Professional Documents
Culture Documents
DATA JACKPOT
More and better information is fostering smarter maintenance
RETHINK
LOCAL PRESSURE
MEASUREMENT
FORESTALL
FUGITIVE EMISSIONS
WALK
THE LINE
AUGUST 2016
Safety built-in
We work with partners like Rockwell Automation to develop real value and cost
saving solutions that address the entire safety loop. For example, our complete
solution for eld-proven, standardized over ll prevention, which includes:
Safety by design - systems with built-in mechanical integrity
State-of-the-art vibronic fork technology with failsafe design - a second
lineinof defense and active warning system with detailed information
Anwendung
Broschren
Simple and remote built-in proof testing function helps reduce downtime
and prevents sta from working in hazardous areas
Anwendung in Magazinen
SIL3 - 1oo1 using point level tuning fork with up to 12 year proof-test interval
Endress+Hauser, Inc
2350 Endress Place
Greenwood, IN 46143
info@us.endress.com
888-ENDRESS
www.us.endress.com
Total TRIO delivers an efficient solution
for vibration condition monitoring
AZIMA DLI ANALYSTS:
500+ YEARS OF COMBINED EXPERIENCE
LEVEL 4 CERTIFICATIONS
EXPERTISE IN DOZENS OF INDUSTRIES
CALL TODAY:
+1 781.938.0707
PDM MONITORING SERVICES sales@AzimaDL I.c o m
20 31 40
Chemical Processing (ISSN 0009-2630) is published monthly by Putman Media Inc.,1501 E. Woodfield Road, Suite 400N, Schaumburg, IL 60173. Phone (630) 467-1300. Fax (630) 467-1109. Periodicals postage paid at
Schaumburg, IL, and additional mailing offices. POSTMASTER: Send address changes to Chemical Processing, P.O. Box 3434, Northbrook, IL 60065-3434. SUBSCRIPTIONS: Qualified reader subscriptions are accepted
from operating management in the chemical processing industries at no charge. To apply for a qualified subscription, fill in the subscription card. To nonqualified subscribers in the United States, subscriptions are $68
per year. Single copies are $15. Canadian and other international annual subscriptions are accepted at $200 Airmail. Single copies are $16. Canada Post International Publications Mail Product Sales Agreement No.
40028661. Canadian Mail Distributor information: Frontier/BWI, PO Box 1051, Fort Erie, Ontario, Canada, L2A 5N8. Copyright 2016 Putman Media Inc. All rights reserved. The contents of this publication may not be
reproduced in whole or in part without the consent of the copyright owner. REPRINTS: Reprints are available on a custom basis. For price quotation, contact Foster Reprints, (866) 879-9144, www.fostereprints.com also
publishes Control, Control Design, Food Processing, The Journal, Pharmaceutical Manufacturing, Plant Services and SmartIndustry. Chemical Processing assumes no responsibility for validity of claims in items reported.
F O L L O W A L E A D E R
)LJKWLQJUHVZLWKDQ\WKLQJOHVVWKDQWKHEHVWSXWV\RXUHQWLUH
RSHUDWLRQDWULVN$168/ 5('/,1(FDUWULGJHRSHUDWHGUH
H[WLQJXLVKHUVSURYLGHRXWVWDQGLQJDJHQWFRQWURODQGRZUDWH
IRUVDIHW\GLUHFWRUVLQKLJKUHULVNLQGXVWULHV6LPSOHWRRSHUDWH
DQGHDV\WRUHFKDUJHRQWKHVSRW5('/,1(H[WLQJXLVKHUVOHW
\RXWDNHFRQWUROEHIRUHLWVRXWRIFRQWURO
)LQGWKHEHVW$168/UHH[WLQJXLVKHUIRU\RXUIDFLOLW\
Visit www.ansul.com/RL
&RS\ULJKW7\FR)LUH3URGXFWV/3$OOULJKWVUHVHUYHG
FIELD NOTES
Stupidity Endures
Engineers continue to make a wide variety of dumb mistakes
IVE SEEN a lot of idiotic things during my ca- tank lasts 1015 years, as some have, then the
reer. Sadly, it never ends. Fools still come up with assessment is turned upside down; youll be lucky
ways to show their stupidity. to get 10 years out of FG in bleach service without
Lets start with chemistry. Some engineers re-lining.
clearly didnt pay adequate attention during Ever see a 32-in firewater line uproot itself
chemistry class. Herere some classic mistakes: 1) from the ground? Not a pretty sight! An elbow
adding a chemical to a hot reactant or solvent for wasnt securely anchored. Lets consider other
an exothermic reaction, e.g., sodium hydroxide hydraulic mistakes. Pumps have been wrecked Ever see a 32-in
to warm water the result is eruption of toxic because installed suction strainers werent
rewater line
spray; 2) adding acid to bleach an ester or weak monitored and clogged up. In addition, Ive heard
acid can cause bleach to generate chlorine gas, as of a $1-million, multi-stage pump completely uproot itself from
Brnsteds definition of a base makes clear (see destroyed, despite meticulous instrumentation,
the ground?
Consider the Consequences of Chemistry,); by a reversed check valve. Another costly error
3) adding inadequate solvent or poorly mixing is forgetting to supply buffer fluid to mechanical
reactants prior to a exothermic organic or cata- seals or providing an inadequate flow.
lytic reaction; 4) presuming its always safe to add Instrument mistakes also can make life inter-
water some chemicals are incompatible with esting. Herere some examples: a tank overflowing
water (e.g., in April 1995, water added to alumi- because the differential-pressure level transmitter
num powder and sodium hydrosulfite at the Napp is set for a denser liquid; burned out instrument
Technologies plant in Lodi, N.J., resulted in an power boards due to a poor ground on an instru-
exothermic reaction that killed five workers). ment; poorly performing control valves or flow
Now, lets consider economics. I frequently meters that were selected based on pipe size rather
shudder whenever a manager or client suggests a than flow rate; using a magnetic flow meter to
cheaper alternative. Usually, the option isnt suit- measure a non-conductive or two-phase organic/
able. However, it takes salesmanship to convince aqueous liquid; faulty temperature readings
the person. Heres a good example: fiberglass because the sensor wasnt immersed in the fluid or
(FG) versus polyethylene (PE) tanks for bleach. was mis-oriented; and setting a pressure switch in
An FG tank reliably can store bleach for 20 years, inches of water column instead of ft. Oh, I cant
although re-lining every five years will be neces- ignore the classic: relying on an analytical instru-
sary; such tanks do best when painted white to ment thats never calibrated and is hooked up to
protect them from ultraviolet light. In contrast, sampling lines that are remote and never cleaned.
PE will last for perhaps 57 years, according to While, hopefully, you havent made such er-
the pulp and paper industry. Lets assume a 20-yr rors, I bet you know people who have.
life for an FG bleach tank and a 5-yr life for a
PE tank, a 5% interest rate, $2,000 to repair the DIRK WILLARD, Contributing Editor
FG every five years, and $11,000 for installation dwillard@putman.net
(crane, pipe work, etc.). A new 12,600-gallon FG
tank rated for bleach service costs $29,900 (base
TELL US YOUR STORIES
price) with a total cost of $33,200. A new PE
If youre like many veteran engineers, you
tank costs $10,100 base, $11,600 with shipping
probably have come across a number of
and handling. Comparing the two on the basis of
equivalent uniform annual cost, I come up with instances of stupidity that amused or, more
$3,800/yr for the FG tank and $9,800/yr for the likely, horried you. Share your experiences
PE one. So, it clearly makes more sense to buy the with other readers by e-mailing a description
pricier tank than replace the cheaper one every of these dumb moves to chemicalprocessing@
five years. Even if you got 710 years out of the putman.net. Please note in your e-mail if you
PE tank, the FG one still has better economics. would like to remain anonymous.
Of course, if you dont re-line the FG and the PE
version of foxySPEC in August 2017, notes IGBs Stier. Shipments (NAICS S325) Capacity utilization Chemical Activity Barometer
Figure 2. Marijke Frederix (left) and Aindrila Mukhopadhyay conducted work in a mi-
crobiology lab at the Joint BioEnergy Institute. Source: Irina Silva/JBEI, Berkeley Lab.
How would you characterize your sites effectiveness Carbon Monoxide Transmitter
in sharing details of safety incident near-misses among staff? TXCO-50 $795
40
OMEGA Introduces
35
Technical Learning
Don't know
30
16.9%
Responses (%)
Visit omega.com/technical-learning
25
Moderate
20
10.6%
Contact Us Today
33.2%
36.9%
Low
Completely
High
ineffective
15
1.888.826.6342 | omega.com
2.3%
10
5
Prices listed are those in effect at the time of publication and are subject to change without notice.
0 Please contact OMEGAs sales department for current prices.
Note: Models with wireless option are approved for use in the US, Canada and Europe only.
COPYRIGHT 2016 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED
Designing and installing mechanical systems with strict standards and short installation schedules
can be complicated. Viega MegaPress provides innovative solutions for hydronic and fire protection
systems. Viega MegaPressG provides innovative solutions for gas and compressed air systems.
Approved for more applications than any other black iron pipe press system, Viega MegaPress is
the solution to meeting tomorrows engineering standards today.
Suitable for ASTM Schedule 5 to Schedule 40 black iron pipe and NFPA 13, 13D and
13R fire sprinkler systems
Secure press connections made in seconds
Equipped with the Smart Connect feature for easy identification of unpressed fittings
No need for messy and toxic threading or cutting oils
T H E G L O B A L L E A D E R I N P L U M B I N G , H E A T I N G A N D P I P E J O I N I N G S Y S T E M S
ENERGY SAVER
PROCESS PLANTS use compressed air for sev- mum choice will depend on the system design,
eral different purposes including conveying, process load profile and plant demand.
controls and actuators, process gas compressing, The simplest control strategy is the start-
etc. Interestingly, compressed air is probably the and-stop methodology. Being the simplest, it
most expensive utility stream in the industry on a has its limitations in applications with frequent
per unit basis. In addition, it is the most misused, cycling. The second methodology load/unload
mismanaged and unaccounted (wasted) utility eliminates the frequent cycling and keeps the
from an overall usage perspective. So, I compared compressor motor running (always providing air, No wonder
the energy used in pumping systems (see, Pump which is unloaded when not needed), albeit at a
compressed air
Out Energy Inefficiencies, http://goo.gl/Y14ZUY) cost in energy consumption. The third method-
versus compressed air and was very surprised at ology has to do with modulation. The idea here is the most
the results. The chemicals sector (NAICS 325) is to introduce a f low restriction at the inlet,
expensive utility
uses a slightly higher amount of energy in produc- thereby restricting the air and meeting the system
ing compressed air (160 TBtu/yr) than pumping demand. Inlet guide vanes are one example of in a plant!
systems (151 TBtu/yr). More importantly, though, such a throttling device. Certain kinds of com-
the compressed air system energy efficiency is only pressors can be designed with stepped controls
11%, which means 89% of the energy supplied these are discrete load points (0%, 33%, 67%
is wasted. No wonder compressed air is the most and 100%) or (0%, 50% and 100%). Sometimes,
expensive utility in a plant! these different controls can be combined to offer
The main subsystems of any compressed a larger operating range and provide a tighter
air system are generation, distribution and end control on pressure. A more recent entry in the
use. All three subsystems work hand-in-hand to control scheme is the use of variable frequency
provide compressed air. A shortcoming or failure drives. In principle, they offer a wide operational
of any one of these subsystems leads to no avail- control with high energy efficiency; however, you
able compressed air. Because production heavily may need to consider additional costs and site
depends upon the reliability of the system, most of electrical specifications, especially for a retrofit
us have built in redundancies to enhance com- application.
pressed air system reliability. Unfortunately, this In the world of sophisticated networking and
redundancy, if not properly designed and used, faster semiconductors, there also are some very
can lead to significant loss in the systems energy simple and complex master controllers available.
efficiency. Many avenues can improve energy ef- These can be implemented on the whole com-
ficiency in a compressed air system. Here, I will pressed air system to ensure that compressed air
touch upon one of my favorites the appropriate is produced most efficiently at all times. Finally,
use of controls and storage. storage plays a very important role and goes hand-
The two main types of compressors are posi- in-hand with any control strategy implemented.
tive displacement (reciprocating, rotary) and dy- Storage is cheap; you always should look closely at
namic (centrifugal, axial). The controls associated the ability to implement storage in every com-
with each compressor type vary. Typically, all pressed air system.
compressor systems are designed for peak demand One final note: the Compressed Air Challenge
with a margin of safety, whereas the actual op- (www.compressedairchallenge.org/) is an excellent
erating load is much less than the peak demand. resource that provides valuable information, includ-
Every compressor has a full-load and design- ing fundamentals, sourcebooks, toolbox, best prac-
point efficiency (being a turbomachine, part-load tices and training opportunities. I have personally
efficiency isnt as good as the design point or used several of these resources as the need arises,
full-load). Based on the demand, the compres- and would recommend you bookmark it in your
sor controls are set to provide the compressed air browser. May the air be with you!
required by the plant at the highest efficiency and
reliability. But remember, all control strategies RIYAZ PAPAR, Energy Columnist
have pluses and minuses. Ultimately, the opti- rpapar@putman.net
www.vega.com/radar
COMPLIANCE ADVISOR
THE FRANK R. Lautenberg Chemical Safety for the chemicals that are persistent and bioaccumulative,
21st Century Act makes seismic changes in domestic and that are known carcinogens and highly toxic.
industrial chemical management. If you think the ex-
tensive revisions to the Toxic Substances Control Act WHAT TO DO FIRST
(TSCA) enacted on June 22, 2016, dont impact your To prepare for the new laws implementation, which
business, think again. TSCA reform affects virtually already has begun, interested stakeholders should do
every domestic business sector involving chemicals several things immediately.
and manufactured goods containing chemicals, and First, read the law. While long and detailed, If you think
will continue to do so for years to come. nothing beats reading the original text Congress
the extensive
penned: http://goo.gl/k2S0Bf. We prepared a
TSCA REFORM: WHAT JUST HAPPENED? detailed memorandum; our blog (TSCAblog. TSCA revisions
TSCA is the federal law that authorizes the U.S. com) focuses exclusively on the new law to ensure
dont impact
Environmental Protection Agency (EPA) to regulate its implementation is reported accurately and in a
the import, manufacture, and processing of industrial timely fashion, and to promote and facilitate broad your business,
chemical substances, defined to include just about public participation.
think again.
every industrial chemical that goes into making a Second, know which chemicals are core to the
finished good. The new law greatly expands the EPAs business. The new law mandates that the EPA priori-
authority, and, if stakeholders and the EPA can get its tize and evaluate high-priority chemicals according
implementation right, it will improve public health to an aggressive and judicially enforceable schedule.
protection and restore much of the publics confidence The EPAs Work Plan for Chemical Assessments list of
in chemical safety, a regrettable victim of the TSCAs chemicals is a must-read for counsel. If this program
deficits. The law shifts the burden of demonstrating is unfamiliar to you, it would be helpful for you to
chemical safety all chemicals, old and new to review the EPAs TSCA Work Plan for Chemical As-
chemical manufacturers, processors and manufactur- sessment website, http://goo.gl/rMrW27
ers of the finished goods that contain them, away Third, reassess confidential business information
from the EPA proving the opposite. A quick rundown (CBI) claims and qualify new claims carefully. This
of key provisions includes: process is not easy and will take time and resources to
Mandating safety reviews for chemicals in do well and comprehensively.
commerce; Fourth, expect more chemical testing. Even if your
Eliminating the challenging least burdensome company isnt actually conducting chemical testing or
requirement for assessing chemicals in com- paying for it, your product line wont be immune from
merce, which for years prevented the EPA from the consequences of testing done on chemicals core to
taking meaningful action on these chemicals; the business.
Establishing a health-based safety standard, and Fifth, focus on the upside and seize opportunities
authorizing the consideration of cost in develop- to develop new products to fill the inevitable chemical
ing risk abatement measures; product deselection void. With change comes op-
Requiring the protection of vulnerable popula- portunity; new products with a distinctly sustainable
tions, including children and pregnant women; profile will do well under the new law.
Limiting the ability of entities to claim informa- As TSCA has now been reformed, its time to
tion as confidential, thus, preventing disclosure, think strategically and prepare to engage in the many
and authorizing sharing needed confidential initiatives that the new law requires, the collective
information with states and first responders, as result of which will fundamentally revolutionize
necessary, to fulfill their duties; chemical management in the U.S. Smart companies
Establishing judicially enforceable deadlines by will see this as both a critically important business
which the EPA must act to implement the law; challenge and opportunity that requires stakeholders
Preserving the role of states to regulate chemicals to be proactive and engaged.
as balanced against the need for a clear and cen-
tralized federal chemical management law; and LYNN BERGESON, Regulatory Editor
Requiring the EPA to prioritize its review of lbergeson@putman.net
CHEMICAL MAKERS will see plant operating staff safety and production are getting more blurry for the
spending far less time collecting and managing data and chemical plant of the future, he stresses.
far more time focusing on critical value-added work and Efforts both by chemical makers and vendors are fostering
decision-making, says Mark Granger, reliability solutions this future.
manager at Emerson Process Management, Knoxville, For instance, Evonik, Essen, Germany, is focusing on using
Tenn. In five years, the continued technology advancements big data as a new digital process optimization tool especially
that Emerson and other vendors are driving will result in in terms of PdM.
more smart assets and systems that monitor themselves The importance of big data simply cannot be emphasized
and their processes, he believes. Moreover, multiple groups enough. Most companies are fully aware of the significance
within a company will take advantage of the embedded and potential of digitization. The actual challenge here is to
smart information from the plant. Predictive maintenance make selective use of this wealth of data for the classic purposes
(PdM), condition monitoring, and asset performance details of a manufacturing organization: for increasing productivity,
will become more closely integrated with control optimiza- optimizing processes, and becoming more efficient, explains
tion and, thus, will play an increasing role in improving Kai Dadhe, who heads the manufacturing intelligence group in
availability, throughput, health/safety/environmental (HSE) the companys performance intermediates business line.
efforts, operations and maintenance, and plant life. The The tools traditionally used for optimizing processes are
boundaries between control, reliability, PdM, operations, reaching their limits with the challenge compounded
MAJOR INITIATIVE
BASF, Ludwigshafen, Germany, also is taking a broader look
at the usefulness of digital information, with PdM an integral
part of its Industry 4.0 activities that were launched in 2015.
Designed to drive digital transformation, the initiative aims
to use digital technologies to increase the effectiveness and
efficiency of processes and to develop new digital products and
Figure 1. Multi-disciplinary project at the site is evaluating the poten- services that offer greater added value for customers.
tial of digital information to improve predictive maintenance. Source: At the moment, multi-disciplinary teams are carrying
Evonik.
www.grundfos.us
MACHINERY HEALTH ANALYZER
RELATED CONTENT ON CHEMICALPROCESSING.COM
Embrace ISO 55000, http://goo.gl/63YeHY
Plants Break Down Reliability Barriers, http://goo.gl/NdTcQl
Petrochemical Complex Ramps Up Reliability, http://goo.gl/98nDhU
Maintenance Gets a Makeover, http://goo.gl/MePfbk
Fix Your Maintenance Program, http://goo.gl/JEqsrW
ensure the plant runs safely, eff ec- packing. In addition, key performance
tively and efficiently, he adds. indicators monitored include pump and
heat exchanger diagnostics.
UPDATED APPLICATION PRM has been installed in a broad
Meanwhile, Yokogawa Corp. of America, variety of chemical sites already. For
Figure 3. Hand-held device makes asset Sugar Land, Texas, has launched version example, a recent project at Asahi
condition information more readily available, R3.30 of its plant resource manager Kasei Synthetic Rubber Singapore,
enhancing decision-making. Source: Emerson
Process Management. (PRM) tool for the centralized manage- Jurong Island, Singapore, focused on a
ment of large amounts of data from plant polymerization process and its associ-
a wide selection of information to monitoring and control devices and ated raw material and chemical feeding,
tablets and smart devices (Figure 3) manufacturing equipment. It includes recovery, finishing and utility processes.
as well as personal computers, both an improved management function for Here, PRM checked all control loops
inside and outside the plant. Basi- HART devices and enhanced naviga- and valves during commissioning.
cally, it culls through mountains of tion. R3.30 now covers applications as Now, operators are using PRM daily
data to fi nd the specific functional diverse as pressure transmitters, magnetic to monitor every field device from a
information needed by each user to flow meters, valve health and gland central control room. This has reduced
workload in the field and enabled a
much more proactive PdM strategy,
lessening the likelihood of unscheduled
plant shutdowns.
In Europe, following installation of
PRM, the MOL Danube Refinery in
Szzhalombatta, Hungary, immediately
saved between $20,000 and $70,000
Engineered Solutions per turnaround on control valves alone.
The software essentially allows MOL
to carry out detailed diagnostic checks
Class 150, 300, 600, 800 on each control valve prior to scheduled
& 2500 maintenance, thus avoiding unnecessary
Metal Seated work and expense.
Cryogenic Commenting on the projects success,
Control V Ball Gbor Bereznai, head of control and
Optional Stem Seal electrical engineering at the refinery, cau-
Designs tions: I think many companies, includ-
Selection of Seat ing the big ones, often underestimate the
Materials need to improve both the process and the
API 607 Certified human side of the activity. Thats why
API 608 Compliant many times they are not able to fully uti-
Complete Automation lize the benefits of available and installed
Packages technology.
SMITH-COOPER INTERNATIONAL
2701 BuSSE ROAd, ELk GROvE vILLAGE, IL 60007
TOLL FREE (800) 314-1031 FAx (708) 562-0890
www.SHARPEvALvES.COM www.SMITHCOOPER.COM
Badger Meter helps you measure what matters today, protecting precious resources for tomorrows
generation. You can depend on our industry-leading flow measurement solutions to help you optimize your
operations, leading to a better bottom line and a better world. Measure to manage, manage to sustain.
www.badgermeter.com
Consider
Gas Engines
These versatile and reliable
drivers suit a variety of applications
By Amin Almasi, rotating equipment consultant
GAS-FUELED internal-combustion engines play an the engine ratings. Overall, combustion control in the engine
important role at many chemical plants as drivers for focuses on preventing detonation.
equipment such as compressors, pumps, generators and In a gas-burning engine, the prime objective is to achieve
blowers. These engines often handle a variety of services at controlled combustion at a predetermined point. This
a site for instance, to transport liquid or gas fuels within requires compressing the gas and air mixture while maintain-
the facility and to meet process compression needs (such as ing the mixture within the flammability limits without
refrigeration cycles). They are versatile prime movers capable promoting spontaneous or self-ignition in the increasing
of reliable and efficient operation. The medium-speed recip- temperature and pressure environment of the cylinder.
rocating engines that are used offer inherently high thermal Conventionally, either an electric spark or injection of
efficiencies as well as attractive costs and operational charac- a small quantity of fuel with a high cetane index initiates
teristics. They operate at 3001,000 rpm and come in sizes combustion by the propagation of a flame front throughout
from 30 kW to 20 MW. the mixture. To achieve this controlled process, it clearly is es-
The engines can use a wide variety of fuel types and grades, sential to use gaseous fuels that wont auto-ignite or detonate
including sour, sweet and wet gas. Economic factors associated in the prevailing cylinder conditions. Such fuels include natu-
with energy conservation, depletion of existing resources and in- ral gases and even some low calorific gases. Work continues
creasing transportation costs will promote the use of alternative to broaden the spectrum of gases that can be successfully
gas fuels, particularly at remote locations with abundant avail- utilized, increase the ratings and achieve fuel consumptions
able cheap gases and at small sites with limited electric power. comparable to those of diesel engines.
The engines have benefited from extensive improvements In the past, developments focused on preventing
and refinements since they were introduced around 80 years detonation by reducing engine rating, lowering the engine
ago. For instance, the specific power output of the major compression ratio to decrease the end-of-compression tem-
engine types has doubled every ten years or so. Further perature, and increasing the air excess characteristics that
developments likely will enable gas engines to offer power cut the potential volumetric power of engines and boost fuel
ratings and consumption levels that match those of the most consumption. Another issue involved the need to promote
modern diesel engines and, long term, that rival those of controlled ignition by external means. These issues now
other well-known drivers. have been successfully addressed. So, development efforts
have turned to improving the ability of engines to operate
COMBUSTION ISSUES at high efficiency with minimum service, maintenance and
Initiating the combustion in a controlled manner in a recip- overhaul costs and with increasingly poor quality fuels.
rocating internal-combustion engine is significantly more
difficult with gases than with liquid fuels. EXPANDING APPLICATIONS
Detonation uncontrolled combustion with ignition In recent years, reciprocating engines have gained increasing fa-
occurring spontaneously throughout the mixture can cause vor as medium- and large-scale mechanical drivers for compres-
a considerable rate of pressure rise that invariably harms the sors, pumps, generators and other equipment. Advances in tech-
mechanical structure of engine components. Therefore, gaseous nology have enabled commercialization of larger capacity, better
fuels are classified according to their inherent tendency to efficiency, dual-fuel capable, and higher availability engines.
detonate in the engine. The characteristic of the fuel may set Large reciprocating engines used in plants and facilities gener-
ZW-REC
$
250
Visit omega.com/zw-rec
Figure 1. Dismantling of unit showed accumulated internal dirt that contributed
to failure of this engine.
Blowers
Handle specialty gases with reliability.
Vacuums
Built for severe duty use.
Systems
Vacuum systems and engineered
solutions designed for your application.
LIMITING LEAKAGE of harmful volatile organic com- look for the following design features pertaining to fugitive
pounds (VOCs) from valves is a business imperative for chemi- emissions control:
cal manufacturers. Process plants must curb such emissions to Two-part rising stem. This isolates the rotational move-
comply with increasingly stringent regulations, and to protect ment of the stem and shields inner components from the effects
workers, communities and the environment as well as the of torque.
companys bottom line and reputation. Full-size safety gland packing made of graphite or polytetra-
A recent report [1] by the United Nations notes that, by the fluoroethylene (PTFE). A safety backup enables continued valve
year 2020, the acceptable level of emissions of VOCs will have function, eliminating the need to shut down the plant in case
been reduced by 95% since 1990 and that more than 60% of emergency or failure.
of fugitive emissions worldwide emanate from valves. Bonnet gasket with tongue-and-groove bonnet flanges. A
The task of complying with applicable standards can prove valve that utilizes a tongue-and-groove design focuses the force
challenging. However, several steps can ensure the highest de- of the nuts and bolts on a smaller area. Therefore, the gasket
gree of protection from fugitive emissions: evaluating external doesnt wear out or become dislodged due to temperature
leak paths such as the valve stem and body joints, and imple- swings, helping achieve leak tightness in volatile applications.
menting onsite compliance measures. This article will explore Despite the benefits of a bellows-sealed design for rising-
these considerations and how they affect valve selection. stem valves, processors often opt instead for quarter-turn valves
for fugitive emissions control to avoid potential leak paths
THE FIRST LINE OF DEFENSE created by the vertical movement of a stem through packing. In
For controlling fugitive emissions, perhaps the most cru- this case, valves with redundant seals and side-load protection
cial consideration in valve selection is the stem seal design. offer the best defense against external leakage. Valve design,
Although traditional packing options such as chevron (v-ring) materials and function can vary greatly among different valve
or cup-and-cone styles can successfully combat most fluid types; therefore, well focus only on considerations for process
leakage, those options alone wont suffice in guarding against ball valves.
fugitive emissions of highly hazardous chemicals in volatile End users should consider the following when selecting a
applications with extreme fluctuations in temperature and quarter-turn ball valve:
pressure. Therefore, processors needing valves for such services Side-load protection. A common fugitive emissions con-
should carefully assess stem seal design and materials. cern with traditional valve designs is stem seal leakage caused
While both rising-stem and quarter-turn valves can be sus- by side loads due to actuator misalignment, improper manual
ceptible to leaks, valve stem movement through the packing in operation or abusive contact. A pressure-assisted stem seal can
rising-stem valves makes them a more precarious choice than provide a high degree of protection against fugitive emissions
their quarter-turn counterparts. while supplying superior side-load resistance. Alternative
To mitigate the leak potential with rising-stem valves, a designs rely on bearings located above or below the packing to
bellows-sealed design has proven highly effective compared to combat side loads on the stem.
alternatives. In selecting a bellows-sealed valve, users should Live-loading protection. Live loading maintains a consis-
tent force on valve packing during pressure and thermal cycles and
reduces the potential for cold flow of packing, which can compro-
mise its sealing capabilities. Live loading usually is more effective on
PTFE than on graphite packing.
Packing types. Packing generally is used in valves because it al-
lows for adjustments that can help stop a leak once detected. Tradi-
tional PTFE packings such as chevron v-ring or cup-and-cone styles
are effective in most chemical applications, and suit temperatures
up to 600F. Graphite packing, which can handle temperatures in
excess of 1,000F, is more common in higher-temperature applica-
tions or where fire safety is a concern. While graphite is less suscep-
tible to temperature fluctuations, it isnt as effective when used with
gases such as helium and methane. Other specialty materials are
available from various manufacturers for niche applications.
Multiple stem seals. These address specific sealing concerns to
provide the highest degree of protection against fugitive emissions.
A traditional, single stem seal with standard v-ring packing can be
adjusted to prevent leakage in standard applications but eventually
will leak in challenging environments. Dual seals build upon the
PROTECT PUMPS
single seal and use multiple materials to deliver added protection
and extend the life of the seals. Finally, a triple stem seal combines
$29 25..).'