Fluid Handling magazine January/February 2015

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Horseshoe Media Ltd Marshall House 124 Middleton Road, Morden, Surrey SM4 6RW, UK www.fluidhandlingmag.com MANAGING DIRECTOR Peter Patterson Tel: +44(0)20 8648 7082 peter@horseshoemedia.com PUBLISHER & EDITOR Margaret Dunn Tel: +44 (0)20 8687 4126 margaret@tankstoragemag.com DEPUTY EDITOR Keeley Downey Tel: +44 (0)20 8687 4183 keeley@horseshoemedia.com ASSISTANT EDITOR Natasha Spencer Tel: +44 (0)20 8687 4146 natasha@horseshoemedia.com STAFF WRITER Daniel Traylen Tel: +44 (0)20 868 74126 daniel@horseshoemedia.com ADVERTISING SALES MANAGER Belinda Smart Tel: +44 (0)20 8648 7092 belinda@fluidhandlingmag.com PRODUCTION Alison Balmer Tel: +44 (0)1673 876143 alisonbalmer@btconnect.com SUBSCRIPTION RATES A one-year, 6-issue subscription costs £150 (approximately $240/€185 depending on daily exchange rates). Individual back issues can be purchased at a cost of £30 each Contact: Lisa Lee Tel: +44 (0)20 8687 4160 Fax: +44 (0)20 8687 4130 marketing@horseshoemedia.com

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ISSN 2057-2808

Margaret Dunn Publisher & Editor

Welcome to the first Fluid Handling magazine of 2015! We hope you had a great festive break and managed to enjoy some time off after a busy fourth quarter. No doubt many resolutions were made (and some already broken!), though of course there is no ‘fresh start’ when it comes to the process industries – only development.

With that in mind, this issue focuses on advanced technology and how it is being applied, as well as taking a look at the maintenance of existing tech and using it to full effect. In keeping with the magazine’s aim to bring you the best in the business each month, we have some of the process industries’ key players offering their thoughts and opinions on various topics throughout this edition.

British-owned manufacturer Flotronic Pumps takes us through five mandatory developments for commercial pump manufacturers over the last few years, giving some insight into the company and its own AODD design.

Also in the pump sector, Cat Pumps addresses the challenge of cleaning marine growth from subsea structures via a recent case study.

If valves are what you’re looking for, Spirax Sarco’s whitepaper on maintenance in preparing for plant outage is a must-read, while SIPOS Aktorik introduces its new advanced actuator design and the importance of valve control’s ‘unsung heroes’.

It is set to be an exciting year for product development across all sectors, with new technology becoming more and more advanced with extensive research, and we’re looking forward to seeing what else is in store as it progresses.

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Front cover_FH_Jan-Feb_2015 converted.indd 1

Front cover courtesy of Honeywell Process Solutions

05/02/2015 14:54

Severn Leeds’ emergency butterfly valve sealant validated by Saudi Aramco An emergency butterfly valve sealant system developed by Severn Glocon Group company Severn Leeds has been validated by Saudi Aramco.

The Sealant Pressure Injection Reserve Endurance System (SPIRES, patent pending) is a progressive technology that overcomes the challenge of resealing damaged valves without a cavity. It mitigates risk of leakage following damage to a butterfly valve’s primary seal caused by abrasive particles.

Saudi Aramco’s validation testing provides assurance of its effectiveness prior to wider adoption.

SPIRES involves the incorporation of an emergency sealant system as a fundamental design feature of butterfly valves. Should the primary seal fail, a secondary sealant is injected into a runner behind the disc to compensate for any seat leakage when the valve is set to ‘closed’ position. Tests showed that bubble-tight shut-off can be achieved,

even if the seat is badly damaged, avoiding the need for unplanned downtime.

Mark Breese, group product development manager – butterfly valves at Severn Glocon Group, explains: ‘This groundbreaking technology enables damaged butterfly valves to be resealed quickly and efficiently without removal from the line. Once the sealant is deployed, the valve can remain operational until the next period of scheduled maintenance.’

Control valves for high pressure injection applications Badger Meter HP-60 ultra-high pressure control valves are ideal for offshore, oil and gas control applications with up-stream pressures of up to 60,000 psi. Available in the UK through liquid handling specialists Pump Engineering, the Type HP-60 control valve utilises a 17-4 PH body along with a solid Stellite inner valve assembly.

The HP-60 valve is also ideal for use in industrial research and process pilot plants on liquids and gases, with typical applications being chemical injection, for example in the production of high pressure, low density polyethylene (HPLDPE).

Standard features include, pressure rating to 60,000 psi at 37.7ºC, a wide range of interchangeable trims, choice of linear or quick opening trims, ANSI Class lll shutoff (size P-1 through P-9) and ANSI Class lV shutoff (size K through O). The inner valve (plug and seat) is constructed from solid Stellite while titanium nitride coated Stellite is available as an option. Standard packing is Torlon/PFA CV rings.

For lower pressures up to 350 bar, the standard RC200 valve in 316 stainless steel is available with a larger range of trims. All the valves can be supplied with standard (air-toopen, air-fail-close, air-to-close, air-fail open)

The HP-60 valve can be used for a number of applications, including (but not limited to) chemical injection

actuators. However, actuators in stainless steel with integral top mounted positioner or side mounted positioner, are also available.

Smith Flow Control launches new Ellis Key Mechanical valve interlocking equipment specialist Smith Flow Control has redesigned the key for its Ellis interlocking range.

Ellis interlocks are used for critical process applications in oil and gas, petrochemical and water industries.

The new Ellis key is suited to aggressive industrial environments. Featuring a spring-loaded rubber seal, which helps prevent ingress of sand, dust and water or any other foreign matter, its robust body has an ergonomically designed grip, ensuring improved handling.

The redesign allows markings to be displayed on both the top and side of each key flag, making tags much easier to see. If a key tag is damaged during operation, the tag plate can be easily removed without needing to replace the complete key.

The key is also compatible with existing plant key cabinets – all that needs replacing are the individual base plates, which clip easily.There is no change to the coded section of the key.

A wide range of accessories, such as filter regulators, gauges, I/P converter, limit switches and solenoids, are also offered.

Four DeZURIK knife gate valve lines earn SIL certification DeZURIK has announced that four of its knife gate valve product lines have earned Safety Integrity Level (SIL) certification per the requirements of the IEC 61508:2010 standard. The IEC 61508 international standard on Functional Safety assures that safety-related systems provide the necessary risk reduction required to achieve safety for the equipment.

The company’s KGC Knife Gate Valves, KSV Severe Service Knife Gate Valves and KUL Urethane Knife Gate Valves have been certified as SIL 3 capable; KSV Double Block and Bleed Valves have

been certified as SIL 2 capable. The SIL certification means that these valves styles are suitable for use in critical applications up to the SIL rating. The SIL rating reflects the level of risk reduction the device can provide when used as part of a safety instrumented system.

The third party assessment and certification by exida verifies that the product and safety manual, as well as the processes that are used for development, testing, configuration management and quality control comply with the 250+ requirements of the IEC 61508 international standard.

Bonomi low-torque full-port brass ball valves now available in both regular and lead-free models New Bonomi two-way full-port brass ball valves with spring return ‘deadman’ handles are now available in both lead-free, sizes 0.5” to 2”, and regular brass alloy, sizes 0.25” to 3”. The valves’ low-torque design makes them easier to hold open during operation and ensures positive closure when released.

Typical uses include sampling, filling and draining tanks, spill avoidance, butane tank water drain, propane tank water drain, steam trap drain, drum

dispensing, pipe plug cleanout, hose vent valve, and other OSHA-required applications.

Because they are full port they fill faster and drain faster than the commonly-used reduced port valves.

Bonomi’s low-torque o-ring seat design makes for smooth operation and extends valve life. Other manufacturers use downstream ‘crusher’ seat designs, elevating the torque required to effectively operate the handle. The Bonomi seat

design utilises Viton o-rings behind each seat allowing ‘energised’ light seat to ball contact in both the up and downstream seats.

The Bonomi 250NSRL (regular brass) and 250NLFSRL (lead free) both feature a forged leadfree brass body that is stronger and lighter than sand-cast valve bodies. Like all Bonomi brass ball valves, they provide bubble-tight shutoff and are 100% factory tested in the open and closed position at 80 psi.

A chrome-plated ball and blowout proof stem, PTFE seats and double O-ring stem seals for leak-free service are standard. Maximum working pressure is 600 WOG or 150 WSP. Maximum operating temperature is 185.5°C. Leadfree brass balls are TEA coated.

The spring-return handles are made from heavy-duty corrosion-resistant stainless steel components to stand up to the environment and the stress of frequent use.

Bestobell secures fire-safe approval for globe valves Bestobell Marine has secured approval of its new DN350 and DN400 cryogenic globe valve designs, developed specifically for the marine sector. This means that the valves are now fully tested and certified for installation on liquefied natural gas (LNG) carriers.

Duncan Gaskin, sales director for Bestobell Marine, says: ‘Shipowners are increasingly requesting that shipyards use higher capacity pumps for discharging cargo from LNG carriers, because it speeds up the unloading process. The cryogenic globe valves which are used for controlling the flow on the discharge line need to increase in size to

accommodate the higher flow rates.’

The fire test procedure is a rigorous process, which exposes the valve components to temperatures of over 1,000˚C, with the valves having to demonstrate that they will not leak gas to the atmosphere and through the valve seat. This can only be achieved by designing the valve to proven firesafe standards, with an all metal seat construction and using graphite gaskets and packings that are not affected by the high temperatures. It is essential for ship safety that cryogenic valves that are set to be installed on LNG carriers are truly fire-safe, as any leakage of gas from

a valve in the event of a fire could lead to a catastrophic explosion on board a vessel.

Chris Hey, lead test engineer at Bestobell Marine, explains: ‘We have seen in recent years what appears to be a lowering in standards by the class societies which appear to be approving cryogenic valves for installation on ships that are not fully fire-safe, especially for LNG fuel gas systems.’

In the SIGTTO guidelines for the selection and testing of cryogenic valves for ships, it states that cryogenic valves should be of a ‘fire-safe’ design to an applicable standard, such as BS6755 Part 2, or equivalent.

Flowserve McCanna introduces cryogenic valve

Nelson Irrigation unveils 1000 Series control valve

Flowserve, a provider of flow control products and services, has launched the McCanna CryoSeal ball valve for cryogenic service. The CryoSeal represents the optimum design solution for cryogen flow isolation at temperatures as low as -196˚C. User benefits with this new product include increased uptime through the use of self-compensating, live-loaded stem seals which provide enhanced sealing life as well as leak-tight integrity. The CryoSeal’s top-entry design allows in-line maintenance which further increases process uptime.The wedge seat design compensates for wear and thermal cycling in various applications.

This latest development from Flowserve McCanna offers a number of features which make it ideally suited to various cryogenic applications including liquefied natural gas (LNG) liquefaction, transportation and regasification. Its quarter turn operation and special low-torque seat profiles make it simple and cost-effective to automate.

The CryoSeal is certified as both fire-safe as well as meeting the ISO15848 standard for fugitive emissions, making it an ideal choice for a number of cryogenic applications.

The CryoSeal is available in sizes 0.5 to 6” full port or 0.5 to 8” reduced port, ANSI Class 150-600, with either butt weld or flanged ends. Both body and bonnet are one-piece construction for superior integrity and reliability.

The valve is certified to these industry standards: BS 6364 and API 608 – design and testing requirements; API 607 and ISO 10497 – fire test; ISO 15848-1 fugitive; emission testing (Low E); API 598 testing.

The American Association of Railroads has approved the valve as suitable for use on tank cars.This is significant not just because rail is an important means of transporting LNG and liquid nitrogen but also as LNG is increasingly being used as an alternative to diesel as a fuel for locomotives.

In October of 2010, Nelson engineers launched an R&D project to develop the next generation of sleeve-style valves.They aimed at addressing critical irrigation issues – the result is the new 1000 Series.

The 1000 Series is geared to handle tough agricultural environments. The internal filter or optional external filter protects ports from plugging. There is no ‘continuous bleed’ port which minimised blockage potential and the improved cage design passes debris more effectively.

A modular design provides ultimate flexibility in valve style and connection type while simplifying installation, trouble-shooting and maintenance.

Buyers can choose from three different flow path options: inline, tee and elbow, along with selecting from five inlet/outlet styles: • Proprietary Nelson ‘Flex-Connect’ ends – interchangeable design allow for ‘mixing & matching’ ends.

- 1 ¼”, 1 ½”, 2” NPT or BSP - 3” splined connection - 2” and 3” Victaulic • Wafer Style - 2” ANSI Flange - 2 x 3” Flange Adapters – allows installing a 2” valve directly between 3” flanges.

1000 Series valve applications include zone control for sprinkler or drip irrigated row crops, nursery crops, orchards and vineyards.

The valve can be fitted under a Big Gun for solid set irrigation, end of pivot solutions and numerous environmental controls including fire suppression, dust suppression and cooling.

Crane ChemPharma launches three new products for fluid handling applications Crane ChemPharma and Energy, a provider of solutions for fluid handling applications worldwide, recently launched three new flowmeter products – the Xomox XLC, Xomox FK and Pacific CSV. Xomox XLC: Xomox XLC fully-lined ball check valves offer economical solutions for a vast majority of chemical applications with a flexible seat that enables Class A and API598 sealing. Critical equipment is protected from cross contamination and the effects of backflow, even in the horizontal position where the XLC’s angled ribs guide the ball tightly into the seat. With metal-to-metal contact at the joint seal and wide conical plastic connection, the risk of dangerous external leaks is reduced.

Xomox FK: Engineered to address the

inherent dangers of volatile chemical applications, the Xomox FK adheres to industry standards and combats the harmful effects of temperature and pressure fluctuation. Three independent stem seals offer superior fugitive emissions control, and are certified to EPA Method-21, ISO-15848 and TA-Luft according to VDI 2440. Self-relieving seats relieve excess pressure to protect the integrity of the valve while maintaining bi-directional operation. The patented SX ball stem design provides maximum stem torque capability and builtin side load resistance, which extends valve life under severe conditions including thermal cycling.

Pacific CSV: Designed to exceed industry fugitive emissions standards with outputs as low as 20ppm, new Pacific CSV cast steel gate, globe and check valves offer optimum

The recently launched valve range from Crane ChemPharma

performance to the oil and gas, power and refining industries worldwide.

The CSV gate valve’s fullyguided wedge ensures smooth operation in both horizontal and vertical orientations to deliver improved resistance to sticking, while the globe valve

features a uniquely-designed line contact between disc and seat for lower seating torque and faster set up. The CSV swing check disc fastener is restrained by the bonnet to eliminate the risk of a displaced disc and prevent damage to downstream equipment.

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NOV Mono helps cement manufacturer improve maintenance operations A UK cement production facility has improved its maintenance operations and safety levels by installing new equipment from NOV Mono.

Hanson Cement has achieved these improvements by adding a duty/standby Mono Munchpump package to the sewage handling operations at its Padeswood plant in Mold, North Wales.

The plant had originally been using submersible pumps for sewage transfer duties, but these had become inefficient.

‘Any maintenance work involved an engineer going down into a confined space,’ explains Hanson’s engineering manager, Paul Cowell. ‘We wanted to make maintenance and cleaning operations safer, easier and more effective.’

Mono designed and installed an aboveground Munchpump package that includes two EZstrip progressing cavity pumps and two SB Munchers, in a duty/standby arrangement, transferring the sewage at 25m3/h to the main sewerage system. The Munchers macerate any solids within the flow to a small particle size, therefore protecting the pumps from any large solids, which could cause blockages.

Each shaft of the Munchers is fitted with a series of interleaving cutters that allow liquid to pass through, trapping the solids and macerating with their high torque cutting action. Low operating and cutter tip speeds dramatically reduce mechanical wear and also offers reduced

Mono designed and installed an aboveground Munchpump package specifically for Hanson’s requirements

noise levels when compared to high speed macerators.

Combining a Mono progressing cavity pump with a Mono Muncher allows the use of small bore pipework, typically 50mm, which is a more cost effective solution to the traditional 100mm rising main sewer and offers the further advantage of eliminating the risks of solids settling and septicity.

As the equipment is surface mounted and installed in a clean, dry environment, access for maintenance is more user friendly than submersible pumps, with no need to lift equipment

Boerger pumps aid production at UK shellfish processor Pump manufacturer Boerger has had its technology installed at a UK shellfish company’s facility in Fleetwood, on the north-west coast of England.

The rotary lobe vane pumps are being used to enhance production by processing saltwater containing shells and sand.

Made of stainless steel, the 3kW PL 200 Classic pumps operate at 20m3 and are fitted with optimum rotors developed specifically for difficult applications.

The facility previously used a progressive cavity pump for the application, which was unsuccessful.

out of dirty sumps and restricted one-man accessibility.

Munchpumps can consume less than 50% of the energy of a comparable submersible pump.

The positive displacement action of the EZstrip progressing cavity pumps allows the speed to be set independent of pressure, allowing slow speed operation of the unit.

This contributes significantly towards low wear rates, reduced energy consumption, extended component life and greater reliability of the overall pump package. The pumps also feature Mono’s unique

EZstrip design which allows maintenance, cleaning and deragging operations to be carried out in situ, without the need to remove the pumps or disconnect any associated pipework. This can reduce a typical day-long maintenance operation down to just 30 minutes.

‘The Mono Munchpump package has certainly made a valuable contribution to the levels of performance we expect at the Padeswood plant,’ concludes Paul Cowell. ‘It continues to operate well and has proved to be a considerable improvement over our previous system.’

Xylem to supply pumps to wastewater plants in Norway Water technology provider Xylem has won a contract to supply pumps and wastewater treatment technology to two new plants in Bergen, Norway.

The company will supply Flygt N3000 submersible pumps, Flygt 4600 series mixers, a Sanitaire Silver Series II aeration system and high efficiency screw blowers to the facilities, the development of which is being overseen by Purac.

Due to begin operating in autumn this year, the plants are part of a project to improve wastewater treatment in Bergen, and will have a combined capacity of 208,000 population equivalents (PE).

Flexicon pumps used to dose small volumes of liquid vitamins Technikon Laboratories, based in the Florida district of Johannesburg, South Africa, has installed four Flexicon PD12I peristaltic fillers with an MC12 controller from Flexicon Liquid Filling part of the Watson-Marlow Pumps Group. The fillers are used to fill a liquid vitamin energy supplement into stickpacks.

The independent pharmaceutical contract manufacturer of distinction is fully MCC (Medicine Control Council) and SAPC (South African Pharmaceutical Council) licensed and today boasts over 40 clients, including several multinationals.

A recent client request to change to sticktype sachet packs for an energy supplement product led to a production dilemma.

‘Our machine for this type of pack was geared for powder filling only,’ explains the company’s MD, Robert Verseput. ‘We needed to acquire fillers/pumps that would allow us to convert this machine to fill liquids as well.’

The solution arrived in the form of four Flexicon PD12I peristaltic fillers with an MC12 controller. Duly acquired from Flexicon Liquid Filling in October 2013, the four fillers service the eight-lane machine

by splitting the dosing into two on each pumphead. Now, instead of filling powder, liquid vitamins get pumped into the sticks as the pack is sealed by the machine beforehand.

The pumphead works with a double tube element with a Y connector to combine two channels of flow into one, thereby providing a higher flow but removing nearly all pulsation.

When required, the two channels of flow can be used individually as is the case with Technikon. This adds versatility to the way the pumps can be used.

The peristaltic filling principle is the fastest growing filling technology in the pharmaceutical industry due to wellestablished advantages such as sterility, guarantee against cross-contamination and easy cleaning. These are achieved by the fact that the product is only in contact with USP Class VI tubing and a filling nozzle.

The modified machine at Technikon is now one of two automatic high speed GMP lines located in a pharmaceutical production area. Operating at 50 cycles per minute, the machine produces sticks (sachets) filled with liquid at a rate which is required in a highcapacity filling line. With a slight modification

in the standard design of the fluid path, 400 fills per minute has been obtained. Stick fill volumes vary between 4 and 25ml, in typical batch sizes of around 1000l.

The Flexicon PD12I is an extremely flexible liquid filling unit, which can fill volumes from less than 0.2ml to more than 250ml with accuracy better than ±1% in the range from 0.2ml to 0.5ml and better than ±0.5% in the range from 0.5ml upwards. This flexibility and accuracy is achieved without having to change anything except the bore size of the tubing.

The PD12 peristalitic filler also features an anti-drip function which is particularly important in sachet-filling applications. This helps to ensure there is no dripping between fills which could potentially prevent a proper sealing/welding of the sachets.

Both speed of fill and ease of cleaning are cited by Mr Verseput at Technikon as ‘important’ in a good investment project.

‘High standards, reliability and service levels, including the ability to meet deadlines, is vital to the success of Technikon,’ he concludes. ‘That is why ongoing investment in the latest technologies is so important.’

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Energy Recovery introduces pumping system for hydraulic fracturing Liberty Oilfield Services, a subsidiary of Liberty Resources, has signed an agreement to be the first well fracturing services provider to use Energy Recovery’s VorTeq hydraulic pumping system.

‘The new VorTeq pumping system will change the way that companies frack, providing a more reliable and more costeffective process. Beginning with our first customer, Liberty Oilfield Services, and given the significant ROI, we believe this product will become the new industry standard and will help Energy Recovery drive substantial growth and shareholder value,’ says Tom Rooney, CEO of Energy Recovery.

‘Liberty Oilfield Services has always embraced emerging breakthroughs in the field, and VorTeq is the next major revolution in hydraulic fracturing technology. This system will give service providers a competitive edge by allowing substantial cost savings and

Energy Recovery, a specialist in pressure energy technology for industrial fluid flows, has released the VorTeq hydraulic pumping system, the first product engineered to increase runtime and reduce maintenance costs by rerouting abrasive frac fluid away from existing hydraulic fracturing pumps.

The current fracking pumping technology requires intensive and costly maintenance. In many cases, pumps are repaired and serviced daily. Energy Recovery’s VorTeq, designed to replace the traditional hydraulic fracturing manifold trailer, or ‘missile’, is expected to more than double the useful life of pump components that most frequently fail.

VorTeq re-routes proppant-filled fluid away from high-pressure pumps on fracking sites so these pumps only process fresh water, and therefore last longer.VorTeq channels the abrasive fluids and sends them down the wellbore.

additional production capacity. With fewer at-risk hours spent on maintenance, we believe VorTeq will also enhance safety during frac jobs,’ says Ron Gusek,VP technology and development, Liberty Oilfield Services.

The core of the VorTeq hydraulic pumping system is Energy Recovery’s pressure exchanger (PX) technology, which is already in use in more than 15,000 desalination installations worldwide. The system handles up to 110 barrels per minute, with a treating pressure up to 15,000 psi. The system is designed with only one moving part and made from tungsten carbide, which is 1,000 times more abrasion-resistant than steel.

Neal Hageman, engineering manager at Integrated Petroleum Technologies, worked with Energy Recovery to provide insight on the maintenance challenges faced by the service companies performing these treatments.

Michael Smith Engineers introduces range of hollow rotary disk pumps A new range of hollow rotary disk pumps designed to operate at low speeds and handle more challenging liquids such as those with suspended solids or higher viscosities (up to 200,000 cSt) has been introduced by Michael Smith Engineers.

Manufactured in Italy since 1952, 3P Prinz low speed rotary, positive displacement pumps are proven and reliable in transferring sensitive liquids at flow rates up to 250m3/hr.

3P Prinz pumps operate at discharge pressures up to 8 bar as standard, although high pressure versions can be specified for discharge pressures up to 20 bar. They are available in a choice of wetted materials

including cast iron, bronze and stainless steel to ensure broad chemical capability, extended pump life and longer service intervals.

With multiple porting and seal options, these pumps are self-priming and, in addition to coping with liquids containing suspended solids, they also provide lowpulsing, accurate output. The self-priming design with high suction lift capability simplifies installation on-site, while its modular construction ensures simple maintenance operations without the need to disconnect the pump from piping.

The elasticity of the disc also allows for thermal expansion and passage of solid

KMT launches new range of waterjet pumps KMT Waterjet Systems, a global manufacturer of ultra-high pressure pumps and components for waterjet systems, has announced the availability of its latest product line.

The first release of the KMT Streamline SL-VI Series pumps will be available for delivery in January 2015 with horsepower offerings of 30hp, 40hp and 50hp at the operating pressure of 60,000 psi.

KMT Streamline SL-VI Series pumps are an advancement and optimisation of the successful Streamline V Series pumps.

The new SL-VI Series pumps will offer enhanced efficiency and productivity with predictable maintenance schedules.

Depending on the application, the Streamline SL-VI Series is a configurable designed waterjet pump that can be custom built based on a variety of

options to meet specific requirements.

Key features include enhanced performance with increased intensifier flow rate and the NEMA Premium Motor Design for optimised motor efficiency and reduced electrical consumption. Options available include the top cover guard interlock design with safety performance standard PLa rating, 60,000 psi redundant topworks, and Power Factor Correction (PFC) to reduce electrical demand and operating costs.

The Streamline SL-VI Series also offers a universal design-based PLC and HMI platform used for the control of the intensifier pumps.

The all colour dashboard control panel has universal icons for quick recognition along with pump performance information displayed in multiple languages.

particles in the liquid.

They are also designed for high hydraulic efficiency which means smaller motors are required along with lower running costs, compared to other types of positive displacement pumps. They have limited dry-running potential which can prevent expensive pump failure in the event of system upsets.

3P Prinz pumps are suited to a range of fluid handling applications in the chemical, petrochemical, oil & gas, food & beverage, pulp & paper, marine & shipbuilding industries or wherever effective and reliable, low-speed pumping of challenging liquids is required.

Damen Dredging expands DOP submersible pump range Dredging equipment supplier Damen Dredging has extended its DOP submersible dredge pump range to run from the smallest possible DOP150, fitting in any corner of a building pit, to the DOP450L, capable of processing 4,000m3 of mixture per hour.

The DOP submersible dredge pump is a heavy duty pump with a robust design that distinguishes it from slurry or wastewater pumps. The main component of the DOP is a wear resistant dredge pump outfitted with exchangeable parts. It also features a large spherical passage preventing blockage, and the impeller shaft is directly driven by a hydraulic motor through a gear box.

This direct drive makes the DOP450L, the largest submersible true dredge pump available, a compact unit.

The standalone pump only requires its hydraulic power.

The DOP can be powered by a diesel-hydraulic power pack or by an excavator. When the excavator boom is plugged into its hydraulics this makes a simple ‘plug and play’ dredger.

Emerson ultrasonic flowmeters enable improved oil and gas measurement accuracy Emerson Process Management has introduced new ‘Daniel’ multi-path gas and liquid ultrasonic meters that feature a next-generation electronics platform.

The accuracy, line size breadth, and flexibility make the new JuniorSonic one-path (3411) or two-path (3412), and SeniorSonic four-path (3414) gas ultrasonic meters ideal for a number of flow measurement applications. In addition, the new four-path (3814) liquid ultrasonic meter expands on the functionality and performance of its predecessor, the 3804 liquid ultrasonic meter, to offer improved reliability for custody transfer applications.

Designed for speed, reliability, ease-of-use, and measurement integrity, the new ultrasonic flow

meters provide measurement accuracy and repeatability.With faster flow sampling rates, the electronics platform increases the data set used to calculate average velocity, allowing rapid recognition of changing flow dynamics. Users will have access to high-volume data capture as well as detailed flow parameters, including pressure, temperature, and gas composition, allowing the meter to act as a redundant flow computer.

Improved calculations for auditing or invoice resolution are enabled by the electronics’ ultra-fast delivery of key data from the meter’s audit trail. The audit trail complies with American Petroleum Institute Standard 21.1, and is supported by a standard 128 MB non-volatile memory.

Access to alarms, events and configuration changes is provided in seconds.

Additionally, the meters’ electronics feature a compact circuit board for increased reliability and maintainability, simplifying field removal and reinstallation. The electronics support remote access as well as true 100BaseT Fast Ethernet connectivity to facilitate enterprise-wide communication and integration.

To further improve reliability and uptime, each Daniel gas ultrasonic meter is supplied with rugged T-20 Series transducers that are engineered for wet, rich and/or dirty gas applications.

The transducers facilitate troubleshooting by enabling

operators to quickly detect and isolate problems, preventing unnecessary de-pressurisation of the meter.

The Daniel gas and liquid ultrasonic meters are also equipped with an updated version of MeterLink (v1.20), a configuration and diagnostic software that utilises an intuitive interface to improve overall functionality and ease of use.

MeterLink displays abnormal flow profiles, upstream blockage, deposit build-up within the meter, and the existence of liquid hydrocarbon in gas. In addition, a guided wizard tool helps configure the meter in the field, decreasing commissioning time and minimising start-up costs and operator error.

Litre Meter ships low flow meters for Valemon UK flowmeter specialist Litre Meter has shipped two highly customised flowmeters via its Korean distributor for use on the Valemon gas and condensate field recently brought online in the North Sea by Statoil.

One is a large V125 positive displacement flowmeter, the other a small LF05 VFF meter.

The order was placed for each meter to be built to a degree of customisation that could not be matched by other suppliers working on the topside element of the project, which was constructed in South Korea.The order required meters to cover two different pressure and flow ratings.

The V125 meter was designed to measure the discharge of monoethylene glycol (MEG) at the wellhead pump while the LF05 monitors the flow of sodium hypochlorite.

The V125 was constructed from Duplex, pressure rated to 758bar, with a PVD coated SS nitronic rotor.The LF05 was constructed from titanium with a titanium rotor with 0.5” ANSI 150 RF connection.The accuracy of the meters was improved to +/- 0.5%.

As standard, the VFF V125 rotary piston flowmeters are pressure rated from 40-1035 bar and constructed from 316 stainless steel.

The meters are temperature rated between -40 and +150ºC and can be used with fluids in a range of viscosities from 0.8 to 2,000 centistokes or greater.The normal flow range of the V125 is 0-6,000 litres/hour (l/h).

Under conditions of low temperature and high pressure, gas hydrates can solidify as crystals which may block the pipeline and valves, impeding the transfer of the oil and gas.This can result in a shutdown and the risk of explosion or unintended release of hydrocarbons into the environment.

Ethylene glycol (MEG) is injected at high pressure where there is a risk of hydrates (dew) forming then freezing at low

temperature. Litre Meter VFF positive displacement flowmeters measure the correct amount of MEG needed to prevent hydrate formation.

The process, known as bullheading, forcibly pumps MEG into the bore hole to act as an ‘antifreeze’ to lower the freezing point of gas hydrate.

This protects the wells’ subsurface valves from hydrates forming under high pressure and low temperatures during long shutdowns.

With the same pressure and temperature ratings as the V125, the LF05 is designed for low flows at high pressures and can accurately measure flow ranges from 0.008 l/h to 30 l/h (0.05 to 190 US gallons Litre Meter has supplied an LF05 chemical injection flowmeter per day). to measure the flow of sodium hypochlorite on the Valemon The low flow capability of platform the meter has been improved by coating the pressure deepwater well bores from hydrate formation, balance chamber and titanium rotor with plugging and organic fouling is a major flow physical vapour deposition (PVD) designed to assurance concern in offshore operations. lower the friction properties of the meter to ‘Hydrate prevention strategies provide provide extended flow ability.The additional protection during normal operation, start-up hardness provided by the PVD coating also and shutdown. improves wear resistance.

‘Our VFF flowmeter is ideally suited for use The LF05 measures the flow of sodium in the oil and gas industry and in particular for hypochlorite - an aggressive chemical used low flow/high pressure applications.Years of for water treatment, hence the titanium experience in chemical injection applications construction.The chemical is used to prevent onshore and offshore have confirmed the the organic fouling of equipment that comes instrument’s capability to reliably measure into contact with water. fluids under extreme conditions of both Litre Meter CEO Charles Wemyss says: temperature and pressure.’

‘Subsea repairs and the associated loss of production are high cost, so protecting

New data recording version of flowmeter software interface from Titan Enterprises Titan Enterprises has released a new data recording version of its Atrato ultrasonic flowmeter software interface.

Designed for ease of use, the Atrato flow recorder enables data recording via an external computer. With features that provide monitoring, reporting and management of flow data, the device delivers a continuous picture of the process and a reliable alternative to restrictive and costly manual metering. The new software interface will be supplied with all new orders and can also be used with any Atrato flowmeter manufactured after June 2013.

The Atrato ultrasonic flowmeter is a true inline non-invasive flowmeter without the contorted flow path and disadvantages of alternative designs. It can handle flows from laminar to turbulent and is therefore largely

immune from viscosity. It also offers good turndown, linearity and repeatability. Available in 60°C and 110°C temperature versions and a 30 bar higher pressure model, Atrato flowmeters use patented ‘time-of-flight’ ultrasonic technology that enables it to operate over wide flow ranges (200:1) accurately (better than Titan’s new software interface can be used with any ±1.0% of reading).

Atrato flowmeter Using the new Atrato flow recorder, users can select from a wide variety of functions and time periods over which to samples or actual readings averaged over a time period. store their results. Flow data sets are saved as .csv files which can then be imported Examples of data recorded include actual directly to a wide range of programmes flow rate, filtered flow rate, total, output for later manipulation and analysis. Data transistors, analogue outputs and ultrasonic recording can be set up for any number of signal strength.

Exol Lubricants introduces new fluid analysis service for machinery Exol Lubricants, the UK’s largest independent manufacturer and supplier of lubricant products, has launched a new fluid analysis service designed to help eliminate the risk of machines failing prematurely.

Fluid Check allows machine operators to regularly monitor the condition of the lubricating fluid they are using in a bid to detect the type of contaminants and wear issues that can cause early machine failure.

Operators draw a sample of fluid from their machine and then send it to Exol for

comprehensive testing. The results are then posted to a secure web-based portal that operators can access to download the test data. If the fluid needs to be changed, the data will tell the operator and they can schedule maintenance before a failure occurs.

Steve Dunn, Exol Lubricant’s sales director, says: ‘Operators often don’t check the quality of the lubricant in their machine at regular intervals but that’s mainly because there isn’t an easy, no hassle system in place to facilitate that.

Victaulic updates highpressure piping system with added plug valve and updated coupling design Victaulic, a manufacturer of mechanical pipe-joining systems, has updated its StrengThin piping system with the addition of the Series 466 plug valve and the redesigned Style D08 coupling.

The StrengThin system, a high-pressure piping system for balance-of-plant applications in desalination facilities, enables direct pipe-end preparation of schedule 10S and schedule 20 super austenitic, duplex and super duplex stainless steel pipe, reducing the need for welding and flanging. The system is designed to facilitate faster pipe fabrication and field installation, improves safety and reduces project costs.

Intended for on/off and control services, the Series 466 plug valve features an increased flow area and smaller end-to-end dimensions than the Series 465. The valve is available in 10” to 16” sizes (250400mm) with StrengThin or Original Groove System (OGS) ends, and features a super duplex body, bonnet and plug and PTFE seats.

The StrengThin style D08 rigid coupling – used to join pipes, valves and fittings with StrengThin ends – now features a ductile iron housing with VC-200 coating, a multi-layer coating that has been tested and qualified to resist corrosive desalination environments.

The topcoat is a non-weatherable coating while the basecoats are a combination of hard metallic coatings. A double washer assembly protects the coating during fastener tightening. The Style D08 is a rigid coupling that delivers weld-like load carrying capabilities, enabling systems to be designed similarly to welded systems. Rigidity and proper assembly are achieved by meeting the minimum torque requirement for the applicable coupling size. With a two-piece housing, the coupling is available in 2” to 16” sizes and features the Grade ‘E3’ EPDM FlushSeal gasket, which can help reduce biofouling and minimise the potential for crevice corrosion.

Other components of the StrengThin piping system include the Series 415 check valve, a full line of super duplex fittings and the VSF216 end-forming tool. Components range in size from 2-16” and are rated for pressures of up to 1,200 psi (8,200 kPa).

‘Our service aims to overcome that problem by making it easy for operators to get a rapid and clear picture of the quality of the fluid they’re using. If there is a deterioration in fluid quality that’s likely to cause a failure, Fluid Check will identify the problem and flag it up so that the necessary maintenance can be completed in good time.’

Each customer using Exol’s Fluid Check service is given a pack that contains all of the equipment that is required to draw off fluid samples safely and cleanly.

Saskatchewan Research Council launches volatile materials expansion project at research facility The Pipe Flow Technology Centre at the Saskatchewan Research Council (SRC) is now one of Canada’s first research facilities equipped to test conditions with volatile materials such as crude oil in a high pressure and high temperature (HPHT) physical model.

SRC expanded an existing speciallydesigned building at the centre to accommodate research on light and heavy crude oils and refined petroleum products, all of which are flammable and require special equipment for safe storage and handling.The facility has been equipped with a 100mm diameter pipe flow loop designed to simulate industrial conditions.The loop will be used to research the flow of complex mixtures in pipes under HPHT conditions.

With the new research capabilities that the expansion has provided, the centre can now test a wider range of substances and help the provincial, and national, oil and gas industry enhance oil recovery, reduce operating costs and improve processes.

‘The expansion to our Pipe Flow

Technology Centre will enable industry to test new ideas and solve current problems with effectively designed solutions,’ says Dr Laurier Schramm, president and CEO of SRC. ‘This expansion has increased the centre’s capabilities even further.’

The expansion will formally be known as the Shook-Gillies HPHT Test Facility in honour of two pioneers in the area of slurry testing and research who were cornerstone contributors to SRC’s Pipe Flow Technology Centre over the past 55 years, Dr Clifton Shook and Dr Randall Gillies.

The federal and provincial governments jointly invested $1.73 million (€1.49 million) through the Canada-Saskatchewan Western Economic Partnership Agreement (WEPA) for this project. SRC contributed a further $1.46 million.

SRC’s Pipe Flow Technology Centre is acknowledged as an international leader in its field and has collaborated with Canadian and international clients on a range of ground-breaking pipeline and fluid mechanics applications.

Onicon acquires Greyline Instruments Onicon, a Harbour Group company specialising in the design and manufacture of flow and energy measurement systems, recently acquired Greyline Instruments, announced Jeff Fox, Harbour Group’s chairman and CEO. Terms of the transaction were not disclosed.

Greyline designs and manufactures ultrasonic flowmeters and level sensors that utilise Doppler, transit time, and area velocity technologies. The company’s customers operate primarily in the water, wastewater, environmental, and industrial markets.

The company was founded by Bill Robson and Ernie Higginson, and is based in Long Sault, Ontario, with additional operations in Massena, New York.

Dunlop Oil and Marine invests millions of dollars in Brazil-based hose production facility Dunlop Oil and Marine has reportedly invested $26.8 million (€22.5 million) in the construction of a new hose manufacturing facility in Macaé, Brazil.

The soon-to-open ContiTech Dunlop Oil and Marine Brazil was completed in October 2014, and will be ready to supply hoses in the first quarter of 2015.

Perfect Connections.

Reports say the investment was made in response to increasing demand for advancedperformance hose products in this sector.

The site is well-placed to supply local clients operating at the centre of Brazil’s petroleum industry in Macaé.

Dunlop Oil and Marine is part of the ContiTech division of Continental AG.

Around $26.8 million has been invested in a new Dunlop Oil and Marine hose production facility

GE in agreement to acquire Oceaneering’s electric actuator line General Electric (GE) has signed an agreement to acquire the Subsea Electric Actuator product line of Oceaneering, a global provider of engineering services and products to the oil and gas industry.

The product line goes to market under the Oceaneering Subsea All Electric and Ifokus brand, which specialises in the design and manufacturing of specialty subsea products, with a focus on electric valve actuators. The closing of the deal – subject to the standard regulatory approvals – is expected to be completed in the first quarter of 2015.

‘We are extremely pleased to sign our agreement with GE, which has the global resources, subsea controls technology and systems integration expertise required to bring Ifokus technology to full-scale commercial production to meet the growing demands for subsea electrification,’ says Mark Peterson, Oceaneering’s VP of corporate development.

Oceaneering’s 16-strong Stavanger-based engineering team dedicated to the electric actuator product line will join GE Oil and Gas, transitioning into the Subsea Systems business that also has operations based in Stavanger, Norway.

Rod Christie, CEO of GE Oil and Gas’ Subsea Systems business, explains: ‘With

Ifokus as part of our solutions portfolio, GE has the opportunity to pave the way for electrification in the oil and gas subsea space, giving us a new technology that is faster to operate for processing applications, has excellent enhanced diagnostic capabilities and can be seamlessly integrated into a customer’s existing controls, communications and power network.’

Ifokus is at the forefront of the offshore industry’s efforts to enhance conventional, hydraulic fluid-based subsea controls equipment with faster electric actuation systems that offer increased diagnostic capabilities.

Electric actuators are fitted to the subsea systems that control the flow, usually oil or gas, out of the well or the injection of fluids into the well to enhance recovery. Electric actuators appeal to operators because they offer potentially lower overall system costs and are more environmentally compatible by reducing the risk of hydraulic fluid leaks.

The technology is suitable for complex subsea processing applications and more difficult extraction environments such as deepwater fields, or fields with longer offsets from the shoreline. With the end of easy oil recovery, this is expected to be a key growth segment for the industry.

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Prepared for fluid handling Power station steam turbines have a tough job. They are exposed for prolonged periods to steam at temperatures of up to 700°C and pressures up to 300 bar.

At those temperatures and pressures, the advanced alloys used to make the thousands of turbine blades are highly susceptible to erosion, corrosion and deposition of materials.

This is not a problem where pure H2O is concerned – it is not itself corrosive to the steel alloys used. What is an issue, however, are any impurities – even at very low levels – that may be contained within the steam.

Erosion, which can create rough surfaces on the turbine blades and alter the steam path, is caused by solid particles – often iron oxide – in the steam.

Corrosion can cause serious issues for turbine blades, including pitting of the surface or corrosion fatigue of the structures themselves, potentially leading to fractures forming.

The most common corrosive compounds are sodium hydroxide, chloride, sulphate and sulphides. Only very low concentrations are needed in the steam to cause problems for the turbine because, even if the steam itself is pure enough not to cause any corrosion on initial contact, the dissolved compounds have a tendency to come out of the solution as the steam expands and reduces in pressure through the turbine. The result is that deposits build up into potentially problematic concentrations at the surface.

Even non-corrosive compounds contained in the steam, such as silica, can cause issues if they are deposited in large quantities on

the blades as they will change the carefully designed geometry of the turbine, potentially reducing efficiency. They can also affect the conduction of heat at the surface of the blades, leading to localised overheating.

Purity The purity of the steam is therefore critical, and this is determined by the level of impurities in the boiler water. Of course, this water is carefully filtered before being introduced to the system in an attempt to ensure it is free from contaminants. However, the very low level of concentration required to cause problems means this can be difficult to control with absolute certainty.

The only way to be truly sure that the steam is free from contaminants is to monitor it at the point just before it enters the turbine. A system is needed to determine the key parameters at this point including the pH and the levels of dissolved oxygen, silicate and sodium to extremely high levels of accuracy.

This is a challenge, as the sensors that test for the compounds in question cannot operate at the high temperatures and pressures of the steam.

Instead, it needs to be carefully turned back into water and tested in its liquid state.

Representative sampling For the analysis to be effective, it is vital that the samples of liquid being tested are an exact representation of the steam being generated by the boiler. If the exact level of any impurities is not

A steam-to-water analysis rack at a waste-to-energy plant

picked up, the monitoring process would be of little value.

The way the sample is transported, cooled and depressurised are all essential in ensuring that the compounds being monitored are not deposited on the pipework leading up to the analysers.

The samples are cooled in a heat exchanger that passes the steam along a pipe surrounded by cooling water to bring the condensed steam within a temperature range acceptable to each of the analysers used to test each different parameter of the sample. The acceptable temperature band is typically between 23°C and 30°C. A chiller may need to be used to reduce the temperature of the cooling water, especially in warmer environments where sufficiently cool water is not available on site.

The analysers themselves are located on a rack – known as a wet rack – and it is important to minimise the transportation distance from the nozzles that extract the high-pressure steam to the on-line analysers. It is impossible to create a one-sizefits-all solution to this, as virtually

every power plant layout is different.

The whole racks – whether open or contained in housing – therefore need to be bespoke to ensure the optimum arrangement of the necessary range of analysers. Modular designs and standardised parts can be used to make the process more efficient, but it is vital that it is underpinned by the expertise of experienced design engineers.

Whatever the source of power – waste to energy, nuclear, coal, gas or oil fire – the financial and environmental implications of even a small loss of output from a large power station are substantial, while obviously the loss of a turbine through excessive fouling of the blades would be a major setback. Steam and water analyser systems play a crucial role in managing the purity of boiler water, so it is vital that there is no compromise on the accuracy or reliability of the system.

For more information:

This article was written by Anuj Sreedhar, project manager, Thyson Technology.Visit: www.thyson.com or follow @AnalyserSystems on Twitter

from structures involves the use of high is given to the pump construction and pressure water delivered to the point of installation.’ application through specially designed lances.

Due to their high specification of design These create cavitation in the water flow, and manufacture, standard bareshaft Cat with the bubbles resulting from this action Pumps products require few modifications exploding onto the marine growth. To be to make them suitable for use in ATEX areas. wholly effective, the systems require pumps Generally, it is only necessary to minimise capable of providing the continuous flow of the risk of static electricity and to strengthen high pressure water from the platform. A a few external parts to protect against pump type that is best suited for this is the accidental impact damage. Fundamentally the high pressure positive displacement triplex pumps never get hot enough in normal use plunger pump. to ignite most flammable vapours.

‘Most platforms can give us a safe location ‘Using seawater being taken from the for our other electrical pumps,’ says HPR platform’s fire water ring main, our ROVs UK director Dave Gillies, ‘but we have had typically work down to depths of 50m, but several requests for ATEX Zone 1 and we can provide up to 200m of half-inch hose 2 pumping equipment. The most recent one came from a customer for whom we had to build a system into a 10’ x 8’ container against a tight deadline.’

With a short time-frame to For several years Aberdeen-based HPR UK build and deliver the system, has provided a one-stop shop for remote HPR UK turned to Cat Pumps operated vehicles (ROVs) and ancillary as the only company that could equipment, experienced pilots and survey offer an ATEX Zone 1 pump engineers to carry out inspection projects to specification at short notice. where the use of divers could be time and The pump supplied was the Cat safety prohibitive.

Cat Pumps’ Pumps high pressure positive Amongst its range of specialist services high pressure displacement triplex plunger are ‘hi-flo/hi-pressure’ systems for cleaning positive displacement model 6821, a compact pump marine growth from structures to allow for triplex plunger model 6821 capable of handling seawater clear visual inspection. Unique to HPR UK, at the required flow rate of 70 these systems use ROVs which can launch litres/min at 200 bar. Along with the pump, for the larger systems,’ continues Gillies. and operate in higher sea state conditions the container included an ex-light and ‘The ROVs can be in the water for anything than divers. They can also stay in the water flashing beacon, an ATEX approved electrical between eight and 10 hours cleaning large for longer, thereby maximising up-time control panel for managing the motor for the project. This also means that the areas of hulls and intricate areas between thermistor and heater, plus a small air driven company has fewer problems with HSE risers and conductors. This level of duty reeler for the delivery hose deployment. requires pumps that can maintain both the issues.

‘Over the last two years, we have found Cleaning or blasting marine growth required pressure and a constant flow over an increasing number of the period of use, which is why the high our customers are asking pressure triplex plunger pump is specified.’ for ATEX pumps and pump packages for use in explosive atmospheres,’ says Cat Pumps GM Brian Hubbard. ‘We have developed and tested a full range of PD pumps that meet ATEX Zone 1 and 2 areas. The area in which they operate might be designated hazardous even though our pump may be handling a non-flammable liquid, such as seawater. Equally, just because the pumped fluid For further product information, may be flammable, this would contact: not automatically create an Mark Austin, general/sales manager, Cat Pumps (UK) explosive atmosphere, provided Tel: 01252 622031, E: sales@catpumps.co.uk, Hi-flo/hi-pressure ROV system for cleaning marine Visit: www.catpumps.co.uk that special consideration growth from structures

Keeping up

with the flow Fluid handling technologies have to keep up with ever more sophisticated and efficient processes in the chemical, petroleum, pharmaceutical, waste/wastewater, and food and beverage industries.

Flotronic Pumps is the only Britishowned manufacturer of AODD pumps in the UK. Fluid Handling asked the company’s sales director, Leighton Jones, to name five ‘mandatory’ developments for any commercial pump manufacturer over the last five years.

Rising to the challenge

The ‘one-nut’ design pioneered by Flotronic can facilitate easy cleaning and maintenance

Founded in 1981, Flotronic’s design culture saw the development of its unique ‘one-nut’ pump design which can be found on all the company’s pumps to this day. The design allows quick pump disassembly for inspection or maintenance which delivers a benefit for customers in terms of reduced down-time, particularly as the pump can be inspected or maintained in line without pipework disconnection.

The original Flotronic AODD pump design has seen refinement over the last 33 years and a commensurate increase in the variety of applications in which they are used. The original design was specifically aimed at the chemical industries, especially the transfer of hazardous chemicals.

The pump’s evolution over the years has led to sophisticated versions of the original design which are now used in critical process applications such as pumping aggressive chemicals, transferring foodstuffs and providing constant liquid feeds. The pumps are also used for thin or viscous liquids, with or without solids and for aggressive chemicals, adhesives, cosmetics, drinks, dyes, foodstuff paints, pharmaceuticals, solvents, slurry and water.

The advantages to customers generically

with AODD pumps over alternatives are numerous, Jones says: ‘These include selfpriming, the ability to ‘dry-run’, ease in dealing with ‘dead-heading’ and solids conduct capability. The absence of a need for electricity also makes the pumps readily portable and very safe.’

Development under new legislature The European Parliament’s ATEX 94/9/ EC Directive, covering equipment and protective systems for use in potentially explosive atmospheres, is a classic case of new legislation demanding product evolution.

In this case, Flotronic developed new pumps initially compliant to Gas Groups IIA and IIB standards and thereafter to meet the more demanding requirements of IIC (including more stringent anti-static regulations and the ability to operate in an environment where acetylene and hydrogen are present). Any pump in the company’s range can be made ATEX-compliant including Gas Group IIC compatible fine-tolerance components where customers require this level of compliance.

Developed for handling hazardous materials, the Minichem is machined from a solid block of PTFE and has both UK and US patents for its design

pump’s ability to shut down immediately to avoid contamination in the event of a problem.

Addressing the pressure

Flotronic’s ‘Slimline’ series of metal pumps is suitable for any liquid transfer application

Demand for a cost-effective solution The ‘Minichem’ pump developed by Flotronic is one example of ‘outside the box’ innovation.

This is a cost-effective pump machined from a solid block of FDA approved PTFE, removing the need for separate manifolds.

This ‘one-block’ approach, incorporating integral ball valves, means there are no manifold seals and therefore no obvious leak paths, making the Minichem safe to operate in hazardous environments and applications.

The pump can transfer aggressive chemicals and other hazardous materials at flow rates up to 100 litres per minute through 0.5” and 1” connections at temperatures up to 80°C. ATEX-approved options include both FDA-approved PTFE and anti-static PTFE. Accessories include diaphragm rupture protection and fully pneumatic alarm systems.

The Minichem enjoys both UK and US design patents.

Taking hygiene into account Another challenge addressed by Jones is the increasing demand from the food, beverage and pharmaceutical industries for hygienic, easily cleaned equipment. Flotronic’s new ‘H’ series pump takes the company’s readily cleaned and maintained ‘one-nut’ design, already proven in hygienic product transfer, and enhances it with wetted surfaces polished to 32μin Ra maximum, an electro-polished overall finish, an electronic rather than pneumatic rupture protection system and a specially designed support stand allowing full rotation for draining. These critical design enhancements have secured 3-A Sanitary Standards accreditation, which confirms cleanability of equipment, the provenance of the parts and raw materials used and the

Fluid Handling asked Jones to come up with five challenges which Flotronic Pumps and other commercial pump manufacturers have faced over the last few years. ‘Pressure’ characterises his fifth example.

‘The traditional AODD pump design has an inherent problem,’ Leighton explains. ‘Any pressure introduced into the suction line, often referred to as “unsupported head”’, can cause stress on the pump’s diaphragms which can ultimately lead to diaphragm failure.

Unsupported head in conventionally designed AODD pumps can also cause process liquids or cleaning liquids to leak through into the pump air system which can subsequently cause damage in the air valve and ultimately either completely destroy or block the air valve and very probably escape the pump into the immediate pump environment. This can be a problem with unsupported head pressures of as little as 0.5 bar.

‘Flotronic’s ‘one-nut’ design allows us to fit a reinforcing plate behind each of the process diaphragms in our pump range. This means that the pumps can withstand pressures in the suction line of up to 7 bar with no damage to the diaphragms,’ he adds.

‘This confers huge advantages, for example, in the food and beverage industry where if any pump has to be cleaned in place using a CIP system, it has to be able to withstand up to 3.5 bar of pressure that the CIP system produces and forces through the pump to ensure cleaning. The reinforced diaphragm option offered on our 316L stainless steel slimline range of pump is used extensively in these industries, fully protecting the diaphragms from any possible stress caused by this pressure.

‘There are advantages too for the pharmaceutical and chemical industries where CIP or steam in place (SIP) of pumps in process lines are concerned. For example, pumps used in sampling lines on top of reactors often need to have either CIP liquid, steam, or dry air/nitrogen blown through them at pressure as part of the cleaning and sanitation regime. This can cause damage to a conventional AODD pump. Again, Flotronic’s 316L stainless steel, PTFE and Hastelloy pump range can be fitted with the reinforced diaphragm option fully protecting the diaphragms from pressures of up to 7 bar.

‘The chemical and general industries can also benefit. Chemical bulk storage tanks/ containers often hold liquid at more than 5m above the pump, which can lead to an unsupported head of more than 0.5 bar.

Reinforcing the diaphragms on the Flotronic pump means this pressure does not damage the diaphragms as is possible in pumps with the conventional design.

‘Conventional air-powered diaphragm

pumps can be a problem for any company where bulk tankers or containers holding the product to be pumped are pressurised to help with priming the pumps, as is sometimes the case with highly viscous materials. Using the reinforced diaphragm option available with Flotronic’s pumps again ensures that the diaphragms are not damaged by the unsupported head resulting from this pressurisation.’

Leighton cites two other examples of process pressures that Flotronic pumps can deal with. ‘Large tanks containing product like wine need re-circulation to maintain suspension and avoid separation and the build-up of sediment. These tanks are often as much as 7m high causing pressure on the re-circulating pump. Fitting the Flotronic pump with diaphragm reinforcing plates avoids any pump damage. And the pressure arising from thermal expansion, which can happen, for example, when solvents are exposed to sunlight, also presents no problem when diaphragm reinforcing plates are in situ.’

‘In fact’, says Leighton, ‘any Flotronic pump fitted with our reinforcing plate barrier system can cope with any “unsupported head” pressures up to 7 bar. As far as we know, this is not the case with any competitor airoperated-diaphragm pump.’

Leighton talks about some of the diverse applications which employ Flotronic pumps to overcome any process obstacles. ‘They include a large food manufacturer transferring a meat, potato and carrot filling for its Cornish pasties’, he says. ‘A cosmetic manufacturer transfers Dead Sea mud in the production of face packs with their pumps. The pumps are also being used for the safe transfer of concentrated sulphuric acid at an oil refinery along with transferring hazardous materials in the nuclear industry. All are applications facilitated by high-specification Flotronic pumps.’

In brief, ease of maintenance to minimise process downtime; European Directives on potentially explosive atmospheres; demand for cost-effective aggressive chemical pumps; everincreasing hygiene standards and increased suction line pressures are all key issues facing pump manufacturers.

Flotronic Pumps clearly enjoys a challenge – and recognises that there will be more to come. ‘We’re really proud of our pioneering heritage’, says Leighton, ‘and welcome any new opportunity to adapt and evolve our products.’

For more information:

Visit: www.flotronicpumps.co.uk

Valve testing

in practice and why Fugitive emissions (FE) are emissions of gases or vapours from pressurised equipment due to leaks and various other unintended or irregular releases of gases, mostly from industrial activities. As well as the economic cost of lost commodities, fugitive emissions contribute to air pollution and climate change, and present a risk to employees. For example, hydrogen fluoride, which is extremely dangerous to human health even in small quantities, is widely used in the petrochemical industry.

Research has shown that leaking of faulty valves, valve parts, flanges and their appendages are responsible for the majority of fugitive emissions in (petro) chemical plants.

Due to this fact valves need to perform to the highest standards. According to the European Sealing Association (ESA) the rate of fugitive emission in the US has been estimated to be in excess of 300,000 tonnes per year. The rate of fugitive emissions from European refineries ranges from 600 to 10,000 tonnes of volatile organic compound (VOC) per year.

Industrial Testing and Inspection Services (ITIS) is an independent technical service company specialising in the field of NDT (Non Destructive Testing) and leak testing, especially valve testing. Most of its projects are related to the oil and gas industries.

Located in Heinkenszand, the Netherlands, the company’s test facility is able to test products including valves, appendages, vessels, heat exchangers and gaskets for functionality, emission, endurance, leakage and safety.

For almost all valve-related products ITIS offers solutions to all NDT and NDT-related services. The facility is a one-stop shop for testing newly manufactured products, prototypes and revised valves but on-site leak testing, project supervision and consultancy can also be provided.

In the ITIS test laboratory, hundreds of type approval and production tests are performed annually under controlled conditions for standard specifications as well as by customerspecific demands. The test conditions can vary from deep vacuum to a pressure of 1500 bar gas with temperatures of -196°C to 800°C

(and over) during high temperature tests or fire safe tests. The required operational cycles can be performed with computer-controlled actuators.

All measured data can be recorded by a log and registration system so that reporting of tests is simple. It is also possible to witness valve tests ‘live’ via internet, including test data and video images.

Type approval Type approval tests for valves are established to check the usefulness of valves, particularly on seat and sealing components. These tests are needed to see if a certain valve is able to withstand the required conditions. Besides the FE tests during the type approval tests and production, the measurement of fugitive emissions in practice is equally important.

Most standards specify the test temperature, pressure and operational cycles. Fugitive emission type approval test standards most widely used in Europe are: TA Luft regulation in Germany, ISO 15848-1 (worldwide), and SPE 77/300 which is the current specification regarding Shell Type Acceptance Testing (TAT). A type approval test could result in a perfect fugitive emission rate but could, however, be a disaster in practice

concerning seat leakage when seat testing is not part of the type approval test.

TA Luft is a test at ‘practical conditions’ but this is a broad concept, so the test temperature and operational cycles are not strictly prescribed. For example, a valve with a TA Luft certificate tested at ambient temperature with 10 operational cycles is only guaranteed for these conditions. These valves could then be sold with a ‘guaranteed’ TA Luft certificate under different conditions to those they were tested under. If built into a plant with a temperature application of -40°C and hundreds of cycles per day the consequences could be serious.

The international ISO15848-1 standard requires fugitive emission testing and operational force at specified temperature steps, the number of operational cycles is specified by the recommended endurance class.

Looking at these three type approval tests, the SPE 77/300 is the only type approval test which specifies all facets of a valve: functionality, external leakage and seat leakage at the specified temperature range.

Sealing materials and certification Besides the type approval testing of valves, valve manufacturers can choose for higher reliability by only mounting sealing material in their valves which has been previously approved during testing at the entire guaranteed temperature range. An example of a type test for packings is the API 622.

Unfortunately, some valve manufacturers make their choice for sealing material for a certain valve application according to information published on a website or in a brochure without taking possible test reports into account. Sealing materials for valves include gaskets, seals or O-rings and (soft) seats. Applying these materials in their valves is actually a leap of faith and can lead to high risk.

At ITIS, test operators have seen plenty of sealing materials which should perform perfectly, according to the brochure of the

Certificate and test report

sealing manufacturer, concerning pressure and temperatures. Too often these materials are sold for a pressure temperature (PT) range without ever being tested at these conditions. In some cases these materials are not sufficient for applications other than low pressure and ambient temperature.Valves to be type approval tested with these sealing materials should, in theory, be able to pass a test easily. However, it is not unknown for a valve to fail on the first helium pre-test.

In the past, ITIS has tested valves for a Leakage of body gasket via bolting

A certificate of a type approval test says something about the performance of the valve at certain test conditions. However, it is arguable that the associated test report is actually more important when it comes to the performance and operation of the valve in practice.

In the test report you can find all necessary information, such as test temperatures, the necessary torque for the gland bolts bush needed to meet the minimum requirements to start the test, including some possible adjustments of the gland bush bolts during the test. This information is essential to guarantee a proper valve operation in practice and the valve performance in relation to fugitive emission.

On site fugitive emission testing

Crack in valve body casting

Stem leakage due to leaking bellow during valve pre-testing

project that were equipped with a special ‘low temperature’ O-ring as a stem sealing.

Unfortunately, the valves were tested at ambient temperature only. All valves passed the ambient tests perfectly. Once built into the plant and exposed to the practical conditions of -40°C, all valves failed.

a test report showing a certain leak rate ‘A’.

However, a retest has resulted in a leakage rate ‘C’, or worse. Sometimes, even a new stem seal replacement by a different type or brand seal has been required to meet the maximum allowable leak rate required by the end-user.

One reason for the different test results might indicate that, during previous tests, the hold duration is not respected. A general observation of many international standards teaches us that the defined hold time for general testing and fugitive emission testing is often too short. Most leakages will appear after a hold duration of minutes instead of seconds.

Often a hydrostatic body test of 15 seconds is too short for most valves (for a 2” valve the hydrostatic test duration is 15 seconds, according to API 598 or ISO 5208). The hold duration should be minutes rather than seconds, especially for higher ratings. The performance of valves in practice should be guaranteed longer than 30 seconds.

Leakage of an O-ring at low temperatures

Hold duration When conducting tests, ITIS is not only focused on fugitive emissions from seals or gaskets but the entire valve body. Sometimes the leakage is via a thread or bolting and not through a gasket. It is even a possibility that a valve is leaking through the body.

During random retests by ITIS, some valves have arrived at the company’s test facility with

Leaking valve during hydrostatic and FE testing

ITIS is often asked to test complete industrial installations for leakages after overhaul or during shut down. Usually all components of the installation will be independently tested for possible leaks.

Any potential leaks, such as valve stem seals, flanges, gaskets and fittings, will be taped to create accumulation chambers (hood method), as tracer gas – usually helium or hydrogen – will be used.

After pressurising the system with a tracer gas (mixture) and respecting a certain hold duration, all chambers of the parts to be tested will be checked for an increase of tracer gas concentration by a mass spectrometer.

The hold duration depends on the tracer gas concentration, volume of the accumulation chambers and maximum allowable leak rate.

The cause of leaks can be attributed to any number of things; wrong gasket, gasket installed incorrectly, loose bolts/nuts, or absence of a gasket or bolts.

Most of the time only the parts which have been disassembled and reinstalled during the overhaul or shut down have to be tested for leaks. However, during some tests it is necessary to measure a high tracer gas background in the plant, for example with ‘high leaker’ stem seals of valves, where leak rates of more than 10cm3/second per stem seal are no exception.

Routine inspections of process equipment with gas detectors can be used to identify leaks and estimate the leak rate in order to decide on appropriate corrective action.

Proper routine maintenance of equipment reduces the likelihood of leaks.

For more information:

This article was written by Colin Zegers, managing director, ITIS.Visit: www.itis-nl.com

Valve maintenance

David Matherly

As production and utility plant areas prepare for upcoming maintenance turnarounds (TAR), outages, and shut-downs, effective planning can save time and curtail expenses associated with the testing, repair, and replacement of control valves within the plant’s total valve population. Effective planning is also a key component to smoothly managing both internal maintenance employees and externally contracted technicians that will be performing the work. Manpower resources make up a large portion of the total expenses associated with the outage so organisation becomes just as important as those planning processes.

While outage employees will be required to document all valve repairs and their associated usage of parts and equipment, plant facility employees will eventually be required to update all equipment maintenance history records with that very repair and replacement information.

In many cases, existing plant Preventive Maintenance (PM) programmes have already identified or scheduled the repair of critical valves within the plant’s valve population.

That PM programme may depend on the utilisation of an existing Computerised Maintenance Management System (CMMS). It can be helpful when scheduling work to be performed during the outage and reconciling its listing of poorly performing valves already identified.

Another method used to identify control valves that need attention is to perform a ‘walk down’ of the plant outage area. A walk down reduces the chance of missing or misidentifying the testing and repairs of those known ‘bad actors’ and reviewing the valve population in this manner can help prioritise or de-prioritise the repair or replacement of expensive valves during the outage over the less expensive valves. This is especially important when considering budget constraints and criticality rankings.

Long before the planned outage date, an estimated budget dedicated to the testing, removal, and repair or replacement of problem valves has usually been established. But the outage budget may or may not fall within the overall maintenance budget for the fiscal year. This fact can sometimes limit funding for the outage project and associated valve work, especially if little to no ‘scope-creep’ is planned for during the work event. As unplanned valve-related problems are found and identified, decisions have to be made quickly about financing additional materials and resources required to resolve those problems. Making sure that some form of cost-overrun allowance is planned for within the budget can overt crisis management decisions.

Outage planning usually begins a minimum of six months before the scheduled outage date.

Planners will be familiar with the preliminary budget allocation along with the preliminary equipment list which includes critical valves to be repaired or replaced. They will also set goals, milestones, and

key performance indicators (KPIs) based upon what they believe can realistically be accomplished. In light of both budget and time constraints, there are many key components to planning, performing, completing, and reporting the valve work to be performed during a successful plant outage.

Once the outage date(s) and period is firmly established and agreed upon, the next step is determining what actual valve work needs to be accomplished during the outage.

The walk down can be performed by a qualified area technician, planner, facility or reliability engineer, contractor outage manager (if used), and/or operations manager, but this responsibility can vary depending on the company.

Walking through the outage area and observing poorly performing valves, leaking flange connections, leaking stem seals and packing, noticeable air leaks, bad positioner air gauges, tubing damage, etc., is all part of the walk down action. Any of these abnormalities are documented as well as the valve manufacturer, serial number, valve type, size, positioner, actuator, photos of the tag, and the valve location description. Noting the valve location is important for when the outage manager plans the actual work, so a detailed location description is necessary. The quicker the valve technicians can move from valve-to-valve while keeping equipment and tool relocation distances to a minimum greatly improves efficiency.Valve-specific information should already be electronically stored and associated with the valve tag in the CMMS or other relational database software programme but verification is still required. Sometimes valves, actuators, positioners, trim type, etc., are changed during regular maintenance and not properly documented or updated within the CMMS application. The walk down serves to remedy this problem. The CMMS information can even be updated after the walk down.

The walk down report plays a vital part in establishing the scope of work to be performed during the outage. When the CMMS work tag list is compiled with the tag list and information gained from the walk down, a preliminary valve work scope can be developed in preparation of the kick off meeting.

PM programmes and their associated CMMS documentation, along with normal everyday spare parts strategies, usually dictate to facilities to keep some valve replacement and repair parts on-hand.

Many facilities desire to pull from their everyday repair/replacement inventory first for the outage and/or purchase repair/replacement parts in advance of the outage to hold within their stockrooms or storehouses. But some facilities will prefer to rely on contractor-supplied valve replacement and repair parts so usually a combination of each strategy is implemented.

The required replacement valves list, critical valve repair list, and long lead-time specialty valves

list can be sent to procurement, planning, or contractor personnel for quoting and comment prior to the kick off meeting along with the walk-down report. Long leadtime parts such as special valve trim, exotic materials, specialty function valves, or large control valves can take up to six months to receive.

Once the quotes have been received back for parts and replacement valves from vendors (not including contractor supplied material and manpower), a preliminary work list of valves can be created. Historical CMMS data, outage experience, technician knowledge, and contractor information can all be utilised in determining average repair or replacement times required when reviewing the preliminary work list and planning the outage. An estimated total number of man-hours required to perform the work should be prepared for the kick off meeting. This information will be required when manpower resource utilisation is planned, quoted, and finalised.

Upon completion of the kick-off meeting, a pre-outage logistics meeting is advised. When the outage manager is planning and working out the logistics of the ‘how, where, when, and who’ will be using support equipment needed to perform the valve repair work, interdepartmental communication within the organisation can be very important.

A discussion should take place concerning the equipment and services required to perform the valve maintenance work. The following items need to be considered with action taken prior to performing the repair or replacement of valves on-site during the outage to ensure that the work can be accomplished: • Compressed air availability • Power availability for tools • I/O loop power and controller/DCS signal active for loop checking • Order/rent cranes, rigging, man-lifts, safety harnesses, fork lifts • Machine shop availability and capabilities with notification to the department • Valve maintenance manuals availability or placed on order • Special tools availability or ordered for valve disassembly or setting • Test equipment availability.

Many factors can negatively impact the outage timeline as the planning moves forward and the actual outage event takes place. It is common for additional outage work to take place in adjacent areas to the valve repair locations at the same time so the sharing of cranes, hoists, rigging, or man-lifts may be possible. There can be a downside to other craft departmental personnel performing work in the same area of the facility where the valve work is taking place; access to the valves may be limited.

Another timeline consideration is valves that are located outside on systems such as heat exchangers, flash steam condensate collection tanks, cooling towers, and HVAC units. Local

weather must be considered. Severe weather can impact everything from equipment rental availability to an employee’s ability to travel to work.

There must be contingency plans made to allow the work schedule to change, slide, or cancel and reschedule. A much smaller valve work list with only the critical repair/ replacement valves should be created in case time or resources are limited based upon a severe weather event.

If planned properly the outage work event should be the most ‘non-eventful’ task, barring any major issues found or problems experienced, but that is rarely the case. It is apparent that if all logistical requirements are taken care of and planned for, the movement of personnel, test equipment, tools, cranes/ hoists, materials, and replacement valves, etc. will require less resource time than the actual repair to the valve. Other than unplanned repair parts that are found during troubleshooting, testing and disassembly, most outage materials including repair kits, valve parts, and replacement valves should have been received, delivered, and staged somewhere within the outage facility awaiting the outage event.

As with normal daily maintenance, properly documenting the valve work performed during the outage so that it is historically tracked is as important as analysing its normal daily performance condition. The CMMS system aids in managing the plant’s PM programme and tracks normal repairs. Most systems already require capturing the basic valve information such as manufacturer, serial number, valve type (globe or ball), port size, end connection type, pressure rating, Cv, body material, packing material, actuator information, positioner information, filter regulator and supply pressure. The CMMS must also be updated any time routine maintenance is performed and changes are made to a valve. The outage event work is no different.

During the outage when valves are evaluated, disassembled, repaired or replaced, a brief description of what was accomplished and what parts were used should be completed for the daily summary report. Each valve tag’s before-repair and after-repair photo should be taken to document as-found and asleft conditions. Additional photos documenting the condition of the valve trim, body, actuator, and any accessories such as positioner, I/P transducer, filter regulator, relays, switches, solenoids, etc., are also helpful when reporting the repairs and deciding the disposition of the valve.

Upon completion of the outage and once all relevant valve repair and replacement information has been collected, a post outage report must be written by the outage manager.

An accurate accounting of repair parts, inventory, and purchase orders written for cost overruns and scope-creep issues that arose should be compiled. This will be necessary in evaluating the success of the planning and budgeting portion of the

outage. The plant will use the outage report information to update their CMMS so that valve repair histories can be referenced and PM schedules established per individual valve requirements.

Lessons learned from analysing what worked and what did not during the outage allow the plant to capitalise on the positive actions and not repeat the mistakes that were made when the next outage occurs.

Some of the common criteria for evaluating the outage success include: • Financial – did the outage total-spend amount come in below budget, at budget, or above budget?

• Work quality – were all valves repaired and left as-new and are performing as expected?

• Timeline – did the outage begin, progress as expected and end on-time as forecasted?

• Material overruns – were the correct material, equipment, tools, etc., ordered, used and returned to stock or to the contractor? Or was it excessive?

• Scope and scope-creep – were the right valves chosen, correct work performed, budgeted for enough time and expense?

Were the correct personnel chosen to perform the work and contractor performance satisfactory?

• Safety – what were the number of minor mishaps or injuries, major accidents, and lost-time to contractor and/or facility employee?

The outage planning and execution process requires communication between all participating departments before, during, and after the outage. An accurate outage work scope document can be developed by utilising information from the maintenance contractor, CMMS valve lists, and walk down information.

Using the work scope information to organise operations and maintenance logistics prior to the outage minimises negative impacts to the outage timeline. Documenting all work performed in daily status reports along with taking as-found and as-left valve photos adds detail to the post outage report. This information is required when the outage is evaluated by all stakeholders.

Regardless of how facilities refer to their maintenance shut-downs, outages, or turnarounds, they have similar goals; repair or replace critical systems and associated equipment in the shortest amount of time possible while spending the least amount of budgeted or non-budgeted money. Reaching these goals can be accomplished by utilising a methodical, multi-step planning and outage management process. The process can be changed to suite individual plant outage length and scope requirements, but the core steps should be followed.

For more information: Visit: www.spiraxsarco.com

Valve control Adopted for valve control across a range of industrial installations, electric actuators are often located behind the scenes and, as such, are frequently the unsung heroes of automation processes.

Actuators, which convert signals into mechanical motion, provide essential control for fluid handling processes. Despite their low profile, the functionality offered plays a key role operating large numbers of valves: front end ‘intelligence’ is provided and actuators are essential to the smooth running of a plant.

These often overlooked pieces of technology are widely adopted. For example, all types of power plant need actuation technology to control valves and optimise plant efficiency – applications include coal, natural gas, oil, hydropower, nuclear energy, and combined cycle power plants (CCPP).

Increasingly popular are co-generation plants that make further use of the steam or heat generated for applications in production or district heating processes.

Power plant processes are complex.

Throughout, there will always be some kind of medium flowing through pipelines which needs to be controlled in the most efficient way and numerous valves and dampers, each with specific requirements, which need to be actuated. Applications range from ‘simple’ shut-off processes such as deaeration, drains and isolation valves to continuous modulating controls including feedwater valves, ID and FD dampers.

Technological advancements in actuation that offer a significant step change in functionality are rare: this is due in part to the opportunities for development, but also the skill sets and investment required to initiate advancements.

One company that is investing in this essential automation technology is SIPOS Aktorik, which is part of the AUMA group.

The organisation, which is heavily committed to R&D and employs some of the leading developers in the actuation industry, has a strong reputation for spearheading actuation advancements.

Variable speed actuation advancement A breakthrough Variable Speed Actuator (VSA)

starting’ or ‘caressing’. The reason that a valve needs ‘caressing’ can be explained by drawing a parallel with the motion of an elevator.

To avoid impact on both the elevator and the people using it, a soft start is required. It is equally important Power plants are a significant market for SIPOS where control of medium that the elevator flowing through pipelines is imperative for automation efficiency does not stop dead in its tracks was introduced in the late ‘90s. This provided when it reaches its destination. The lift should an innovative alternative to the traditional ease gently into its journey, gradually gather motor plus reduction gear solution. momentum and slow to a stop at its selected A key area that the VSA addressed, and end point. The science is the same when continues to address, is the issue of ‘soft applied to water – flow needs to be managed.

VSA technology is an innovation that is benefitting a wide range of fluid handling applications

SIPOS Aktorik addressed the pressure peaks associated with water hammer, which have been known to rupture pipes and the widespread damaging impact – this was achieved by controlling the operation speed of the flow restrictor with a variable speed actuator that provides the necessary ‘soft start’ technology.

An integrated frequency converter ensures that motor speed is automatically reduced in the end positions. Therefore, there are no magnification torques if the valve is blocked between the end positions. The voltage for each of the many available speed/cut-off torque combinations is pre-selected so that the cut-off torque setting corresponds to the stalling torque of the motor.

In other words, if a VSA is used, the usual massive current peaks experienced when

Combining the integrated frequency converter with a control board in the VSA gave the flexibility and functionality to provide a solution to ‘soft starting’. The landmark initiative in the history of the actuator also enabled control of the valves in both an open or closed loop; it provided functional reliability which could be monitored in the interests of efficient process operation and ensured that a general high standard of performance and quality could be achieved and maintained.

Additionally, actuator performance is extremely tolerant to power supply fluctuations – even with a 30% voltage drop, speed and torque are not affected.

One case-study example of the VSA in action is the installation of around 1,000 SIPOS Aktorik electric actuators at the Kozienice 11 coal-fired power plant in Poland,

The new SIPOS SEVEN electric actuator range offers state-of-the-art functionality

a motor starts are eliminated and even an unscheduled, indeterminate stop does not result in torque damage.

A further design feature of the VSA is its ability to operate the actuator at different speeds in different sections of the valve stroke – this bypasses critical positions within the process without stimulation by resonances.

It also maintains the process variables, such as pressure, temperature and flow at a fixed level, or a level that linearises the valve characteristics. What can only be achieved via switching on/off cycles (stepping mode) for fixed speed actuators, and with many small impulses with start-up current spikes, is provided as a standard function with the variable speed actuator.

which will extend the country’s power generation capability and provide a dependable electricity supply for the expanding economy.

Working with consortium partner PolimexMostostal, Mitsubishi Hitachi Power System Europe (MHPSE) signed a contract with Polish energy supplier ENEA Wytwarzanie for plant construction.

The Kozienice 11 plant is planned to commence commercial operation in 2017: the unit will operate within an existing power plant complex. Designed to be highly economical with fuel and reduce CO2 emissions, the plant will have a 1,075 gross megawatt output.

The landmark project, which has been hailed one of the most modern power stations of its

kind, underscores the benefits and appeal of variable speed actuation technology. Factors key to SIPOS securing the contract were the company’s advanced VSA technology and local support by AUMA Polska for all service requirements including installation, maintenance and revisions.

Latest innovations More recent actuation advancements initiated

by SIPOS include a valve stem synchronisation solution and the HiMod which, with an accuracy of 0.1-0.2%, addresses the most challenging valve control requirements for high end modulating duty, precision and longevity.

The company’s latest actuator development, which sits alongside the SIPOS 5, is the SIPOS SEVEN – a new range that features a number of breakthrough innovations to enhance the flexibility and functionality of actuation technology. Designed to provide users with versatile control capability, fieldbus compatibility, long-life and reliability, features include colour display, ‘joystick’ control and USB interface. Products include the Ecotron, Profitron and high precision HiMod. The SIPOS SEVEN’s large, full colour display is a first for an electric actuator.

Designed to be easy to read, all essential information is visible and configurable by the user in a variety of different languages. Simple animations provide step-by-step instructions for actuator set-up and operation, reducing the need for instruction manuals on-site. A drive controller also enables easy, intuitive actuator operation: controls are managed with a single, multi-functional ‘joystick’ which has no through-housing connections, ensuring leaktight operation. The drive controller simplifies use of the actuator in any orientation and multi-level access passwords ensure tamperfree operation. Another design breakthrough is a USB interface which means process control set-up can be carried out without connection to a mains power supply using a laptop or USB battery. Set-up and spare parts management is also simplified using the USB port for cloning.

Conclusion The unobtrusive, often unseen, electric actuator performs an extremely important fluid handling function. What might appear to be a static market in terms of development is receiving major investment by market leading manufacturers, resulting in evolutionary changes that are providing significant operator benefits.

For more information:

This article was written by Steffen Koehler, SIPOS Aktorik.

Email: info@sipos.de.Visit www.sipos.de/www.siposseven.com

In favour of actuators The electric and pneumatic actuators of today deliver safe, reliable, hardworking and truly efficient solutions for modern process automation. They have become an integral part of process control, offering functionality that would be difficult to achieve using more traditional, manual valve systems.

Offering the user a cost-effective, single source of on/off and analogue control, actuated valves can be used wherever fluids need to be measured, controlled and/or regulated; in conjunction with ball, butterfly, gate, globe and other types of manual valve.

Integrated solutions Actuated valves not only expand the capabilities of process automation, but deliver a number of benefits and efficiency savings when compared against manual valves.

For applications that require a precise level of control, a range of integrated solutions exist; comprising of pneumatic rotary and linear actuators, positioners and process sensors.

For existing manual valve systems, retrofitting with directly mountable actuators via a comprehensive range of mounting kits can minimise outlay while offering improved modularity, providing system users and integrators with necessary functionality.

iv.) Protection class IP65/67 v.) Flexible mounting solutions according to IEC534-6 and VDI/VDE 3845 (Namur).

Actuated valves and applications The recent launch of actuated butterfly valves, following the introduction of actuated ball, diaphragm, gate, globe and knife gate valves, has provided users and installers with an economical alternative in sizes 4” and above.

Actuated butterfly valves help to create an extensive range of process solutions in larger sizes from a single source for the food, pharmaceutical, bio-technology, water treatment, petrochemical, and oil and gas sectors.

They are generally a better choice for isolation above 4” due to their lighter weight (in larger sizes) when compared to alternative types of valve. This in turn makes them easier to handle and install.

Additional savings on actuator weight are made due to their lower torque, resulting in further cost savings.

It is therefore fair to say that the actuation of manual valves is an integral part of modern process automation as the following three examples demonstrate:

The problem…

An OEM bakery equipment manufacturer was looking to source a large diameter (12”+), bulk handling valve that could be automated into the process. Food grade requirements limited the use of traditional large bulk handling valves i.e. knife gate valves.

In addition, the actuator had to comply with ATEX regulations (due to the atmosphere) and be compact in order to fit within the machine.

The solution…

A food grade butterfly valve with 90º rotary pneumatic actuator was specified and subsequently selected to meet the required levels of certification and the intended application. The actuated unit’s small form factor maximised the limited space available within the machine.

Additional modular capabilities were offered e.g. PIC control (on/off/solenoid manifold) and modulation (actuator mounted process controller).

All elements, including the actuator, were supplied with ATEX certification and suitability.

Process steam The problem…

A steam trace line, remote from the main boiler house, needs isolation at its point of use. It cannot be manually operated as elements are managed remotely via a central computer system.

The solution must be automated and linked to the main control system.

No process air is available and the solution must have position feedback. It must also return to the closed position in the event of power failure to prevent over pressure downstream and safety implications.

What are the benefits?

The benefits of actuating manual valves include: i.) Simple start-up and ease of operation ii.) Efficiency savings over traditional manual valves with reduced downtime iii.) Improved safety solutions that would otherwise be difficult to implement i.e. spring return or battery backup (fail close or fail open) iv.) A higher degree of accuracy and feedback information v.) Can be used and operated where manual valves would be unsafe to operate.

Solutions A comprehensive range of solutions exists to meet every requirement and specification: i.) Pneumatic, hydraulic and electric actuators ii.) Rotary 90º, rotary multi-turn and linear (piston) iii.) Safe area, ATEX zone and harsh (aggressive) atmospheres

Food processing and production

Pneumatically actuated butterfly valve with solenoid

The solution…

An IP67-rated, electrically actuated stainless steel ball valve for steam with extension piece was selected (providing heat dissipation), featuring two limit switches for position feedback.

In the event of power failure the accompanying battery backup system powers the ball closed, together with a manual override; meeting the safety functionality the application demands.

Despite its remote setting, the actuated

Frankfurt am Main · 15 – 19 June 2015

valve delivers improved efficiency, being easily controlled from its central location.

The end result is a compact, effective solution that meets the engineer’s criteria in a way that would otherwise be unattainable, via manual operation, due to a lack of manpower.

The solution also enables the option of retrofitting into existing control systems, thanks to feedback from the limit switches.

Manufacturing (wax filling process) The problem…

Electrically A manufacturer undertaking actuated process wax filling had stainless initially used solenoid valves steel ball to automate its process. valve for Over time, numerous failings steam were identified which included: blocked pilot holes, frequent coil burnout, lack of feedback to the control system and the inability to shut-off effectively due to lack of power and the viscous media.

Replacement manual valves had been identified as suitable replacements but would still not automate the process.

The solution…

Pneumatic piston actuated diaphragm valves were selected, offering a range of benefits over the existing solenoid valves. These included: improved flow, easier maintenance, better shut-off, simple integration into existing control systems and pipework and a future proof solution providing easy integration into future control systems (limit switches, position feedback and modulating control).

Conclusion As an important part of today’s modern process environment, valve actuation delivers a reliable and flexible solution across a wide range of applications; wherever fluids need to be measured, controlled and/or regulated.

For more information: Pneumatic piston actuated diaphragm valve with banjo solenoid

This article was written by the technical team at Valves Online.Visit: www. valves-online.co.uk

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Release the time and cost pressure: gauging the benefits of rupture discs over valves

Saving downtime and associated costs is a major part of managing costs, known to significantly increase efficiency and profitability across many industry sectors.

Most modern process plants now implement pressure control equipment to monitor developments within their increasingly complex systems. To ensure the plant remains safe, it is now essential to also proactively manage variations in this pressure using relief devices to prevent hazards caused by over-pressurisation.

Pressure relief device comparison Traditionally, engineers used reclosing safety relief valves to address this danger. Using spring or pilot-operated valves, the pressure is released if it exceeds the set pressure within the system and the valve recloses when a safe level of pressure is achieved. An increasingly common alternative to a valve is a non-reclosing rupture disc, designed to open and relieve overpressure or vacuum at a predetermined pressure or temperature.

The table below compares some of the key characteristics of the two main pressure relief device options. Rupture discs are very simple, and are often preferable due their ability to withstand a range of pressure and processing conditions. Offering instantaneous and unrestricted relief for a complete discharge

of pressure in the installation, rupture discs are much less complex than valves in their construction and require a much lower upfront installation investment. Rupture discs act as a more effective seal due to their leaktightness. Pressure relief valves are one of the hidden culprits of fugitive emissions, which not only has environmental implications, but financial ones as well. For this reason, even if valves are not located in certain areas, rupture discs are often fitted below them to prevent these emissions from occurring.

Although valves can be adjusted and reused, they are restricted in their mounting options, the size and materials available, as well as the media for which they can be used. However, the biggest drawback, and probably the most costly to any process plant, is the ongoing service requirement for recalibration and maintenance. Reduced downtime means increased efficiency and ultimately greater profitability – a global key performance indicator.

Increased reliability through technological advances The last 50 years have seen a complete overhaul of risk and hazard management, with most companies adopting a safety culture. Following this, the importance of pressure relief device accuracy, as well as the information available on board, is paramount.

Many operating problems with pressure relief devices stem from incorrect selection, so it is always recommended to consult specialists before specifying any particular device. Indeed, users need to be able to rely on their chosen device matching their exact specification requirements to ensure they perform as they should in situ.

Given the clear advantages, many plant engineers now rely upon rupture discs

Safety relief valve

Rupture disc

High installation investment Prone to leakage Extensive maintenance required Settings can be adjusted Multiple use

Simple installation Leak-tight Minimal maintenance required Specification set One-use

Key pressure relief device characteristics

and detection systems as a safety measure to manage their processes in a variety of pressure conditions. The introduction of computer-controlled production equipment has increased the accuracy of rupture discs, which can now be offered with a burst-pressure tolerance of ±3%, a vast improvement on historical values of ±10-15%.

Testing procedures have also contributed to this accuracy, with many rupture discs now being tested to over one million life cycles – over four times longer than previously achieved within the industry.

When a rupture disc operates after an over-pressure event, eliminating the cause and replacing the disc quickly is of the utmost importance. The traditional approach to coping with these events is to purchase spare discs for each installation and retain them in stock on an ongoing basis. The cost of this stock is becoming significant for many plants.

Not only does stock tie up finance, it incurs as stock has to be stored, physically protected and managed. Releasing this cash by managing down the value of stock is becoming a useful technique to increase financial efficiency.

With tighter tolerance discs and the use of advanced manufacturing methods bringing significant reliable lead time reduction, it has been found that a typical facility can reduce the variety of spares by up to 65% while maintaining the service levels required of a modern operation.

Environmental concerns and the drive to reach zero emissions have changed the way many plants are run, particularly as unregulated leakages have implications beyond simply the environment: fines, sanctions and proposed government taxes on emissions could all have considerable financial repercussions. As a result, the need for burst detection alongside rupture discs is vital, as plants need to quickly identify when a disc has burst.

Burst detection developments Traditionally, detection systems featured a simple membrane design, complete with an insulated, electrically conductive path mounted between supportive rings. Following the functioning of the rupture disc, fluid flow would cause the membrane, and in turn the

conductive path, to break, producing an open circuit signal and notification that the disc had functioned and needed to be replaced. This method of detection is useful in many ways, being suitable for a number of applications and as a low-cost option. However, the sensitive nature of the membrane design means it is vulnerable to sudden process changes and corrosive atmospheres, making it liable to give false signals. General maintenance inspections require the disassembly of the disc and holder installation, causing avoidable downtime. Another notable disadvantage is that the membrane is very easily damaged during installation and needs to be replaced, along with the disc. This can lead to expensive stock ordering and holding, while the potential for spurious failures or damage can result in unnecessary plant downtime while a replacement is ordered.

Some alternative methods of detection, such as break wires, pneumatic switches and resettable switches, are reusable, but remain invasive to the process and sensitive to damage through repeated use and general wear and tear over time. However, magnetic technology has offered the ability to develop a more sophisticated system that remedies these concerns. The user’s trust in the reliability of the system has been enhanced with the introduction of a non-consumable, magnetic means of detection that is noninvasive to the process.

Rupture disc burst detection: membrane vs. magnetic

Membrane

Disc with integrated magnet

Detector vulnerable to process environment

Magnetic

Detector immune to process environment

Non-invasive Test-Tel

Magnetic burst detection Recent innovations have led to the development of detection systems which offer greater performance and reliability in a reusable design, offering both a higher level of protection and a cost-effective alternative to traditional methods of rupture detection.

These products operate on simple reed switch and magnet technology, the sensor fitting directly into the disc holder. The disc itself is provided complete with a small magnet. As the disc bursts, the magnet is pulled away from the sensor, giving an open circuit signal. Only the disc itself has to be replaced after it functions, eliminating the need to hold stock of detectors or order excessive spares. Unlike membrane systems, this method of reed switch and magnet detection is non-invasive to the process and so is not susceptible to process change and false signals, and therefore does not affect the performance of the disc. Since the sensor is non-invasive to the process, it is suitable for use in corrosive environments and can

In situ testing during routine maintenance

making maintenance checks more efficient and simple. The fail-safe design only operates when a disc has ruptured, eliminating false alarms and limiting downtime in the event of a rupture disc functioning. Being reusable, the detector only needs to be wired once, which cuts costs – particularly as the cost of wiring often exceeds that of the detector – and saves on downtime.

Summary Magnetic systems are also enhanced by the portable tool, Test-Tel. This tool can check the status of detection and disc, without the need to disassemble the installation.

also be used in explosive atmospheres, in process temperatures ranging from -55°C to 250°C. Such detection is therefore Zone 0 compatible, meeting ATEX and IECEx approvals, with all components featuring a minimum IP66 rating. The sensor can be tested in situ without interrupting the process,

Advantages of integral magnetic burst detection 1. Non-invasive – immune to process conditions and removes potential secondary leak path 2. Integral part of rupture disc – always available and not a secondary SKU 3. One-time fitting – a ‘zero-time’ re-installation requirement 4. Simple and logical technology – reduced complexity Main benefits of using integral magnetic burst detection

In order to monitor and control pressure build up within modern process plants, traditional valves are increasingly being replaced by rupture discs due to their improved specification and reliability. The development of sophisticated integral burst detection systems alongside the discs has further enabled plants to cut costs, increase efficiency and become more profitable all round. The recent technological advances in rupture discs and associated detection systems has gained the trust of users in safetycritical plant processes worldwide, making them the preferred pressure relief option to protect against disastrous explosions.

For more information:

This article was written by Elfab.Visit: www.elfab.com

What does not fit is made to fit

Transmitters are used in plant construction in numerous applications. For example, they detect the pressure or differential pressure in oil and gas pipelines and other process lines.

However, in contrast to a pure measuring device, they not only show the pressure but process the measured values further – the measured input signal is converted into an output signal in the transmitter via various physical or chemical effects. This is often a standardised analogue electrical signal unit which ranges from four to 20mA. Frequency or pulse outputs are also typical variants. The output variable is proportional to the input variable – the higher the measured value, the higher the value at the output of the transmitter. The output signal can then be read on a display or sent directly to a control system. Thus the flow rate can be calculated from the signal of the pressure transmitter to the gas pipeline.

Transmitters are constantly evolving with more and more features.

Additional sensors detect housing or ambient temperatures, processors process data in real-time, wireless modules enable remote monitoring. This means that the Shorter lever handles allow easy opening and closing of the valves manufacturers without the handles hitting against the transmitter housing when turning

of the devices also need to develop larger housings.

But what happens when the transmitters suddenly no longer fit to the manifold? One company, industrial valves specialist ASSchneider, which supplies valve manifolds to process plant operators, has found a simple but innovative solution together with its customers.

New functions cause a lack of space in the housing Pressure and differential pressure transmitters are frequently used in power plants, chemical and petrochemical plants. These are used, among other things, to determine and forward pressure and flow rate in pipelines or the fill levels of liquid containers. They play a central role in the safety and reliable function of processes. With the increasing complexity of the systems, the demands also increase on the transmitter. This means that additional components must be incorporated into the devices: for example, digital outputs, sensors for monitoring the housing or ambient temperature as well as processors that further process the measured data in real time. The displays no longer only show the output signal, but provide a variety of other information and are therefore more extensive than previously.

Add to that the possibility of wireless data transmission and remote monitoring. Many transmitters already have WLAN modules that transmit the output signal to other systems.

The increasing functionality of the transmitter means that the housings are now larger than they were a few years ago due to more components having to be accommodated inside. However, this has resulted in connection difficulties. Most process plants are built as compactly as possible and therefore offer very little space.This also applies to the instruments used.The larger the housing of the transmitter, the harder it is to connect to the measuring point.

When valve failure is not an option.

Increased inclination angle of the valve assembly, which consists of the two vent valves and the equalising valve. Due to the inclined arrangement of the valves, more free space is created on the upper side of the manifold

Pressure and differential pressure transmitters are usually connected to a valve manifold which, in turn, is connected via a pulse line to the plant. Consequently no flow takes place at the two inputs of the gauge. Only the static pressure of the respective medium is exerted. On the one hand, the valve manifold is used as a barrier if the transmitter should need to be removed, for example, for repairs. In this case, two valves seal the connection to the inputs so that the medium cannot escape from the pulse line. In addition, the valve manifold has two exhaust valves – one for each input – as well as an equalising valve which can be used to calibrate the transmitter. The connection of the transmitter is directly connected via a flange.

Thus, the entire structure is as compact and robust as possible.

Standard component no longer meets requirements ‘Our valve manifolds are manufactured for direct connection to the transmitter as standard components,’ recalls Markus Häffner, design and development manager at AS-Schneider. The company from Nordheim,

manufacturer of pressure and differential pressure transmitters to revise our product accordingly,’ says Häffner. Apart from its standard range, AS-Schneider has expertise in the development of customised solutions. The company manufactures numerous instruments and accessories according to the exact specifications of its customers.

New design solves the problem of space The development engineers at AS-Schneider revised the complete design of the manifold and constructed a new top that offers more space and is therefore also suitable for the installation of the larger transmitter. The valve assembly’s angle of inclination was also increased, consisting of the two exhaust valves and the equalising valve. These had previously stood in the way of the transmitter.

Due to the inclined arrangement of the valves, more free space was created. In addition, the developers were able to use shorter lever handles than before because of the low operating torque of the new valve tops. Thus, the valves can now open and close

PR-SM

Pressure-Reducing Control Valve with Integral Back-Up • Reduces emergency call outs • Provides downstream surge protection • Rolling diaphragm design on

‘Increasing transmitter functionality means housings with more components inside, resulting in connection difficulties’

valves 6” (150mm) and up • Ideal for critical applications such as anti-cavitation valves • Complete back-up control if primary pilot system fails • Valve continues to operate

near Heilbronn, Germany, is a manufacturer of instrumentation valves, manifolds and accessories and supplies, among others, numerous operators of process plants in the oil, gas, energy and chemical industry.

‘Recently, customers and also manufacturers of transmitters have experienced the same problem, that the larger transmitters no longer fit on the valve manifolds.’

The reason was soon found – the voluminous housing and the lever handles of the valves were in each other’s way.

The proven standard valve manifolds no longer met the different requirements.

‘Therefore, we received the enquiry from a

smoothly without the handles hitting the transmitter housing when turning.

‘The valve manifolds had now been optimally rebuilt for direct connection to a pressure transmitter,’ says Häffner. These manifolds are now used in various plants worldwide following successful development and installation. ‘No matter how long a product has proven itself in practice, you can still improve it,’ he adds.

For more information:

This article was written by Stefan Heine, sales engineer, ASSchneider.Visit: www.as-schneider.com

until maintenance can be performed.

Contact a Singer Solutions Specialist today!

SINGERVALVE.COM

Radar benefits are out in the open The measurement sites

The inland waterways of the East Riding of Yorkshire are important for many reasons, including navigation, recreation and trade, as well as being a key part of the ‘ecological infrastructure’, providing crucial corridors of green space and a refuge for important wildlife.

Inland waterways additionally provide a crucial flood risk management function as part of the land drainage system. Monitoring the current capacity of each waterway at key points is vital for safely managing or providing accurate warnings of flood risk, especially with the advent of more extreme weather events seen in recent years, in combination with urban development and its effect on drainage to water courses.

A key area of this is monitoring the water level, ensuring that regular information is on hand to manage levels both in ‘drought and deluge’. This information needs to be reliable, accurate and accessible.

East Riding of Yorkshire Council persevered with ultrasonic level and submersible pressure sensor technologies for drainage and open water level measurement for many years.

Recently it turned to Vega radar sensors to solve issues it experienced at a number of sites. Problems encountered included: high maintenance levels, measurement accuracy, sensor replacement and regular ‘loss of measurement’. The applications are located in urban and rural environments – with differing and shared challenges for the sensors.

This case study looks at two of the first applications installed, one in each environment.

The urban application is a typical one: a small unnamed tributary stream which runs close to and under a housing estate in a built-up area, downstream it feeds into the City of Hull sewer network, so monitoring the flow rate is important.

Ensuring that the level and flow is monitored reliably has been highlighted as it is so close to a residential area that has recently experienced flooding.

The site consists of a small culvert approximately 2m wide and typically runs at a depth of between 0.3 and 0.6m, flowing into a concrete underground tunnel structure with an angled metal screen, which prevents larger debris from entering. A nearby industrial estate sited up river has caused occasional large waste items to block the flow through the screen.

A hydrostatic sensor was previously deployed, however the accuracy, especially at low levels, was not suitable.

Silting was an issue and equipment also suffered frost damage at low levels with ice formation blowing apart the sensitive diaphragm of the sensor.

It was then replaced with a non-contact ultrasonic sensor, which did not suffer damage. However, loss of echo would occur in high winds and other

Radar level measurement of a stream in the urban environment: the radar is mounted in a plastic tube, with a 2m measuring range close to the screen and channel edge, following the water level reliably

Rural monitoring site: The radar is mounted off a road bridge on a simple bracket, the assembly is easy to mount, robust and lightweight, easily fabricated and relatively anonymous

Getting reliable readings would be difficult to achieve with other devices, as their installation would be expensive to engineer and maintain.

The flow of the river, potential silting, water traffic and debris would also be factors for any sensor structure or fixing mounted at the side of the river. The measurement point would also need to be inconspicuous in the remote site.

Process challenges for open water measurement

environmental factors would cause unreliable readings. There are existing structures and conduits built to accommodate and mount devices and cables, along with an existing data station installation mounted in a bollard next to the drainage structure, to record and transmit the data to the control centre in Beverley,Yorkshire.

The rural site is a main river heading towards the coast, approximately 20m wide. The river is tidally influenced and in a navigable section with a flood wall protecting a small rural hamlet with vegetation on both sides of the river. The measurement point is on a road bridge and the span is around 8m above the river with a 3-4m level change.

• For level sensors working out in the ‘open environment’ – remote, urban or rural – there are many challenges.

These can be split into two areas: - Operational – weather (wind, ice, sun), corrosion/wear, sensor drift and low power consumption capability - Physical – from plants to spider webs, silting, risk of damage in river flows/ floods, vandalism or theft risk.

• Protection from weather – ultrasonic sensors will lose their signal if the wind is too strong. In fog or heavy rain or mist, attenuation can result in loss of echo. Cold days with sun on the sensors can cause significant temperature-related accuracy issues too. For submersible pressure sensors, ice can cause issues, particularly in shallow water, initiating drift or damage to the sensor and accuracy/linearity is generally not very good with low water pressure heads. This means that, for the

signal and sensor to remain impervious to all conditions, either design of sensor will need mounting in ‘stilling’ tubes or ‘wells’.

These installation costs can add significantly to the cost of a ‘cheap’ level sensor.

• Incidental occurrences – solving the problems for a sensor with a stilling tube can instigate other common issues, such as blockages to the tube by debris or silt causing slow flow in and out affecting the level reading until it is physically cleared.

Webs and debris collecting inside an ultrasonic sensor have also be known to cause problems for loss of echo. Even a submersible pressure sensor may need the cable fixing to a wall or installing down a tube to protect it from being snagged or washed away, but sometimes when removal is needed, they can get stuck, requiring even more time and money, as well as the safety issues of working close to, or in a water course.

• Security from wilful damage – in urban or rural areas sensors can attract unwanted attention, including theft or vandalism. All sensors need some level of protection, or at least a good disguise. Many sites have no power and solar panels are difficult to site unless the area is protected, so the ability to operate with battery power over long periods of time is a necessity too.

How does radar solve it?

Vega has developed a radar level sensor with the water industry as its focus. The sensor needs to be adaptable for outside use, submersion incidents and vandal resistance.

To meet this requirement,Vega’s units are submersible IP 68 (2 bar) and compact enough to be mounted inside a 6” diameter plastic or metal pipe. This means they are ideal for mounting, along with their logger, at a remote site in an inconspicuous way at a minimal cost.

Good focusing often allows mounting closer to a wall than an ultrasonic sensor.

For open water applications, a radar level transmitter is an ideal solution because it needs no extra engineering, like stilling tubes, to protect the signal. Being contactless, it just needs mounting above and looking down perpendicular to the liquid surface. It has very good focussing, which means it does not require mounting out on long arms. Unlike an ultrasonic it can be mounted out in the open, without fear of measurement interference from wind, rain, mist surface turbulence and sun/solar temperature error. They can even measure wave height – as Vega radars emit 3.6 million pulses a second, a rough water surface can be brought to a standstill.

Another critical problem overcome by radar is spiders and insects, as they can cause signal loss for ultrasonic sensors with the webs they weave and more importantly the debris that gathers in them. A radar with microwave signals will just look straight through.

The difference with radar technology

power when no bollard is available. The device is measuring in excess of 10m range as the river is partly tidal at this point.

East Riding of Yorkshire Council is planning to roll out radar technology across a number of its sites and has found the integration and installation with existing data loggers easy using the 4-20mA signal. Brackets and mounting designs have already been standardised and fabrication costs are minimal, using ‘off the shelf’ pipe and brackets.

Radars use microwaves instead of sound pulses to reflect off a surface to measure levels. The microwave signals are virtually unaffected by temperature (e.g. sun on the transducer with cold air near a water surface), vapours (e.g. mist, rain, fog) or air movement (wind). Radar can still measure reliably with challenges like heavy surface turbulence, high levels of foam and they can ‘see through’ nonmetallic materials like plastics, vegetation, and cobwebs. Conversely, they get a high signal return off a water surface.

Radar has a small dead band/blocking distance and is also accurate, typically providing 2mm precision over a range of around 15m (there are other versions with range up to 75m that can measure liquids or solids). It is capable of being spanned down to measure over a few tens of mm with the sensor mounted several metres away, or used over the whole range.

Benefit summary

The site requirements Each site in the council’s area utilises an Isodaq Frog GPRS/GSM data logger. These mainly provide the telemetry on battery power, enabling remote harvest of the data on a twice daily basis, ensuring that the data is collected and trended. Poling sites to retrieve real time data is also an option.

The radar sensors use minimum startup current when ‘awake’, to maximise the battery capacity. This means they can power the sensors, on a 15-minute interval, for up to three years. If connected to mains power, the radar can operate in continuous operation, so they can dial in on a timed or event driven basis, such as flooding or rapid level change.

Sensor set up No special set up of the radar is needed for standard applications as they are preconfigured and ranged. Because of the high accuracy of the sensor, the ranging can be done in the data logger or on the raw data

Simpler installation. A diagram of radar logger design for installation in standard 150mm heavy duty PVC pipe

In the field At the urban site, the radar was mounted in a tube on a simple arm. Fabrication was done with a piece of 150mm black plastic (also good for GPRS/GSM signal) drainage pipe with the bracket arm around 500mm long and the radar approximately 1.8m above minimum level. Despite being close to the bank, it reads the level of the water reliably. Some of the existing cable and conduit was used and the software of the bollard mounted data logger was easily modified and tested with the sensor, to suit the ‘warm up’ time for the radar. Since the set up was finalised, the radar has monitored the level faultlessly every 15 minutes. There are now plans to change the

‘Radar users are seeing reliable and accurate readings with no echo loss through environmental conditions’ values afterwards. However, if needed, the sensors can be re-configured to suit the application parameters via a PC-based FDT/ DTM PACTware industry standard software and VegaConnect interface. It can connect anywhere on the 4-20mA signal cable and gives access to all configuration settings, uses Windows based menus and allows sensor back up files. The low operating voltage of the radar is compatible with most data loggers.

data reading time to a higher frequency as this is a mains powered site.

The rural river site has the radar mounted off a bridge, using a very similar configuration.

The bracket was around 450mm long with 150mm diameter tube approximately 0.7m long. This time the data logger was also installed in the tube, directly above the radar. This compact configuration will be the standard for future sites with mains or battery

Users of radar technology are seeing high reliability and accuracy of readings with no loss of echo from environmental conditions.

Simpler installation – no stilling tubes, cable fixings and special structures and lower maintenance – results in total expenditure savings.

The power consumption, especially over longer ranges (10m+) is much lower than an ultrasonic sensor, without sacrificing performance.Versatility is a key advantage – the same unit for open water applications featured in this case study will also enhance measurement reliability in water, chemical and sewage applications above and below ground; open channel flow, CSOs, chemical tanks, digesters and sludge tank indication.

This creates, for a large utility provider, lower sensor stocks and fewer model choice decisions.

There are models available for even longer ranges (up to 75m) still using the low power 4-20mA Hart, (many versions have communications capabilities for Profibus, FF, SDI12 and Modbus formats). Compact sensors enable easy integration and space savings in SCADA, telemetry, PLC and pump control panels, with no coaxial signal cables and level controller boxes needed.

Non-contact radar also means no drift and re-calibration visits, saving further costs.

Certification for ATEX areas is intrinsically safe. EX ia IIC T6 is suitable for many sensor types – Zone 0, along with SIL 2 approval options, which adds a safety and security element to the approval portfolio.

Radar sensors are now becoming affordable and everyday technology for the water industry. While sensor costs may be a little higher in some applications, lower installation, operational costs, personnel safety and longer sensor lifespans are the result. This technology is being taken forward across a number of utilities, applications and processes, where before it was considered a luxury.

For more information:

This article was written by Doug Anderson, marketing manager,Vega Controls.Visit: www.vega.com/uk

Levelling up Level measurement equipment is arguably the most important instrumentation for large storage tanks. Storage is at a premium, and making the best use of it at a terminal is what the business is all about. And, while some terminals still rely on manual processes for level measurements, the argument for automatic tank gauging has largely been won.

The benefits for terminal operators integrating gauging into the central control room have always been difficult to argue against and are wide ranging: • Accurate tank inventory and availability contributing to improved profits from better utilisation of the storage • Increased safety and efficiency through prevention of spills and leakages to improve compliance with health, safety and environmental requirements, as well as reduced wastage • Productivity; cutting down man-hours devoted to collecting manual readings.

• Improved understanding of the value inside a tank and how much has been loaded or unloaded; in several countries, the tank gauge is used for custody transfer.

The result is that the preference for automatic tank gauging is now both widespread and official; blasts caused by overfilling at facilities in Jaipur in India, Baymon in Puerto Rico, Texas City in the US and Buncefield in the UK, and fuel spills such as one in Caltex Terminal in Sydney in 2013, have focused regulators’ attention worldwide on the importance of reliable level measurement. That focus is manifested in standards, most notably perhaps in API 2350.

Both regulatory pressure and compelling returns, therefore, mean adoption of automatic gauging is increasingly common in Europe, the US and elsewhere in the world.

Looking to wireless In fact, operators have moved beyond simply automatic tank gauging and have embraced terminal-wide wireless solutions. These allow a typical terminal to save $1.5 to $2 million (€1.3 to €1.75 million) per year in materials,

labour, engineering costs and improvements in productivity and efficiency.

The benefits come in part through the adoption of wireless tank gauging, which builds on and adds to the existing benefits from automated solutions. As with automatic gauging, there are clear benefits in operating expenditure from the move to wireless, but capital expenditure savings are also realised to deliver an enhanced return on investment.

Moreover, the benefits are achievable at almost any stage of a terminal’s lifecycle.

First, for new plants, wireless offers much lower installation costs, all but eliminating wiring costs, other than for power, and giving greater freedom in the design and layout of the tank farm. Similarly, for expansions, particularly where existing infrastructure or features such as water or railways make wiring difficult, that increased flexibility is valuable.

ISA100 Wireless (IEC 72734) networks offer a

multiplies the return on investment. The impact on project schedules alone is difficult to overstate. Wireless projects can be implemented much faster than those using a wired system. Once the site assessment is completed, there is little coordination to be done and bringing in additional input/outputs down the road takes a couple of hours instead of days which is the case for wired solutions.

By taking a broader view of wireless, operators move beyond cost savings in wiring and man-hours to achieve a transformation of the terminal operation.

Benefits for productivity, for example, can be achieved from not only eliminating manual rounds, but by equipping operators with mobile devices and intelligent applications, such as Honeywell’s Field Advisor and Experion Mobile Access. This enables them to complete their tasks more efficiently and be a stakeholder in the site’s operational and

‘Terminal-wide wireless solutions allow a typical terminal to save $1.5-$2 million per year’ significant potential range for wireless gauges.

For existing terminals, meanwhile, wireless promises increased efficiency and lower maintenance by eliminating problems such as corrosion of wiring and deterioration (or even theft in some regions), and expands the possibilities when it comes to placing gauges.

The result is cheaper, more efficient and more accurate level measurement.

In Europe, meanwhile, many customers already have wireless infrastructure for other applications and processes and are now looking to extend this to the tank farm.

Innovations such as Honeywell Enraf Wireless Field Interface (WFI), which enables wireless communications for existing installations, will further expand the pool of users.

Wireless, however, reaches far beyond just tank gauging. The lessons from level measurement and overfill protection are applicable elsewhere, and establishing an integrated plant-wide wireless network

maintenance excellence programme. The result is greater asset reliability, with improved asset availability indexes, lower maintenance costs and a more profitable operation.

There are similar savings across safety and security for the plant and personnel.

Leveraging wireless’s flexibility and lower cost, operators can implement CCTV cameras to monitor remote areas and critical assets and processes that may not be otherwise feasible.

Honeywell’s OneWireless Video Solution tightly integrates live video into the central control system to improve detection of abnormal events and improve the speed and accuracy of operators’ responses. Likewise, floating roof monitoring could prevent vapour build up and potential explosions as a result of stuck roofs or serious damage from roof collapses.

For personnel, safety benefits need not be restricted to a reduction in tank climbs.

Console operators can be automatically

For a start, solutions should be genuinely wireless. Honeywell’s SmartRadar FlexLine gauges integrate the entire solution in the device housing.

Solutions that rely on separate gauges, hubs and antennae, remain dependent on wiring to connect the gauge at the top of the tank, the hub, often at the bottom of the tank, and the antenna, again, at the top.

This leaves operators exposed to traditional problems of wiring deterioration through The FlexLine Radar is Honeywell’s most advanced tank corrosion, while using gauging system a system with multiple elements adds to the warned when the wireless portable gas complexity of diagnostics and maintenance. All detectors worn by mobile operators detect this adds to costs. a high concentration of hazardous gases. The Moreover, the extent to which wireless same wireless portable gas detectors also results in a simpler and cheaper installation allow them to quickly locate mobile operators will vary according to the approach taken. at risk and take the necessary actions in an Commissioning should be easy, in particular emergency situation. by allowing local commissioning and overFinally, the regulatory incentives that have the-air provisioning, integrating everything helped make the case for automated tank needed within the body of the gauge ensures gauging are present for wider adoption of this. An integrated screen and keypad means wireless too. Wireless promotes enhanced necessary measurements and entries can be detection of not just leaks and overfills, done, checked and adjusted in place. Without but H2S, other hydrocarbon gas emissions such a display and keypad to enter the data, and baby fires too, with reliable data and however, adjustments and readings need to be alerts communicated to control rooms to verified with the central control room, either improve compliance, aid responses and avoid requiring trips between the two, or twice the regulatory sanctions. Applications in the US, man-power during set up. for example, have helped operators meet Similarly, firmware upgrades can also be OSHA requirements that any alarm generated done over the air, enabling operators to keep be acknowledged within 15 minutes by the gauges at the latest standard and allowing equipping operators with mobile stations so for improved algorithms to be loaded into the this can be done in the field. gauges, for improved accuracy, for example, as The result is savings in both CAPEX and they become available. With a wired network, OPEX that have a profound impact on the this takes a huge amount of time. With a operation. Savings on wiring, labour and wireless network – or at least with ISA100 commissioning time, reduced downtime for Wireless networks, since WirelessHART does setups, and reduced maintenance compared not support this approach – updates and with wired installations are typically between upgrades take only minutes.

60 and 70%; time savings over wired Perhaps the most important aspect for installations between 55 and 80%; and overall harnessing the wider benefits of wireless system cost savings of between 60 and 75%. technology, however, is the integration of Furthermore, because it is an integrated, other systems and devices. Again, much plant-wide system, funding for establishing the depends on the wireless network that is infrastructure for a wide range of applications selected. can be spread over several departmental budgets.

With Honeywell’s OneWireless solution, Taking a wider view of wireless opportunities the same wireless infrastructure used by the means the investment no longer has to be purely ISA100 Wireless devices is also used by Wi-Fi allocated to field devices or gauging. devices to support applications that require Wi-Fi connectivity such as wireless portable Getting the right system gas detectors, wireless videos and handhelds.

The result is a wide range of applications However, the potential benefits will not be managed within the scope of a single wireless fully achieved by every wireless system. Much solution: tank gauging, overfill alarming, and depends on the technology used to implement floating roof monitoring, but also workforce it. mobility solutions, fire and gas detection,

personal safety equipment, perimeter and critical area monitoring and mobile video monitoring.

Measuring savings Terminal operators today therefore are no longer simply faced with evaluating the cost savings and efficiency that can be achieved by automatic tank gauging; nor the cost savings achieved through the move to wireless gauging, or even the benefits of a wider wireless portfolio of solutions that are now open to them. The case for all these is so well made, it should be accepted already.

With those advantages well established, assessments will focus on the savings that can be achieved by competing wireless solutions.

Many applications provide functionality beyond instrumentation and use Wi-Fi to do so. A single wireless network for Wi-Fi and instrumentation (ISA 100 Wireless) such as Honeywell OneWireless, therefore, not only provides flexibility and ease of integration, but also offers approximately 25% cost savings against a solution with separate wireless networks and infrastructure for Wi-Fi and instrumentation.

Finally, in examining the potential for savings, it is not just current requirements and likely uses of the network that are important; the potential for further development is equally relevant.

An open, flexible wireless infrastructure will tightly integrate traditional applications such as gauging, overfill protection and leak detection with wider offerings such as video and personnel tracking, but it also gives plants the flexibility to add new applications as they become available. Plants are already pushing the boundaries in combing different wireless applications. Fire trucks mounted with pan-tilt-zoom cameras, mobile computers and streamers to enable ‘contextual’ video monitoring and coordination with central control rooms for better response to events are just one example of the ways operators are harnessing wireless technologies.

As wireless becomes ever more tightly integrated into the plant, the possibilities and variety of applications will continue to grow.

Those with the correct infrastructure already in operation are best placed to harness the benefits from today’s technology, but will also be better placed for tomorrow.

In applying these, customers need solutions and providers with turn-key experience for the wireless solutions. This expertise and experience not only allows seamless integration of new infrastructure and applications into existing work-processes and culture, but also allows the customer to focus on the core operation of the terminal rather than the technology.

For more information:

This article was written by Vibhor Tandon and John Joosten, Honeywell Process Solutions.Visit: www.honeywellprocess.com

The pressure to conform The early 1960s was a period of significant engineering advancement. In the UK, the Forth Road Bridge was opened to link Fife and Edinburgh, the British Motor Corporation launched the Austin 1800, which went on to become European Car of the Year, and Dorothy Crowfoot Hodgkin became the first and only British woman to win a Nobel Prize in chemistry for her work using X-rays to determine structure in biochemical substances.

Meanwhile, in Japan, global automation business Yokogawa was developing its first pressure transmitters, which represented a significant step forward in pressure and differential pressure measurement.

Accurate pressure and level readings are essential to the safe, reliable and profitable operation of plants. Both are key process variables, alongside considerations such as flow, temperature and liquid interface.

The pressure under which a material is held can severely impact product quality by increasing variance and reducing efficiency.

Crucially, accurate pressure measurement is also a key component of an effective health and safety strategy. For example,

maintaining correct boiler pressure by controlling the inflow of air used in combustion and the outflow of exhaust gases is crucial in preventing boiler implosions that can clearly threaten the safety of workers.

Accurate pressure measurement is critical in batch chemical and oil and gas applications in particular, as well as the pharmaceutical sector. However, it is hugely relevant across the process industries, from food to plastics and from metals to cosmetics.

Differential pressure transmitters compare two pressures and transmit the difference to a control unit, performing multiple functions. For instance, by applying Bernoulli’s equation, differential pressure transmitters can be used to infer the flow of fluid through a pipe.

In fluid dynamics, Bernoulli’s principle states that for an inviscid flow, an increase in the speed of the fluid occurs simultaneously with a decrease in pressure or a decrease in the fluid’s potential energy.

Differential pressure monitoring applications include filter monitoring and

feed pressure monitoring in liquid or gaseous media, density and flow measurement, measurement of aggressive or viscous media, flow measurement of gases and vapours, level measurement of aggressive or adhesive media, measuring liquid in pressurised vessels and interface measurement.

Defining our terms Because of the pressures engineers face, it is not uncommon for a non-specialist to come across problems in specifying pressure transmitters as the result of loosely defined technical terms.

Transducer accuracy refers to the degree of conformity of the measured value to an accepted standard. It is usually expressed as a percentage of either the full scale or of the actual reading of instruments. In case of percent-full-scale devices, error increases as

and gas, where factors such as validation and traceability, lack of access to remote applications and the hazardous nature of the environment mean that maintenance opportunities have to be carefully scheduled.

Similarly, in these sectors it is essential that the manufacturer you choose to partner with can provide a range of materials for wetted parts to cater for aggressive process media.

The most advanced pressure transmitters on the market use silicon resonant sensors, fabricated from a single crystal, using proven 3D semi-conductor micromachining techniques.

In these cases, two ‘H’-shaped resonators are patterned on the sensor, each operating at a high frequency output. As pressure is applied, the bridges are simultaneously stressed, one in compression and one in tension. The resulting change in resonant frequency produces a high differential output (kHz) directly proportional

‘The most advanced pressure transmitters use silicon resonant sensors made from a single crystal’ the absolute value of the measurement drops.

Repeatability refers to the closeness of agreement among a number of consecutive measurements of the same variable.

Linearity is a measure of how well the transducer output increases linearly with expanding pressure. Finally, hysteresis error describes the phenomenon whereby the same process pressure results in different output signals, depending on whether the pressure is approached from a lower or higher point.

Choosing a pressure transmitter In choosing a pressure transmitter, it is important to take into account the key benefits it can provide. The market for this kind of product is extensive and includes many grey market devices that can negatively impact on product quality or health and safety.

Digital precision is an essential element in this choice, something which goes hand in hand with a high level of repeatability. This also removes the possibility of errors in the analogue to digital conversion process.

In choosing a differential pressure transmitter, one should ensure that it provides the ability to measure differential pressure and static pressure in a single instrument. This kind of versatility is essential in the modern, highly adaptive process environment. In such a product, overpressure protection is also essential to obviate the possibility of damage to the device.

In all pressure transmitters, a high level of accuracy, repeatability and stability is essential, as is a robust and reliable design, particularly in hazardous environments.

Weight may also be a consideration, depending on the application, and easy maintenance almost certainly is. This is particularly true in batch chemicals, oil

to the applied pressure. This simple time-based function is managed by a microprocessor.

The net effect of silicon resonant technology is that temperature effects are reduced to less than 1/10th of other silicon technologies (10 ppm/˚C), making these sensors stable in the most demanding process applications.

The output produces a much higher signal to noise ratio than traditional analogue sensors and, compared to piezoresistive silicon sensors (the silicon resonant sensor’s immediate predecessor) the output is at least four times greater. Errors resulting from temperature and static pressure are thus insignificant in relation to total output.

Finally, one should ideally consider advanced digital diagnostics to help avoid unpleasant surprises and minimise downtime. Other essentials are mass flow output direct from the transmitter, without the need for a flow computer, thus minimising cost, as well as technology to reduce process leak paths.

Common application problems One frequent application issue is impulse line blockage. Common differential pressure sensor configuration includes impulse lines that couple the sensor to the process fluid or gas to be measured. The impulse lines are typically small bore lines filled with a fluid. This fluid provides pressure coupling between the sensor and the process.

Dirt in the process can settle in these lines causing blockages to form. Typical blockages include solid depositions, wax depositions, hydrate formation, sand plugging, gelling, frozen process fluid plugs and air or foam pockets.

All of these blockages can cause errors in measurement.

The impulse line condition can be detected

by extracting the fluctuation component from the differential pressure and static pressure signals. The extracted component of the process fluctuation is used to determine the amount of impulse line blocking. The ability to detect the early signs of instrument impulse line blockage problems is a key requirement of an advanced differential pressure transmitter.

While this is not by any means a common function of even the most advanced products currently on the market, it is very useful.

Standards and accreditations As with most equipment used in the process sectors, it is essential for the pressure transducer you choose to provide the appropriate accreditation to the most relevant industry regulations and standards.

Typically, these would include hazardous area accreditation such as ATEX (Appareils destinés à être utilisés en ATmosphères EXplosibles) and testing-house approvals from accreditation agencies like FM Approvals and CSA, as well as the IEC (International Electrotechnical Commission). One might also expect marine certificates, CE marking, GOST for transportation into the Soviet Union, PED (Pressure Equipment Directive) compliance and SIL2/3 capability (Safety Integrity Levels determined by TUV Nord and certified to IEC61508) as standard.

What does the future hold?

Generally in industry, pressure exceeding 1,000 psig (pounds per square inch gage) is considered to be high pressure. However, due to advancements across the sector, there are now devices that can measure high pressure up to an incredible 200,000 psig or more.

To give an indication of scale, extremely high power water jet cutters might operate at 100,000 psi, the pressure on the hydraulic system of an Airbus A380 is around 5000 psi and the blood pumping through your veins while you read this is probably somewhere between 1.55 psi and 2.35 psi.

The demand manufacturers of pressure transmitters face is the continually developing requirement for even higher pressure measurement than is currently offered to the marketplace. While manufacturers provide this, they must also maintain high standards of accuracy, stability and repeatability along with robust construction, low maintenance and suitability for the application.

Pressure measurement has certainly come a long way since Yokogawa introduced its first products in this sector in the early 1960s.

However, just like the Forth Road Bridge, many of the company’s oldest technologies are still relevant today.

For more information:

This article was written by Andrew Fenn, UK product specialist for transmitters and flow,Yokogawa.

Visit: www.yokogawa.com/uk

The UK petrochemical and chemical industry has been implementing higher safety standards at new and existing plants since 2009, following recommendations agreed with the Health and Safety Executive (HSE) in the wake of major refinery accidents in the UK and US. Due to the nature of fluids stored at refineries, petrochemical and chemical sites, pipe seals must be able to withstand substantial liquid pressure. They must also have a level of resistance against corrosion to maintain bund wall integrity against oil and chemical spills or leaks.

Safety background New safety recommendations were agreed by a number of UK oil and chemical industry associations and the Health and Safety Executive (HSE) and Environment Agency in 2009.

The UK Petroleum Industry Association, Chemical Industry Association, Tank Storage Association and UK Onshore Pipeline Operators’ Association backed the HSE recommendations, along with the TUC and Environment Agency.

The HSE report recommendations included an emphasis on easier inspection, testing, reliability and maintenance of facilities, and better tertiary containment measures to prevent the escape of liquids from sites.

It was also agreed that revised standards should be applied to new-build sites and to new partial installations. On existing sites, authorities said it might not be practical to

fully upgrade bunding and site drainage. If so, operators should develop and agree on risk-based plans for the phased upgrading as close to new plant standards as is reasonable practicable.

Other key recommendations included: • the prevention of flammable vapour clouds forming • training, experience and competence assurance of staff for safety-critical and environmental protection activities • management of instrumented systems for fuel storage tank installations and improved transferral safety The regulations mainly affected the chemical industry but also businesses which store fuels including gas and those with large warehouses or distribution facilities or which manufacture and store explosives.

The HSE emphasised the importance of trust between all parties and a willingness to voluntarily accept measures that require significant investment in financial and human terms.

The HSE enforces Control of Major Accident Hazards (COMAH) regulations in England and Wales with the Environment Agency. In Scotland, the HSE works with the Scottish Environment Protection Agency. The regulations aim to ensure that businesses take all necessary measures to prevent major accidents, limit the consequences of any major accidents, reach high technical standards in existing, new and emerging technologies, and share good practice.

Mechanical seals are recommended because

A Roxtec RS150 round frame, in stainless steel, and seal

they allow for the inspection of a pipe passing through a wall and they can be easily checked over time.

International cable and pipe seal specialist Roxtec has supplied its products and training to a number of UK petrochemical sites recently, protecting people and property from spills, leaks and multiple hazards, and ensuring businesses meet the latest safety standards.

Roxtec seals can be used in a variety of structures and hazardous zones where safety is paramount. They are used across many industries including fluid-handling sectors such as water treatment, oil and petrochemicals.

The company’s products perform a key role at oil refineries and chemical plants, sealing cables and pipes passing through floors, ceilings, walls and equipment like junction boxes and enclosures. Likewise at water treatment sites, they are used in control rooms and treatment buildings.

Two recent projects at an oil refinery and a polymer plant highlight the use of products like Roxtec’s. At a UK oil refinery, the company carried out retrofit work on bund walls, which offer a secondary line of containment to protect environments from spills or leaks.

Roxtec sealing solutions, which can be opened to allow for inspection, were installed on existing cable penetrations which needed upgrading to meet the latest recommendations. In this case, there was a strong focus on preventing oil spills and leaks, corrosion of pipes and seals, and in protecting the structural integrity of storage tanks and retaining walls.

At the refinery, Roxtec retrofitted its

An example of Roxtec’s G frame

on a number of UK refineries, specifically around existing cable and pipe penetrations.

HSE guidelines for petrochemical sites include recommendations about the sealing of cables and, more specifically, pipes passing through bund walls. The structure of bund walls, joints and pipework penetrations should be fire-resistant. Where existing penetrations are identified as weak points, new penetrations should be fitted that meet the BS EN1366 fire-resistance standard, super-ceding BS476-1987. The latest standard contains test procedures to ensure fire dampers are installed properly.

‘Mechanical seals are recommended as they allow inspection of pipes passing through walls’

openable GH frames on bund wall areas where existing cable penetrations needed upgrading to meet current health and safety regulations.

The transits were required to fit around existing cable penetrations and to meet liquid pressure of 4 bar and a H60 fire resistance rating. The system was further tested by being fully submerged in diesel oil for four weeks.

At the end of the submersion test period, the sealing system showed no reduction in performance levels.

The Roxtec Multidiameter modular-based sealing system meets three key safety criteria for petrochemical sites – fire, corrosion resistance, and liquid containment. Due to their removable layers, the sealing modules can be adapted to seal a range of pipes and cables measuring from 3.5mm to more than 500mm in diameter. The system has been used

It is also recommended that seals should meet a liquid containment level, outlined by the water standard BS8007. This standard includes recommendations for the design and construction of a range of concrete structures to contain or exclude liquids, the need to carefully consider liquid pressure on walls and joints, and the impact of ground movement, soils, chemical deterioration and cracking on structures.

The second case was at a UK polymer plant, where Roxtec G frames were bolted onto modular buildings to provide ingress protection and on internal walls, to act as fire barriers for sealing electrical control and instrument (EC&I) cables.

The G frame is a flanged metal frame available with a single opening or in combinations of several openings in various widths and/or heights. The frames can be

attached to walls or partitions by bolting, casting or welding. A casting mould accessory and a GE extension frame accessory are also available.

In some projects such as bund walls, individual pipes pass through individual entry points. However, in other cases, a number of pipes or cables are passed through a single entry point in a wall or cabinet which maximises space and efficiency.

Software The polymer plant cable sealing system was designed by contractors using the Roxtec Transit Designer computer software and installed by other contractors after on-site training from specialist staff.

This software is used to plan pipe and cable transit solutions. It offers a range of services to designers across many disciplines and industries – whether they are planning petrochemical storage facilities, industrial buildings, pharmaceutical facilities or ships, for example.

The software produces detailed designs, showing how and where pipes or cabling will be located, after analysing safety requirements and adapting these for the specific structure being designed. Finally the software produces drawings indicating the best overall design.

Roxtec is now sealing electrical equipment, panel enclosures and containerised equipment by challenging traditional cable gland products.

Its testing has shown its seals are slashing costs by being quick to install and easy to maintain. In the US, cable glands are often known as a cable connector or fitting.

For more information:

This article was written by Graham O’Hare, managing director, Roxtec UK.Visit: www.roxtec.com/uk

Bearing isolator seals - an ideal way to reduce TLC and MTTR costs As the name suggests, bearing isolator seals are primarily used to protect often the most expensive components in any rotating plant and equipment – the bearings. They utilise labyrinth technology with other methods to protect bearings from contamination ingress and lubrication egress.

There are many other dynamic seal types available which, at first glance, can provide the same function as a bearing isolator seal, most of which are contact seals which, by definition, have a sealing element in contact with the rotating shaft. However, there are numerous benefits that bearing isolator seals offer compared to other seal types available, including: • An extended service life. Where an oil seal’s life is typically measured in weeks or months, bearing isolators will typically last a few years • An oil seal without lubrication will wear either the seal or the equipment, whereas – depending on the design – an isolator can run dry, partially lubricated and, in some circumstances, completely submerged • Bearing isolators are also considered to be equipment-friendly. A contact lip seal in a contaminated environment could potentially cause the shaft to groove due to friction • Friction generated by contact seals also equates to power loss during motor/pump operation • Bearing isolators are ‘non-contact’ seals, thus will not cause shaft grooving, and consume considerably less power overall than traditional contact seals.

All of these factors contribute to longer periods required between scheduled maintenance, reduction in unscheduled maintenance, and extended equipment life, resulting in significantly improved TLC and MTTR.

Bearing isolator seal basics To understand the benefits of bearing isolator seals it is important to understand the key elements in their design:

Fig.1 Hybrid bearing isolator sealing an oil flooded gear box

Fig.2 Labyrinth seal

• The stator is typically fixed to the housing either by being pressed into a recess or surface mounted. In Fig. 2, this design is pressed into the housing and retained by the two adjacent stator O-rings • The rotor is in static contact with the surface of the rotating shaft. The larger section singular rotor O-ring is used to create a static seal between the rotor and the shaft • The unitising element is a critical component in the operation of a bearing isolator seal. It not only keeps the rotor and stator apart, it also provides a low-friction bearing surface to provide an energy efficient sealing solution.

What bearing isolator types are available?

There are numerous styles of bearing isolator seals available to suit different applications but they can be broadly classified as: • Metallic • Non-metallic • Composite

Metallic design Many metallic bearing isolators are manufactured from bronze due to its ‘nonsparking’ nature.

This is essential in most process industries where the risk of sparking cannot be tolerated due to the consequent risk of explosion.

The inherent low shearing forces of the bronze itself means that should, however unlikely, the Fig.3 Metallic bearing rotor and stator isolator come into contact with each other resulting in the shearing of small pieces of bronze, then subsequent pieces will be of sufficiently low energy and temperature as not to ‘spark’ and therefore are not a potential source of ignition.

A typical bearing isolator design is outlined in Fig 3.

Fig.4 Cross-section of metallic bearing isolator with micro-cellular filter

The seal can be pressed into a housing and will provide ingress protection. Typically, seals of this design are not intended to be used in a submerged or flooded application and are ideally suited to providing protection against the elements, for example, to protect the bearings of an electrically driven centrifugal pump in a plant room exposed to dust, dirt and contaminants in the air.

For increasingly dusty environments with high levels of airborne particles, additional elements must be added to the bearing isolator seal in order to ensure that the bearings are not exposed to contaminants. The micro-cellular filter prevents particles from entering and passing through the labyrinth.

This design incorporates a shaft grounding ring for protection against electrical discharge machining (EDM).

EDM occurs as a result of an electrical arc that appears when the shaft voltage overcomes the dielectric of the oil film between the rolling element and the bearing race. The electrical current arcs through the oil and grease and melts the steel race wall creating a pit in the surface. Over time, this will develop into bearing fluting, which is an accelerated ‘washboard’ wear pattern in the bearing race as a result of continued EDM pitting. As the rolling element travels over already damaged areas, more damage occurs.

High system vibration and noise are often the result of bearing fluting which will result in costly system failure.

Non-metallic design For chemical applications or where food grade compliant materials are required, a nonmetallic bearing isolator seal may be required.

A highly chemically resistant grade of polymer such as glass-filled PTFE and fluoroelastomer O-rings provide excellent performance even against the most aggressive of chemicals.

Shaft grounding bearing isolators seals

seals. However, in order to overcome this process when replacing seals, split versions are available that allow users to keep their equipment intact when replacing the seals, reducing costly downtime.

Surface mounted design When retrofitting existing equipment with a bearing isolator seal there may not always be a machined recessed housing into which the seal would normally be pressed. The machining of housing is not always practical or even possible. Similarly, where there are space restrictions there may be insufficient clearance to install a flanged version of the seal. In these instances, a surface mounted bearing isolator seal is an ideal solution. A single-piece or split design can make the preparation and installation of the seal both simple and cost effective, reducing the MTTR significantly.

Ease of installation and removal In addition to the design features discussed that primarily focus on the function of the seal, there are also bearing isolator seals available that can be installed and removed without the need for specialist tooling. Bearing isolators that can be installed without the use of a special tool or Arbor press, and that can be removed without damaging the surrounding housing or shaft offer an obvious additional benefit to the maintenance technician as well as reducing TLC and MTTR. For more information:

This article was written by Russ Pimblett, product/ applications engineering leader at Garlock (GB).Visit: www. garlock.com’

Anybody that has ever been witness to the whining of an electric motor will understand the need for a shaft grounding bearing isolator.

Fig.7 Non-metallic bearing isolator

Composite design

Fig.5 Shaft grounding bearing isolators

Most bearing isolator seals are designed to prevent the ingress of airborne contaminants in typical conditions found in many process industries. However, there are many instances where the bearing housing or surrounding will be flooded or subject to a wet mist. In this instance a more complex design of seal may be required in order to withstand both the moisture and higher-than-atmospheric pressures that this typically presents.

Split design

Fig.6 Bearing fluting damage

As anyone involved in the maintenance of plant and equipment knows, the disassembly and reassembly associated with routine and unscheduled maintenance can be both timeconsuming and complicated. This can be the case when using one-piece bearing isolator

Fig.8 Surface mounted bearing isolators

– don’t forget to top up Every 12 months, the heat transfer fluid in a system can lose between 3-5% of its volume due to system venting. This represents the ‘breathing out’ of light ends in the form of a gas that is produced as the result of thermal cracking. This loss can have a serious impact on operational costs. While the decrease of thermal fluid volume cannot be avoided, it is easily treated.

The hottest recorded place on Earth is the Mponeng gold mine in South Africa. Two miles below the surface, rock temperatures can reach 65.5˚C. Workers can only survive there if slurry ice is pumped into the mine and the walls are insulated with concrete.

As impressive as this temperature is, it doesn’t come close to the ones in which thermal fluid operates in industrial environments. For example, the Globaltherm range includes oils which are designed to operate in temperatures of up to 400˚C. As chemically stable and secure as these oils are, they will suffer deterioration caused by heat.

Regular maintenance and topping up as often as necessary are therefore essential actions for any operation.

The volume of thermal fluid can expand by 25-30% when the fluid is hot, compared to its volume when it is cold. Industrial plants normally operate incessantly, which is why thermal oil is kept at a constantly high temperature. Because of this, the volume of thermal fluid is always expanded. However, periodic shutdowns for planned maintenance result in a decrease in temperature, which makes the oil volume shrink, often below the low level switch.

As a rule of thumb, the expansion tank should be one third full when the heat transfer fluid is cold, and half full when the fluid is hot.

Volume reduction caused by problems with system venting or leaks can result in very low thermal fluid levels in the header tank.

When this happens, there is a good chance the system will not restart without a top up, because it has ‘tripped out on low level’ or fallen below the low level switch indicator.

There are several ways to resolve the

Low level switch (removed for cleaning) shows build up of carbon as a result of oxidation

problem in this situation, depending on the type of heat transfer fluid a company is using, the size and capacity of the system and the amount of fluid required.

Is volume loss inevitable?

In a nutshell, yes. Assuming the system vents adequately, if it generates more light ends than it breaths out, the volume will not change significantly. However, this will cause low flash points, fire points and auto ignition temperatures, which is a more serious issue all together. Heat transfer fluids degrade over time, because of extreme temperatures and continuous temperature fluctuation. The two main chemical processes during which thermal fluids degrade or break down are thermal cracking and thermal oxidation.

Thermal cracking takes place when heat is applied under pressure to the thermal liquid. It results in the breaking of the fluid’s molecules into smaller molecules. This chemical reaction releases several types of fractions, depending on the type of oil in question. The first byproducts of thermal cracking are light ends (also called light distillates or low boilers).

These fractions have a low boiling point and are highly volatile.

The production of light ends is inevitable, because it is the chemical consequence of heating up thermal fluid. The quantity of light ends in the system has to be constantly monitored, because their presence lowers flashpoints and can create dangerous situations in the event of a loss of containment. The legislation DSEAR/ATEX 137 requires flash points to be managed by taking regular and representative samples, and submitting them for expert advice. This goes hand in hand with surveys that demonstrate a safe system and knowledgeable staff or operators.

The flash point is the minimum temperature at which the vapour released from a liquid will ignite in the presence of an external ignition source and oxygen. Flash points vary depending on the type of thermal liquid used.

Because of their volatility, light ends have to be managed and removed, despite the fact that this causes thermal oil levels to shrink.

There are several ways of managing and removing light ends. Good system ventilation, for instance, maintains steady flash points.

Alternatively, Global Heat Transfer’s Light Ends Removal Kit (LERK) is an entirely automated system that removes light ends and manages flash points, fire points and auto ignition temperatures by a process of continuous distillation.

The only downside to managing and removing light ends is the loss of thermal fluid from the system. This also causes the existing thermal oil in the system to be worked particularly hard, which means its deterioration rate can grow exponentially. To avoid this situation, it is important to top up thermal fluid as often as necessary.

When the thermal fluid level is very low in the system, the first priority is to investigate why it has decreased. The reasons could be anything from a high number of light ends to leaks. Finding and fixing whatever caused thermal fluid levels to drop is an essential step before topping up. After this is achieved, there are several ways of adding more thermal oil to the system, depending on the situation.

Topping up The best time to top up thermal fluid is after a system shutdown. Topping up can also be done while the system is operational, but only after certain precautionary measures have been taken. The best practice is to contact your thermal fluid provider and get a specialist team to take samples and check the condition of the oil before topping up.

Topping up thermal fluid is an essential yet very simple operation, which can save costs and time, especially when production is resumed after a system shut-down.

When thermal fluid levels are low, the existing fluid is worked excessively hard, which could lead to system breakdowns. To avoid this, thermal fluid top up should be facilitated as often as possible. To ensure you get the optimal support for your needs, the best thing to do is let your thermal fluid provider know at least a month in advance before total system shut-down.

The name of the hottest place on earth, the Mponeng mine, means ‘look at me’ in the local Sotho language. Sometimes, the only way to detect system issues or weaknesses is by taking a close look at the hot and unwelcoming environment of heat transfer fluid.

Regular thermal fluid testing and analysis is essential throughout the year, and becomes particularly relevant during shut downs, because it entails a comprehensive inspection of the system. This allows you to top up thermal fluid levels whenever necessary, ensuring you have a fully working and efficient system.

For more information:

This article was written by Andy Burns, technical business manager, Global Heat Transfer.

Visit: www.globalheattransfer.co.uk

Don’t miss your chance to appear in the March/April 2015 issue of Fluid Handling magazine For editorial suggestions contact: Daniel Traylen, daniel@horseshoemedia.com +44 (0) 20 868 74126 For advertising information and prices contact: Belinda Smart, belinda@fluidhandlingmag.com +44 (0) 20 864 87092 Next issue features include: Displacement gauges Rotary pumps Magnetic meters Check valves High pressure pipes

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