on-shore plants. The exact details of the execution depend on the manufacturer’s experience and on practical key tests; until today there has been no possibility to theoretically determine the required flame arrester adequacy. For this reason, an ISO standard (ISO 16852) has been created which determines the different risks and defines the corresponding test conditions to meet the standard required. As a result it is possible to discern between the previously mentioned explosion groups. Only devices which comply with these strict requirements are allowed to get the European CEmark, ensuring a facility’s protection provided the devices are correctly applied. It is also important that the chosen device fully complies with the potential operational conditions. This is especially valid for pressure and temperature as both parameters are limiting factors for flame arresters. When exceeding these maximum allowable values the arrester may fail, the consequence of which could be accidents with heavy material and personal injury. In daily practice it must be considered whether the material used is corrosionresistant and unaffected by the fluid. Even controlled removal which is otherwise accepted, is not permitted for flame arresters as the consequence could be that the tight grid gaps lose their stability and suitability. A further typical problem is the arrester’s susceptibility to fouling because of the required tight gaps, especially in processes which work with soiled media that forces regular stops and frequent short maintenance intervals. In cases where 100% availability is needed a parallel installation is often required so that one line is always in operation while maintenance or repair works are carried out at the other installation. In the interest of continuous availability, crucial spares can be stored or even a third device can be kept available in stock. In some circumstances it can also be beneficial to supply the devices with isolation and trace heating. Condensation or sublimation problems can then be partly avoided. Caution is recommended here though, as the use of, for example, steam as a heating medium often exceeds the allowed device temperature. For end of line devices which give protection for longtime fire exposure, called endurance burning, an inexpert isolation can often even be dangerous. It may prevent heat
KITO RV-N at Vopak
remains with the user, or is agreed with the responsible authorities. Valves as flame arrester solutions
dissipation and as a consequence the effectiveness can be affected. Making the correct material choice can also help to avoid problems. For instance, KITO has had a positive experience avoiding problems with sulphur deposits by using strips made of extreme low-nickel stainless steel. Setting the standards (and regulations) Not much literature exists explicitly concerning flame arresters and their use. At European level, KITO therefore worked out the CEN/TR 16793, in which important tips for the use and choice of flame arresters are given. In Europe, the European directive 2014/34, ATEX, sets requirements for the obtainment of CE certification for protective systems manufacturers. The parallel 99/92 directive concerns the user, as it describes the employees’ obligations. . These very general, international directives are nationally supported by different sets of rules. Germany has, for example, the Industrial Safety Regulation and the included Technical Rules, as well as the Ordinance on Hazardous Substances. In other countries however, there are no national technical rules for safety; the practical implementation of the European Directive requirements
Often, valves are also used to maintain pressure within tank protection. They reduce medium loss through evaporation and unnecessary breathing processes. Additionally, flame arresters are needed when the medium is flammable liquid or gaseous fluid and no other safety measures have been taken to protect ventilation lines. Among others, ISO 28300 gives appropriate suggestions. There are integrated solutions with which the flame arresters simultaneously perform a valve function, these valves with integrated flame arrester element then meet all safety technical requirements. In practice, single devices are often combined. Generally, a flame arrester will be installed as an inline device below an end of line valve. As here the flame arrester is stressed differently to the standardised tests for inline devices, ISO 16852 states that such a combination is tested as a single entity. If this is not the case, there is a risk that adverse effects occur through each device construction, which in a worst case scenario leads to a flashback. For tank protection, valves are mostly used which work in the lowest pressure range, below 20 HPa (hectopascal). Consequently, weight load valves are predominantly used, wherein the weight load can also be replaced by a fluid column. Usually, the set pressure is set at the factory. Various designs are used in the market whose response and blowoff characteristics are very different. Common to all valves is that they need a pressure accumulation upon the respective pressure set for the nominal capacity removal. This imperative must be considered during the construction so that the allowed tank pressure isn’t exceeded. In addition, the closing process issue must also be taken into account, as it is not guaranteed that after reaction of the valves there is a reclosing at the exact set pressure value when the internal tank pressure is decreasing. This could cause problems, especially when tanks are inerted or when pressure for process reasons is operating near to pressure set. z
For more information:
This article was written by Joachim Romeick, managing director and sales manager at KITO Armaturen. Visit: www.kito.de
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 27
Sealing the standards for LNG SEALS
Developing a new generation of seat-to-body seals for cryogenic trunnion mounted ball valves to exceed LNG industry leakage rate standards With the liquefied natural gas (LNG) industry representing a high business potential for valve manufacturers, trunnion mounted ball valves (TMBV) are being used extensively for cryogenic service. The performance requirements for valves handling LNG are among the most demanding in any industry, especially with regard to low-temperature performance at temperatures of around -163° C, bubble-tight seat sealing, and stringent fugitive emissions requirement. These cryogenic service applications are governed by several industry and IOC standards: BS6364, ISO 28921-2, Total GS EP PVV 150and Shell SPE MESC 77-300. BS6364 from the British Standard Institution is the most commonly used standard for valve cryogenic testing in the LNG industry, but it is also the oldest (having not been revised since 1984). As a result, the standard’s maximum allowable seat leakage rate remains the highest among other standards (see Figure 1). IOC and Shell standards in particular have designated their valves more in line with the technological progress of the valve industry. As indicated in Figure 1, the maximum allowable seat leakage specified by Shell MESC SPE 77-300 is half of the most severe international standards. In addition to extreme low leakage rate, Shell requires very severe high temperature cycling. Why are there such ambitious requirements for cryogenic applications and how do valve companies handle these types of requirements? Top entry trunnion mounted ball valves are widely used in the LNG liquefaction Specifications
BS6364
Maximum allowable 100 mm³/s x DN seat leakage (soft-seated)
supply chain, mostly in the medium size range. TMBV design and construction codes refer mostly to API 6D with ASME B 16-34 being used for pipeline and process applications, however, special consideration should be taken with regard to the body cavity relief to avoid over pressurisation when the valve is closed. Thermal cycling of LNG in the line can create a catastrophic failure considering that LNG takes 600 times its volume when it reaches the gaseous state. To minimise the risk of leakage, TMBV manufacturers have developed a device called a “SelfRelieving Seat”, providing what is normally referred to as a Single Piston Effect (SPE), for which seat-to-body seals are critical components to ensure the valve integrity within the operating temperature range. As a result of these stringent conditions, TMBV manufacturers are seeking out companies who can upgrade the leakage performance and integrity of their valves at -162°C, companies such as Saint-Gobain Seals, who are developing next generation seat-tobody seals that meet and surpass the leakage requirements given by Shell MESC SPE 77-300. This allows TMBV manufacturers to bring environmental and production confidence to an industry where safety is the first priority. How are these next generation sealing solutions developed? Using their OmniSeal PTFE rotary lip seals, Saint-Gobain Seals launched an internal research and development project to develop and pre-validate new single piston seat seals in full accordance with Shell MESC SPE 77-300
ISO 28921-2& Total GS EP PVV 150
Shell SPE MESC 77-300
50 mm³/s x DN <= class 900 100 mm³/s x DN <= class 900
25 mm³/s x DN (=1.5 ml/min x DN)
Figure 2: Saint-Gobain Seals Cryogenic Test
test protocol. The following were their internal testing capabilities (Figure 2): • Pressure up to 420 bar He • Temperature from -196°C to +150°C • 2 mockups available: 3” and 8” At this stage, it is important to notice that there are two possible leak paths that account for seat leakage. For TMBV, the seat tightness is ensured by a seat insert pressed against the ball and seat seal, commonly called seat-to-body seal (see Figure 3).
Figure 3: TMBV Single Piston Effect seat design, Saint-Gobain Cryogenic Test Rig
Based on input from major cryogenic TMBV manufacturers, the decision was made to set up a leak rate target for a seat seal at 25% of Shell MESC SPE 77-300
Figure 1 : Maximum seat leakage rate
28
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
SEALS standard, giving 75% for leakage through the seat insert. Maximum seat leakage specified by Shell is MESC SPE 77-300 for 8” TMBV= 300 ml/min is 75ml/min for seat seals, and 225ml/min for seat inserts. Saint-Gobain Seals’ main objectives for their R&D project: • Understand the seal key design parameters to exceed SHELL MESC 77-300 leakage requirement • Understand the impact of valve hardware and size on leakage performance • Provide a new solution to fit into existing TMBV seat configuration • Define clear design rules to cover the entire cryogenic TMBV range of applications up to class #2500 The main challenges to overcome when designing lip seals for cryogenic TMBV seat seal application were: • Shrinkage of the lip seal • Misalignment in the valve trim • Roughness of sealing surfaces • Ease of seal installation • Seat must be free to move for over-pressure body cavity relief • Shell MSEC SPE 77-300 preheating cycle at 120°C or 150°C does not allow the usage of materials commonly used for cryogenic temperature A two-part development programme through parametric study was implemented to understand the key application parameters and FEA design optimisation. Jacket Materials
Jacket Design
Spring
CTE Transition temp Hardness
Profile Finish Interference
Shape Load Deflection
1. Parametric study: Each parameter was then identified that could affect seal performance at cryogenic temperature. For each parameter, tests were conducted to understand their impact on leakage. i. The team selected four thermoplastic jacket materials to assess and quantify the impact of cryogenic conditions. The material selection was based on analytical data and mockup testing at elevated temperature followed by cryogenic testing. ii. Jacket design was optimised in order for ease of installation while ensuring optimal tightness even in
misaligned conditions. Tests were performed on 3” and 8” mockups. iii. Multiple spring configuations were characterised with load/ deflection curves at room and cryogenic temperatures.
2. FEA (Finite element analysis) design optimisation: All selected jacket materials were fully characterised so that they could utilise their proprietary polymer material model in order to run FEA thermo-mechanical validation. FEA input: i. Material parameters from characterisation of spring and jacket ii. Large strain formulation iii. Hardware shrinkage iv. Shell MESC SPE 77-200 test protocol (installation, pre-heating, pressurisation, cooling) Seal designs were evaluated based on the evolution of interaction between sealing force and contact length with the hardware. What was the conclusion of SaintGobain Seals’ testing? The extensive test programme combining the efforts and expertise of design engineering and research & development teams has resulted in the pre-validation on 3” and 8” mockups of a new generation of lip seals in full accordance with Shell MESC SPE 77-300 test protocol: the most stringent LNG industry specification. The graph below shows the evolution of performance obtained through the testing programme. - The red curve shows the leakage rate with previous generation of Cryogenic Single Piston Effect Seat Seal - The green curve shows the performance obtained with first design optimisation - The blue curve shows the near zeroleakage performance measured with latest design optimisation
The new Cryogenic Single Piston Effect seat seal surpasses the requirement of Shell MESC SPE 77-300, since the team were not able to measure any leakage through the flowmeter. This new generation of design brings the performance of lip seals to the next level with remarkable benefits to manufacturers of Cryogenic Trunnion Mounted Ball Valves: - Ranging from -196°C to +150°C - Up to class 2500 (420 bar) - Able to cope with 0.4mm misalignment of valve trim - Roughness of hardware sealing surface Ra 0.2-0.4µm - No need to modify the hardware/ valve seat concept. No additional parts required. - Cost-effective design rules have been defined by pressure class, temperature and size.
How can Saint-Gobain Seals’ research apply to other applications? The above data collected for a wide range of pressure and temperature through FEA and application testing on many parameters such as jacket profiles, springs and hardware conditions provides a much better understanding of their interaction. The outcome of the parametric study has been translated into design rules that could be applied by application engineering teams to address other challenging applications not limited to Cryogenic Trunnion Mounted Ball Valves, but toward applications where a high level of stringent tightness is required on a wide temperature range, e.g., fugitive emission valves, space applications for propulsion and ground support systems and life sciences equipment. z
For more information:
This article was written by Christophe Valdenaire, global market manager oil & gas for Saint-Gobain Seals. Visit: www.seals.saint-gobain.com/
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 29
PUMPS
A positive choice for multiphase fluids Progressing cavity pumps for pumping multiphase fluids in oil Increasing production of heavy oil, extra heavy oil and bitumen is critical to a stable world economy. These crudes generally require special production techniques to overcome their high viscosity. While many in the industry have focused on such methods as steam assisted gravity drain (SAGD), cyclic steam injection (CSI) and vapour recovery, flow assurance solutions are also of vital importance. These well streams are a combination of crude oil, water, gas and sand; the proportions of each varying by region and reservoir. There are distinct economic, environmental, and facilities management advantages to transferring the complete well stream to gathering and processing facilities rather than separating the components at the well site. To make this transfer, the pump system selected must be reliable, safe, and capable of handling the variations in fluid composition and process conditions. Positive displacement pumps, especially the progressing cavity pump (PCP), are a good choice for multiphase fluid transfer for crude oils with high viscosity. The PCP is a cost-effective solution compared to other conventional oilfield in-field pumping alternatives. Increasing production rates by stimulating reservoirs In recent years, many have tried to increase production rates by using new techniques to stimulate reservoirs. Most 30
Table 1 – Comparison of conventional separation with multiphase pump Item
Conventional separation
Multiphase pump
List of process equipment
2-phase product separator
2-phase vertical surge vessel
Crude oil transfer pump
Export LP compressor
LP compressor suction scrubber
LP compressor after-cooler
Pump control system
Optional seal oil & seal system
List of utilities package
Instrument air packages
Instrument air packages
(air compressor/dryer/receiver)
(air compressor/dryer/receiver)
Diesel generator
Diesel generator
Environmental concern/s
Continuous venting/flaring from
No concerns – gas handled
LP product separator, positive
in closed system with no
crankcase ventilation (PCV)
venting
Amount of gas venting/flaring
is significant during compressor
Multiphase pump
shutdown
Operability consideration
Require frequent monitoring
Usually unmanned
Footprint
>100m²
Can be as little 20m²
Table 1 provides a simplified comparison between the two operating scenarios
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017
PUMPS of these methods require flow assurances and surface transport techniques. Selecting pumps to transport multiphase fluids, consisting of oil, water, gas, and formation solids (sand), is critically important. Multiphase fluids in traditional field developments will typically free flow to gathering stations, through surface lines pushed by the natural formation pressure, as shown in Figure 1.
Figure 1. Free flow of wells to gathering station
However, heavy oil and extra heavy oil pose particular challenges for flow through pipelines because the increased viscosities result in high friction losses.
Figure 3. Multiphase pump boosting flow to far away gathering stations
to add energy to the unprocessed well fluids, which enables the liquid/gas mixture to be transported over long distances without the need for prior separation. There are typically two in-field separation operating scenario options – conventional separation either close to or at the well site, or use of a multiphase pump. Separation close to the well site is not always possible, and may require significant infrastructure and investment. This increases facility investment costs due to the complexity of the extreme environmental conditions, for example, cold temperatures, in which heavy oil fields are often located. Figure 4 shows a diagram of conventional separation equipment.
is especially an issue for the many multiphase pumps deployed in depleting fields, which have a tendency to demonstrate unstable cycling behaviour characterised by an active production period followed by an inactive period. In addition, the unprocessed multiphase oil streams may have entrained (free gas) fractions as high as the high nineties. The pump equipment is already coping with challenging conditions, so when sporadic slugging is thrown into the equation, it can affect the pump. The slugging can result in gas flow for periods lasting from only 15 minutes to several hours. The pump must be able to cope with such variations. During gas slugging periods, it is likely that some liquid will be carried with the gas as a liquid or a vapour. The worst case scenario for a pump is long duration of dry gas flows, which is tantamount to dry running of the pump. These technical design and control challenges must be overcome to ensure equipment is reliable and efficient when placed into service. System design and integration philosophy
Figure 2. Business model for multiphase flow
Figure 2 shows a typical production model for multiphase flow. The flow assurance aspect is critical for carefully managing production rates. Flow line resistance can have a strong influence on the production rates. For heavy oil regions, it becomes a key factor in deciding the specific production philosophy. A simple way to use a multiphase pump is shown in Figure 3, where the pump is applied at the well head to simply boost the well flow to gathering and processing stations. In this case, multiphase pumping is quite simply a way
Figure 4. Conventional separation equipment
The information suggests that multiphase pumping may be the simpler choice from an equipment perspective. From an environmental point of view, using an enclosed system to handle gas with little or no need for gas venting to the atmosphere is the more desirable option. Pumps located at the well head or on pump pads must handle changing process conditions, due to the variations in formation and well behaviour. This
Process and environmental installation challenges While there are many benefits to installing multiphase pumps, there are also a variety of challenges posed by process and environmental conditions. The following conditions must be addressed in any successful multiphase pump package: • Well shut-in pressure is often high, >20 bar. Pump suction side design is for the shut-in pressure, as well as the normal running pressure, which is typically much lower. • Varying inlet pressures lead to varied required displacement volumes, so the pump must have a variable speed drive that can vary the flow rate. • The pump must be able to tolerate periods of gas slugging. • Installation is nearly always outside, so the pump must be able to handle extreme heat and cold.
Good system integration is required to overcome process challenges, including prolonged slugging. More than in any other PC pump application, the system needs to be orientated to work with the pumps to ensure they are not damaged during such times. A dry run protection probe is a simple way to protect against damage from overheating caused by prolonged slugging or dry running. The dry run protection device embedded in the stator can detect a frictional heat build-up due to a lack of lubrication from the pumped fluid. The control system can react by starting a lubrication pump. In the simplest form, the dry run protection can just trip the pump until the temperature reduces. System complexity will vary based on geographical location. The lubricant injected by the small pumps is usually collected process fluid, or can be water or oil from separate sources. Another example is a simple liquid collection tube and recycling line arrangement, which has been widely used in Russian oilfields. It is usually applied with a recycle line flow controlled by a manually set throttle valve. The leakage collection device is sized to give a buffer of fluid to allow a reasonable operating period during typical slug flow durations. Environmental considerations
FLUID HANDLING INTERNATIONAL l SEPTEMBER/OCTOBER 2017 31
PUMPS Pump equipment must be protected from harsh environmental conditions, especially extreme cold temperatures. The pump stator is made of an elastomer; effective pump operations depend upon flexible elastomeric properties. As the temperature goes lower, elastomeric properties reduce and the tear strength reduces. As they approach the glass transition point, pieces of the stator material can become mechanically overworked and shear off. Elastomer recipes can be adjusted to increase the rebound rate and change the effect of low temperatures. Alternative stator material recipes have been successfully and reliably applied in extremely cold Russian oilfields. Mechanical seals Mechanical seal selection is less critical than might be expected. It is essential that ‘O’ ring material is selected based on the expected temperatures, especially when operating in exceptionally cold temperatures. Seal selection
depends on the gas fraction and the expected risk that the field could operate in slugging conditions. For low gas fractions (<60%), using single mechanical seals with either no quench (API plan 02) or a simple quench (plan 62) has proven successful. Where gas fractions are higher, the use of higher integrity solutions can be considered, for example, a double mechanical seal and systems. The simpler the solution, the more reliable it is likely to be. Even for higher gas fractions, the use of tandem seals with simple atmospheric buffer fluid tanks is very effective and avoids the need for more expensive and complex double seal and plan 53 systems. It is also important to carefully select the buffer or barrier fluid. Use of 75/25 glycol/water solutions and diesel has been successful, with upgrades to fluids like isopropyl alcohol (isopropanol) or methanol. PCPs are forgiving to mechanical seals, because the shaft speeds are very low and stuffing box pressure is the same as the suction pressure. Only
one shaft seal is required, unlike twin screw pumps with four shaft seals. A reliable, robust solution for handling multiphase liquids PCP equipment can be easily tailored to meet the demands of multiphase oilfield locations. Elastomer selection is essential to deal with cold conditions, and use of package process and control solutions is especially critical. A PCP is simple to control; temperature increases are easily detected and the pump responds well and quickly to control adjustments. The fluid handling qualities are extremely useful for handling low or very high viscosities. The PCP can also handle gas fractions as high as 99%, and can tolerate slugging conditions even without requiring control systems. z
For more information:
This article was written by Robert Kurz, manager Business Field Oil & Gas, Netzsch. Visit: www.netzsch.com
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