www.processingmagazine.

com NOVEMBER 2016

FEATURED PRODUCTs
Venturi Wet Scrubber
The Sly Venturi Scrubber efficiently collects fine soluble or insoluble particu-
lates and mists. Scrubbing liquid is atomized into fine droplets in the Venturi
throat allowing for inertial impaction of particles. Adjustable throats for per-
formance optimization are standard. The scrubber sys-
tems may include recirculation, piping, instrumentation,
control panel, ductwork, fan, stack and skid mounting
and have capacities of more than 76,000 cfm per unit.

Sly Inc.
www.slyinc.com
502

Blower system
Dynamic Airs Series 457 Model 316 QUIET-PAC blower package reduces
sound levels to 85 dBa or less. The complete blower and motor are enclosed
in a sound-attenuating acoustical enclosure. Four access doors are provided
for maintenance of all components. A cooling fan also is included for maxi-
COVER SEries mum motor protection and life. The pre-
PAGE 22 assembled package includes a vacuum
PLANT OPERATIONS and pressure relief valve, blower, motor
and V-belt drive.
Planning for successful
turnarounds and imple-
Dynamic Air Inc.
menting maintenance
www.dynamicair.com
with CMMS
503

MultiIngredient Handling System

VAC-U-MAX Multi-Ingredient Handling Systems are designed around the parameters of the ONLINE EXCLUSIVE
process, whether conveying powders, flakes, pellets or any type of granular bulk material. The
systems incorporate complex controls and weighing of the bulk material
at the pickup point for a loss-in-weight bulk material transfer or at the
discharge end of the system for a gain-in-weight bulk material transfer.
These systems combine modern computerized technology with pneumatic
and mechanical conveying for automated, dust-free ingredient handling.

VAC-U-MAX
www.vac-u-max.com
500

the importance of data monitoring

Flexible Screw Conveyor TrendMiner CEO Bert Baeck discuss-
es why the process industries are in
Hapmans Helix Flexible Screw Conveyor with a hopper and ribbon agitator is designed to need of and prepared for the Industrial
improve material flow in regular process or small batch research and development applica- Internet of Things, among other impor-
tions. It is engineered for batch, intermittent and continuous material flow,, makingg it optimal
p for tant points concerning data's relation-
processors testing multiple ingredients including powders, granules ules and ship to processing.
eeps
larger ingredient solids. The integrated hopper with ribbon agitator keeps
material from sticking to the sides of the hopper and eliminates flow w www.bit.ly/2dWKeDn
issues into the conveyor.
Special SECTION INSIDE
Hapman
www.hapman.com WASTEWATER PROCESSING
501 between pages 32 & 33
 www.processingmagazine.com JANUARY 2016

FEATURED PRODUCT
HVAC Packaged System
The Grundfos PACOpaQ is a fully integrated and compact HVAC packaged
pumping system designed for chilled and hot water distribution, condenser
water, geothermal loop, district heating and
cooling, and other water-based systems. The
system pairs centrifugal pumps with a dedicated
HVAC control, which automatically determines
the most efficient speed and optimum number
of pumps needed. For more, turn to page 47.
Grundfos
www.grundfos.com
502

COVER STORY PAGE 36 MBR Modules

Screen classifying Koch Membrane Systems PURON MBR modules
cutters used to reduce feature a central aeration and single header
calcium chloride design that allows for minimal clogging and
crash-resistant air scouring. Braided membrane
Demand for calcium chlo-
filters prevent fiber breaks and minimize downtime.
ride (CaCl2) has grown
The products new fiber chemistry improves solids
with the surge in North
reject, increases sustainable permeability, reduces
American oil and natural
fouling and is Title 22 compliant. For more on filtra-
gas production. The Cal-
tion and separation, turn to page 24.
Chlor Corp. plant runs
four cutters and keeps a Koch Membrane Systems
fifth ready. www.kochmembrane.com
503

Coriolis mass flow meter

Badger Meter's RCT1000 Coriolis mass flow meters, the latest addition to its line of WEB EXCLUSIVE
instrumentation
entation products, allow the simultaneous
flow instrume simult measure of mass, volume, den-
sity and temperature,
tem providing control options to
synchronize precision processes. Complementing
the transmitter and sensor, every RCT1000
Coriolis
C or mass flow meter comes with the
RCT
R CT Console software package. For more
on flow
f meters, turn to page 34.
Badger Meter
Ba
www.badgermeter.com
ww
500
Breakthrough Products on
HVAC Motor/Blower Assembly processingmagazine.com
Did you miss our December cover fea-
Regals DEC Star system reduces input wattage by 15 to 35 percent over standard
ture on the Breakthrough Products" of
blowers with traditional ECM motors in HVAC appliances. Its dual-efficiency configu-
2015? Check out the online article at
ration (DEC) removes the motor from the blower inlet
processingmagazine.com. Each product
and eliminates restriction to improve efficiency. The unit
is described, and you can access links to
weighs less than 10 pounds and achieves similar CFM
learn more about the equipment and the
results as bigger and higher-rated blowers. For more
winning companies.
HVAC products, turn to page 49.
Regal Beloit Corporation
www.regalbeloit.com
501

Connect
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 The Only Coupling
To Earn Its Wings

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205
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204
 CONTENTS
NOVEMBER 2016 | VOL. 29 | NO. 11

22
COVER SERIES: PLANT OPERATIONS

Safe shutdown for a turnaround project

22 By Dipl.-Ing. Olaf Fuchs, TV SD Chemie Service GmbH
25,000 individual steps in a tight schedule were completed
at a German Dow Chemical plant.

26 Top 5 industries for CMMS implementation

By Lindsey Walker, NEXGEN Asset Management
These systems streamline preventive maintenance and workflow.

FEATURES

How to troubleshoot pump noise & vibration

34 40 16 By Ray T. Hardee, Engineering Software Inc.
& Jeremy Frank, Ph.D., KCF Technologies Inc.
When the usual suspect is not the culprit, vibration monitoring
and simulation software help solve the mystery.

34 The DC motor advantage

By Joe Kimbrell, AutomationDirect
These motors continue to be the best solution for many
industrial applications, particularly those requiring constant
torque across the motors entire speed range.

40 The next generation of level control

By Ryan Spooner, Singer Valve
The same historic management provided by hydraulic altitude water
control valves can now be achieved with panels and instrumentation.

46 52 46 Going green 1 milliwatt at a time

By Otto Fest, Otek Corporation
New energy-efficient meters use process energy for power.

2 Processing | NOVEMBER 2016

 WHY WE DO IT

CLEAN AIR
MATTERS
We believe breathing clean air is a human right that employees,
friends and family members in the workplace all deserve.
Contact Camfil APC to learn more.
camfilapc.com/cleanairmatters

Farr Gold Series

Dust Collector
camfilapc.com/videos/fgs

/RRNV/LNHD6DIH%HFDXVH,WV
TM

Dust, Mist and Fume Collectors

www.camfilapc.com e-mail: filterman@camfil.com 888-804-4716

211
 NOVEMBER 2016
FEATURES

Modern tank technologies

38
52 By Wayne B. Geyer, Steel Tank Institute-Steel Plate Fabricators Association
Storage tanks have evolved to meet the highest standards
for safety, quality, corrosion resistance and longevity.

56 Bulk solids handling system design

By Carrie Hartford, Jenike & Johanson
Measuring flow properties leads to proper equipment
selection and process reliability.

DEPARTMENTS

6 From the Editor

8 Industry Watch
44 20 Pumps & Piping
30 Plant Operations
32 Trade Shows & Events
38 Motors & Drives
44 Level Measurement & Control
50 Energy Efficiency
55 Tanks & Vessels
60 Weighers & Feeders
61 Classifieds
50 63 Ad Index
64 This month on ProcessingMagazine.com

www.ProcessingMagazine.com Facebook Twitter LinkedIn

facebook.com/ProcessingMagazine @ProcessingMag linkedin.com/groups/4050058

AIR POLLUTION
CONTROL
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SINCE 1874

TUBEJET No-tool bag changes means reduced down time 50 to 200,000 CFM
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PLEATJET Nuisance and process applications Top or bottom bag removal

Pulse-Cleaned Cartridge Collectors Specialists in dust collection for OEM processes Low / high pressure housings WET SCRUBBERS Low pressure drop 500 to 80,000 CFM
Venturi / Impinjet / Eductor Corrosive / moist / high temp Condensing applications
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Tubejet and Impinjet are registered trademarks of SLY, Inc.

248

4 Processing | NOVEMBER 2016

BulkBusterTM Bulk Bag Unloader Bella Twin Shaft Dyna-SlideTM High Precision Dense Phase Transporter, J-Series
Fluidized Zone Mixer Air-Activated Feeder

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installations worldwide. They
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Each Dynamic Air system is
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Multi-Port Switch - Up to 15 positions

214
 FROM THE EDITOR

CONTENT
Editor in Chief Lori Ditoro
lditoro@grandviewmedia.com

Group Managing Editor Amy W. Richardson

arichardson@grandviewmedia.com

Group Associate Editor Amanda Hosey

ahosey@grandviewmedia.com

Senior Editor, Content Marketing Matt Migliore

matt@grandviewmedia.com

Contributing Editor Robyn Tucker

rtucker@grandviewmedia.com

Art Director Ryan Carlson

rcarlson@grandviewmedia.com

Production Director Jaime DeArman

jdearman@grandviewmedia.com

Processing Editor in Chief Lori Ditoro discussed the Lightnin

mixing system with the SPX Flow team at its WEFTEC booth. ADVERTISING
During WEFTEC, the Processing team visited with Milton Roy to learn Group Publisher Michael C. Christian
about its new E.R.I.C. Metering Pump and the MI-Branded Excel XR pump. 908-507-5472 | mikec@grandviewmedia.com

MARKETING
Marketing Director Annee Cook

Marketing Manager Nick Phillips

nphillips@grandviewmedia.com

Digital Business Director Stuart Anderson

stuart@grandviewmedia.com
t the end of September, the Processing team In Part 1 of a two-part series (Part 2 will be featured

A
spent several days in the Big Easy for the
Water Environment Federation Technical
Exhibition and Conference (WEFTEC).
During this time, optimism for the process industries
was high, and we met with many people looking forward
to promoting their new technologies and learning more
about how energy efficiency, reuse and the Industrial
Internet of Things are revolutionizing how we do busi-
ness and how we process and manufacture products.
With cloud-based systems beginning to dominate
many facets of our lives, the use of online systems to
monitor assets and processes continues to be a hot topic
among process engineers, operators and equipment
manufacturers. In this issue, asset management using a
cloud-based computerized maintenance management
system is featured with information about the types of
facilities that the systems benefit (see page 26).
In some situations, more than remote and cloud-
based technology is required to keep a facility up and
running at full capacity. Sometimes, plant operations
have to be shutdown to be thoroughly maintained,
especially if the facility is a refinery that operates almost
24 hours per day, seven days per week. On page 22, a
large-scale Dow Chemical plant turnaround project
that required a shutdown and took about six weeks to
complete is detailed. System and equipment safety and
other inspections, maintenance, repairs, and equipment
replacements were carried out during this project.
Digital Operations Manager Mary Beth Romano
in the December issue), how to troubleshoot noises in marybeth@grandviewmedia.com
a pumping system is explained (see page 16). Problems
Audience Marketing Associate Christina Huang
arose when the backup pumps in a waste treatment
plant in State College, Pennsylvania, were operated. Digital Audience Marketing Analyst Stacy Jess
Discovering the problem and its cause revealed that the
usual suspect is not always the true culprit. Analyzing GVM CORPORATE
an entire system is often requiredthe pump is some-
times not the problem. President Vicki Denmark
As we head to Chicago for PACK EXPO this month, we Chief Revenue Officer Chris Dolan
look forward to sharing our journeys with you. Follow
Chief Marketing Officer Mary Beth Shaddix
me, @LoriDitoro, and Processing, @ProcessingMag, to
keep up with all the happenings and new technology at Financial Director Randy Lyle
this show.
Production Director Andy Estill
Audience Development & Analytics Director
Heather Thompson
Sincerely,
VP, Audience Marketing Delicia Poole
editor in chief
lditoro@grandviewmedia.com
@LoriDitoro
Processing (ISSN 0896-8659) is published monthly by Grand View Media Group. Editorial and
Executive Offices: 200 Croft Street, Ste. 1, Birmingham, AL 35242. Periodicals postage
paid at Birmingham, AL & additional mailing offices. POSTMASTER: Send address changes
to Processing magazine, PO Box 2174, Skokie, IL 60076-7874. SUBSCRIPTIONS:
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Canadian and foreign surface subscriptions: one year, $93; two year, $162. Air mail
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Processing magazine assumes no responsibility for validity of claims in items reports.

For Subscription Questions/Inquiries:

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Email processing@omeda.com
Subscribe / Renew / Change of Address
EDITORIAL ADVISORY BOARD www.processingmagazine.com/subscribe

Christine Banaszek, Application Engineer, Charles Ross & Son Company | Robert J. Bockserman, President, Conatech
Peter S. Cartwright, President, Cartwright Consulting Co. | Barry Charnay, President & CEO, Whisper Ingredients Inc. | Ken Delafrange, President, Jadee Inc.
Don Graham, President, Graham Sanitary Design Consulting, Ltd. | Stanley Herzog, President, Princeton Process Technology Consultants
B. George Kniazewyz, President, Renovare | Eric Langer, President, BioPlan Associates | Ed Marshall, President, Maintenance Management Technologies
John Stansfield, Plant Manager, Accelerated Curing Inc. | Robert M. Donnelly, Vice President of Marketing, Flo-Tite Valves & Controls

6 Processing | NOVEMBER 2016

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252
INDUSTRY WATCH
COMPANY NEWS | SAFETY | ENERGY | FOOD & BEVERAGE | PHARMACEUTICAL

recognition of the AEE. He has led the way in ener-

gy efficiency in manufacturing as well as helped
change the way organizations think about energy
efficiency. Rappas work also gave way to industrial
energy assistance public policy.
AEE presented Rappa the award during the World
Energy Engineering Congress in September in
Washington, D.C.

MCAA appoints new president

Th e Measurem ent, C ontro l & Automation
Association (MCAA) named Teresa Sebring presi-
dent, effective Aug. 1, after approval by the organiza-
tions board of directors.
Sebring replaces Cynthia Esher, who will continue to
be involved with MCAA in her retirement. Sebring pre-
viously served as vice president of MCAA.

Image courtesy of Siemens AG

Image courtesy of GE
Siemens manufactures and tests worlds Oil refinery hits 100 percent reuse
The Federated Co-Operatives Limiteds Co-Op Refin-
largest geared compressor rotor ery Complex of Regina, Saskatchewan, Canada, will
become the first refinery in North America to recycle
he worlds largest the outside diameter of the gases company) integrated all wastewater for steam production. The refinerys

T geared compressor
rotor, with a first-
stage impeller mea-
first-stage impeller rotating at
1,350 km/h.
The compressor was
gasification combined cycle
power plant (IGCC) in Saudi
Arabia. The compressors are
decision to upgrade its wastewater system came
after it increased its operations from 100,000 barrels
of oil per day to 130,000, which also increased waste-
suring 1.8 meters, was engi- d e sign ed for th e air -se p- expected to be commissioned water production.
neered and tested by Siemens aration unit of th e Jazan and erected starting in 2018. The refinery is in the process of installing ZeeWeed
at its Duisburg, Germany, facil- Gas Projects Companys (in The air separation plant is set membrane bioreactor technology with a high-effi-
ity. The impeller was balanced collaboration with a U.S.- to be the largest industrial gas ciency reverse osmosis system from GE for the waste-
at a speed of 3,970 rpm, with h e a d q u a r t e re d i n d u st r i a l complex in the world. water improvement project. The advanced water
recycling system will allow the refinery to recycle and
reuse 2 million gallons of wastewater each day. The
project also will allow the refinery to reduce its fresh-
water consumption by 28 percent and decrease vola-
COMPANY NEWS CHA Consultings senior VP named tile organic compound emissions.
Energy Engineer of the Year
Turbomachinery & Pump Symposia see T h e A s s o c i a t i o n o f E n e rg y ASTM International presents Presidents
record numbers Engineers (AEE) presented its Leadership Award
The Turbomachinery & Pump Symposia (TPS) Energy Engineer of the Year award Sudarsan Rachuri, a founding member and vice
was attended by a record 5,375 attendees from 40 for the northeast region to Rich chair of the ASTM sustainable manufacturing stan-
countries and hosted a record 360 exhibitors at its Rappa, senior vice president and dards development subcommittee, received the 2016
September event in Houston, Texas. Co-located market leader of manufacturing ASTM International Presidents Leadership Award.
with the Roseland Oil and Gas Houston Oil & Gas and energy for CHA Consulting Inc. Rachuri was given the award for his work as editor in
Convention, TPS presented attendees with full-sized AEE awards the Energy Engineer chief of ASTM Internationals Smart and Sustainable
equipment, cutting-edge technology and emerging of the Year designation to those in the industry who Manufacturing Systems journal, which will begin pub-
industry trends as well as a chance to network with readily promote the practices, principles and proce- lication in January 2017. He has recruited more than
other industry experts. TPS 2017 will be held Sept. dures of energy engineering. 50 academic and industrial experts from around the
1214 in Houston. Rappas work as an energy efficiency innova- world who will contribute editorial and advisory ser-
tor, speaker, leader and mentor for the industry, in vices to the journal.
addition to his professional pursuits, won him the Rachuri is the federal program manager for the

8 Processing | NOVEMBER 2016

245
Clean Energy Smart Manufacturing Innovation
Institute and holds a bachelors degree in mathemat-
ics, a masters degree in applied mathematics, and a
masters and Ph.D. in aerospace engineering.
KEYENCE named one of Forbes' Worlds
Most Innovative
KEYENCE Corporation, a provider of research and
development, manufacturing automation and quality
assurance solutions, has been named to Forbes annu-
al list of the Worlds 100 Most Innovative Companies.
This marks the sixth consecutive year Forbes has
included KEYENCE on the list. KEYENCE, which was
ranked number 64, and the other companies on the
list were chosen and ranked based upon their likeli-
hood of inventing the next big innovation.
10 Processing | NOVEMBER 2016
Bunting names new CFO
Bunting Magnetics Company
named Steven Peiffer its new chief
financial officer (CFO). As CFO,
Peiffer will oversee all four Bunting
Magnetics divisions financial
reporting, budgets, accounting and
human resources. Peiffer previ-
ously was senior manager a leading
accounting firm located in Wichita, Kansas.
Parson Peebles announces new COO
Graeme Robertson has been named Parsons Peebles
new chief operating officer (COO). Robertson joins
as the company is working to become the number
one electromechanical products and services pro-
vider. Robertson brings extensive electromechanical
256
executive-level experience and previously worked with
the Sulzer Organization where he held a number of
senior roles and worked in the Parson Peebles market.
Flexicon opens German office
Flexicon Ltd. opened a new office in Aschaffenburg,
Germany, in an effort to expand its factory-direct
engineering services and technical sales offerings
across the country. The German location will be
headed by Regional Sales Manager Christian Lchler,
who comes with 20 years of experience in plastics
processing, compounding, and recycling and holds a
degree in plastic processing technology engineering.
This effort is expected to help fuel rapid growth for
the company in Germany.
Siemens Nigerian energy service center opens
Siemens Power Generation Services opened a new
service facility in Port Harcourt, Rivers State, Nigeria,
to provide service support to its customers in the
region. The facility is the first of its kind in West,
Central and East Africa.
PepsiCo launches 2025 sustainability agenda
PepsiCo Inc. announced a global sustainability agen-
da designed to foster continued business growth in a
way that responds to changing consumer and societal
needs. The company's efforts, which focus on creat-
ing a healthier relationship between people and food,
include specific 2025 goals to continue transforming
PepsiCo's food and beverage product portfolio, con-
tribute to a more sustainable global food system and
help make local communities more prosperous.
SAFETY
Applied Risk warns of MOXA security risks
Industrial control systems security company Applied
Risk reported detected vulnerabilities in the MOXA
E1242 Ethernet remote I/O series due to code injec-
tion within the devices web application, weak pass-
word issues and other security risks including those
that allow bad instrumentation commands to trans-
fer to devices. The application is used in more than 30
million facilities, including oil and gas and manufac-
turing, in more than 70 countries. MOXA has released
a firmware update in response to Applied Risks
findings.
TIMET required to improve chemical safety
The U.S. Environmental Protection Agency (EPA)
required Titanium Metals Corporation (TIMET) to
invest in overall chemical safety and an emergency
preparedness program for its Henderson, Nevada,
facility as part of a settlement with the company.
TIMET also agreed to pay a civil penalty of $500,000.
The settlement comes after a March 2015 inspection
by EPA that found the facility in violation of federal
chemical safety and release reporting requirements in
addition to violations of the Clean Air Acts Chemical
Accident Prevention regulations.
Mining deaths down 30 percent
to reach record low
The U.S. Labor Department reported an all-time low
for mining-related deaths during the organizations
2015-2016 fiscal year, which ended in September. A
total of 24 deaths were attributed to mining activi-
ties during the time period, down 30 percent from the
previous year in which 38 miners died and down from
74 deaths in 2006. Injuries are also at an all time low,
with just 6,500 reported injuries last year.
Improvements are attributed to the National
Mining Associations CORESafety program, which
254
was introduced in 2011. Approximately 181,000
people are employed in mining, including coal, ENERGY
metal and non-metal mining.
ASTM to revise standards on oxygen systems
ASTM International met in Orlando in October to
develop a new standard guide for oxygen fire risk
analysis and revise key Standard G86 on mechani-
cal impact ignition of nonmetals. The committee on
compatibility and sensitivity of materials in oxygen-
enriched atmospheres aims to increase oxygen safety
across industries. The committee is chaired by Elliot
Foryth, WHA International Inc.s senior oxygen safety
and forensic engineer. Worlds largest power plants are
hydroelectric facilities
The worlds nine largest operating power plants are
hydroelectric facilities, according to a report by the
Integrated Bulk Material Handling Systems
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material handling system together for you, please contact us.
249
12 Processing | NOVEMBER 2016
U.S. Energy Information Administration (EIA). An
estimated 62,500 power plants are operating around
the world, with a total installed generating capacity
of more than 6,000 gigawatts (GW) in 2015. The nine
largest operating power plants in the world by capac-
ity are all hydroelectric power plants.
Four of the worlds 10 largest power plants are locat-
Courtesy of the EIA
ed in China, and all four of those hydroelectric plants
began operating in the past 13 years. The worlds larg-
est dam, Three Gorges, is located on the Yangtze River
and has a capacity of 22.5 GW. Hydroelectric power is
the second-largest source of electricity in China after
coal and accounted for 20 percent of the countrys
total generation in 2015.
Solar generates more electricity than coal
for 6 months in UK
In the six-month period from April to September, solar
power generated more electricity than coal in the U.K.
for the first time. During the period, coal generated
6,342 GWh, comprising 4.7 percent of total demand in
the U.K., while solar generated 6,964 GWh, comprising
5.4 percent of demand. Solar generated more electric-
ity than coal for the entire month of May, with coal
generating zero percent several days in the month.
FOOD & BEVERAGE
USDA to buy cheese surplus, supports TPP
The USDA will purchase a $20-million, record-level
cheddar cheese surplus to aid U.S. dairy production.
The USDA has authority to purchase this and other
food surpluses as part of the Agriculture Act of 1935.
As part of the purchase, the cheese would be used as
part of public nutrition assistance programs such as
food banks and those for needy families. The USDA
expects the market to improve in the near term but
sees the surplus purchase as an opportunity to reas-
sure farmers while aiding others in need. The surplus
food is expected to be issued to assistance programs
starting in March 2017.
The USDA also shared a new report that found
growth within the dairy market is dependent upon
the creation of the Trans-Pacific Partnership (TPP),
which could add up to $300 million per year in dairy
exports. The organization supports TPP and other
free trade agreements, which have previously sub-
stantially improved the dairy market.
Nestl makes voluntary Drumstick recall
In October, Nestl recalled its Drumstick ice cream
cones produced at its California factory between
Aug. 31 and Sept. 17 because of potential Listeria
contamination. The nationwide recall was voluntary
after positive Listeria test results were confirmed
on production line equipment. No related illnesses
have been reported.
Natural & organic market outpaces overall
food & beverage market
The natural and organic retail food and beverage mar-
Schenck Process
Kansas City, MO
ket is expected to reach $69 billion by the end of 2016,
888-657-3098 a more than $6 billion growth over the previous year.
mktg@schenckprocess.com Sales rose at a compound annual growth rate of 7
www.schenckprocess.com percent over the last five years, with sales 32 percent
higher now than in 2012. Growth of the natural and
organic market outpaced the overall food and bever-
age market during the five-year period, and the natu-
ral and organic market is expected to grow by almost
70 percent over the next five years.
US food & beverage manufacturing hits
$54B in first quarter
A new report from BMO Harris Bank found the U.S.
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food and beverage manufacturing industry reached a
new earnings high in the first quarter of 2016 of $54
billion. The industry is expected to continue growing
over the longer term. This growth is contributed to
successful crop seasons, lower crop prices and grow-
ing consumer demand. BMO Harris also contributes
growth and the industrys positive outlook to a 1.6
percent drop in food prices.
PHARMACEUTICAL
Growing CMO market changing to influence
pharmaceutical industry
The contract manufacturing organization (CMO)
market has begun expanding services into early stage
drug development, complex technology transfers and
flexible production capacity supply in order to create
higher success in the market. This move should allow
pharmaceutical companies greater optimization of
manufacturing capacity. Growth opportunities for
CMOs are available by:
Enhancing technical capabilities
Amending business models (including risk sharing)
Exploring early-stage production, virtual biotech
and out-licensing
Manufacturing biologics, biosimilars and high-
potency active pharmaceutical ingredients
Detracting from opportunities are breach of patent
and IP information concerns, manufacturing control
loss concerns and in-house manufacturing expansions.
Rwandan pharmaceutical market damaged
by material & utility shortages
A new survey commissioned by Rwandas National
Industrial Research and Development Agency titled
Research and Technology Assessment, found 46 per-
cent of companies in the pharmaceutical and chemi-
cal industries report enough raw materials are not
available. Power and water outages are common in
the country, substantially limiting production capac-
ity. Availability of skilled labor is also a problem for
businesses in the region, as 65 percent of companies
reported difficulty finding qualified employees.
Send news and events for consideration to
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PUMPS & PIPING

how to TROUBLESHOOT

PUMP NOISE
& VIBRATION
When the usual suspect is not the culprit, vibration
monitoring and simulation software help solve the mystery.
By Ray T. Hardee, Engineering Software Inc., & Jeremy Frank, Ph.D., KCF Technologies Inc.

Part 1 of a two-part series

ften when troubleshooting a system, capstone project for Penn State students, which willing to participate in the capstone, and all involved

O many people only consider the obvious

choice. Common occurrence and expe-
rience sometimes blind teams to other
would demonstrate how continuous monitoring
technology and piping system simulation software
can be used together to identify a problem in a
agreed that this would be an excellent project.
The members of Penn States senior capstone
design team, along with the members of the clients
possibilities and may lead to time and resources pumping system. operations staff, installed wireless monitors on
spent solving the wrong problem. Part 1 of this article Initial identification of excessive vibration is an the suction side of the three pumps in the system.
explores a situation in which the obvious choice for important step during diagnosis. Digging further into Once the sensors were installed, the plant staff
the source of pump noise did not add up. the root cause with system simulation allows for a operated the system to determine the source of the
A backup system using three centrifugal pumps was total system view and efficient troubleshooting and noise and vibration.
added to a waste treatment plant in State College, optimization of pump performance. Together, vibra- As shown in Figure 2's data, high-magnitude
Pennsylvania. The primary system consisted of a pair tion instrumentation allows for real time identification vibrations occurred within the time history for all
of centrifugal pumps running from a sewage storage of system issues, while simulation allows for a systems the backup pumps. The corresponding frequency
tank to the discharge tank, and the backup system approach to issue resolution. After some discussion, data had elevated broadband noise typically seen
drew from the same storage tank and discharged the clients team members indicated that they were with cavitation, air entrainment or recirculation. A
into the same discharge tank. An initial sketch of the
pump suction piping is shown in Figure 1.
The main pumps were sized to operate at 600 gal- Initial identification of excessive vibration is an important step
lons per minute (gpm), and the three backup pumps
were sized to operate at 1,200 gpm. With the main
during diagnosis. Digging further into the root cause with system
pumps running, no issues occurred. However, any simulation allows for a total system view and efficient trouble-
time a backup pump was started, noise and vibra-
tion occurred. As a result of the excessive vibration, shooting and optimization of pump performance.
the plant decided to investigate the operation of the
backup pumps.
KCF Technologies Inc., a manufacturer of smart
diagnostic equipment and software (including vibra-
tion monitoring) in State College, worked with the cli-
ent to determine the root cause of the backup pumps
issues. Several wireless sensors were installed close
to the backup pumps' suction nozzles, and the sys-
tem was started again to analyze what was happen-
ing in the pump suction pipeline. Figure 2 shows the
vibration sensor data in terms of time history [upper
graph, millisecond values] and the corresponding fre-
quency spectrum [lower graph, hertz (Hz)] when one
of the three backup pumps was started.

Determining the cause of cavitation Figure 1. A section of the waste treatment system in which excessive
The genesis of this joint project started when the noise and vibration occured on backup pumps 1, 2 and 3
diagnostics manufacturer was looking for a senior All images courtesy of Engineering Software Inc.

16 Processing | NOVEMBER 2016

 Figure 2. The dashboard of
the vibration sensor data shows
excessive vibration occured
after 10 minutes of backup
pump operation.

Figure 3. The piping system

model contains a piping sche-
matic showing the different items
within the system.

20-g peak was present, indicating that rapid wear of

the components would occur if the situation were
left uncorrected.
Based on the results of the vibration sensor
spectral data, the team believed the culprit was
cavitation likely because of inadequate net posi-
tive suction head (NPSH).
During a review of the vibration data, the following
questions surfaced:
Why did the backup pump operate for 10 min-
utes before vibration occurred?
Since all the pumps shared suction on the same
sewage tank, why were only the backup pumps
exhibiting excessive noise and vibration?
What were the suction and discharge pressure
gauge readings for the operating backup pumps?
What was the calculated value of NPSH available
for the operating backup pumps?
What was the NPSH required for the backup
pump when operating within the system?
Since these points had not yet been addressed,
a definite determination of the cause could not be
made. NPSH calculations were subsequently per- to gain insight regarding how the whole system oper- the product or provide the service, and the control
formed using a system simulation of the pump suc- ated. The students created a model with the aid of elements improve and manage the quality of the
tion only (Figure 1) and indicated that the NPSH PIPE-FLO Professional from Engineered Software Inc. product or service within the system. Without an
available (NPSHA) at the pump suction was 39 feet, Once the Penn State capstone design team had understanding of how these three types of elements
and the NPSH required (NPSHR) for the pump was access to the piping simulation software, they eas- work together, one cannot fully comprehend how a
only 11 feet. Therefore, the pump should not have ily created the model by inserting design data for all system operates.
been cavitating. Since the calculations did not match the items within the system. Figure 3 shows the con- The pump elements consist of the three backup
the observations, the team needed to see what was nections for all the items found in the backup piping pumps (see Figure 3). The process elements consist
occurring in the actual system. system. Note that the main pumps are not displayed of the sewage storage tank and interconnecting pipe-
on the drawing. This is because during the walk down lines, along with the outlet tank. The control elements
Building the entire piping system model it was determined that the primary system was not consist of the tank level switches and on/off control
Since the piping system was vital to operations, shut- interconnected with the backup system, which, as an of the pumps to prevent the tank from overflowing
ting down the system to run tests to understand what aside, highlights the benefit of visually verifying that when on a high level and operating the pump dry
was happening was not permissible. Instead, an accu- the model and the system match. with a low tank level.
rate total system simulation was developed to under- All the piping systems, regardless of size or func- The piping system model contains the design
stand the true source of the measured vibrations. tion, are made of interconnected primary elements. parameters for each item included in the system. How
First, the students developed a model of the total The pump elements add all the hydraulic energy. the equipment in each element is used in making the
piping system, both the suction and discharge sides, The process elements are used to make or transport model is described here. For the process equipment,

NOVEMBER 2016 | www.processingmagazine.com 17

the bottom tank elevation and liquid level in the sew-
age storage and outlet tanks are used to define fluid
energy at the boundaries of the piping system. The
pipe size, length, and valve and fitting coefficients are
used to describe each pipeline. The Darcy method is
used to calculate the head loss in the pipelines.
The pump elements are defined by the pump
curve supplied by the manufacturer and created in
accordance with multiple Hydraulic Institute (HI)/
American National Standards Institute standards.
Once this information is entered, the model deter-
mines the pump operation across a wide range
of conditions.
The control elements in this system consisted of the
level switches within the tank level indicators. When
the level in the sewage storage tank is low, the pump
stops to prevent it from running dry. With a high level
in the tank, the pumps start to maintain the tank with-
in the working level parameters.
Analyzing the piping system model
Once the model was created, the system was calcu-
lated with Backup Pump 101 in operation and the fluid
levels in the tanks set to operational levels. The pip-
ing system model results indicated that the flow rate
through the pump was in excess of 4,736 gpm, which
was well outside the designed flow rate of 1,200 gpm.
Considering the pumps NPSH, the simulation
showed an NPSHA at the pump suction of 38.4 feet
of fluid with a pump NPSHR of 30 feet. Initial indi-
cations revealed that the noise and vibration on the
pump suction was not, in fact, because of cavitation.
However, the simulation also calculated a system
flow rate much greater than the intended design flow
of the system.
Conclusion
With NPSHA values greater than the NPSHR and a
calculated flow rate of more than three times the ex-
pected flow rate of 1,200 gpm, clearly more was afoot
than commonly experienced pump cavitation, but
what could it be?
Look for Part 2 in the December issue, which covers
what occurs in this application when analyses are per-
formed during a walkthrough to troubleshoot using
the system simulation followed by validating the result
using test data.
Ray T. Hardee, P.E., is the chief engineer and a prin-
ciple founder of Engineering Software Inc., creators
of PIPE-FLO and PUMP-FLO software. The PIPE-FLO
product line helps companies across many indus-
tries find hidden profit in the design and opera-
tion of their fluid piping systems through simulation software, modeling
services and training opportunities. Hardee is a member of the Hydraulic
Institute, American Society of Mechanical Engineers Energy Assessment
for Pumping Systems standards committee and the International
Organization for Standardizations Pumping System Energy Assessment
committee. His publications include Piping System Fundamentals
and contributions to HIs Pump Life Cycle Cost and Optimizing Piping
Systems. He may be reached at simguyray@eng-software.com.
Jeremy Frank, Ph.D., is the president and cofounder
of KCF Technologies Inc., an engineering technol-
ogy company that develops and integrates innovative
devices for use in the emerging world of the Internet
of Things. Frank earned an MBA and a doctorate in
mechanical engineering from the Center for Acoustics
and Vibration at Pennsylvania State University, researching smart material
devices and actuators. Founded in 2000, KCF provides wireless condition
monitoring sensor systems for defense and industrial markets based on
vibration sensing technologies. KCF has achieved successes in multiple
industries such as pulp and paper, oil and gas, automotive, and food and
beverage products as well as institutional building sectors. Frank coordi-
nates KCFs Smart Diagnostics product line in these industries, and under
his leadership revenue has grown at an average annual rate of more than
72 percent since 2000.
Engineering Software Inc.
www.eng-software.com
KCF Technologies Inc.
www.kcftech.com
MORE Visit processingmagazine.com
ONLINE
for more articles on pumps and piping.

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INSTRUMENTATION VALVES

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PUMPS
& PIPING P RO D U C T SP O T LLI GH T
1 | Pipe-forming technology
Transfluid uses a CNC-controlled type
SRM rolling forming machine and two axi-
al forming machines with a forming power
of up to 25 tons to perform tests on com-
ponents and tools. The process chain can
be implemented with an additional CNC-
controlled pipe bending machine and an
orbital pipe separation system to ensure
that requirements, such as burr formation,
can be met. The team has experience as
a developer of incremental pipe forming,
which permits partial rotation-symmetrical
forming of pipes made of high- and very-
high-strength materials.
Transfluid
www.transfluid.de
510
20 Processing | NOVEMBER 2016
1 3
2 | Self-aligning pipe coupling
The Tuf-Lok ring grip pipe couplings
are low-cost, heavy-duty, self-aligning
couplings for either high-pressure, to 150-
psig, or full-vacuum-rated applications.
These leak-proof couplings install quickly
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are available in 2-inch (50-mm) through
10-inch (250-mm) pipe sizes and are
made for use on plain-end pipe, regardless
of pipe wall. No machining or grooving is
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Other features include self grounding and
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TUF-LOK International
www.tuflok.com
511
2
3 | Wastewater pumping system
Xylems Flygt Concertor is the world's first
wastewater pumping system with inte-
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system are up to 70 percent higher than
with a conventional system, and inventory
is reduced by up to 80 percent due to flex-
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operation and clean wet wells, the unit
saves up to 80 percent in vacuum cleaning
costs, and its compact design combines
IE4 motor efficiency, Adaptive N-hydraulics,
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pumps in the 3-to-10-hp range.
Xylem Inc.
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512
4 | Slurry pump
The ITT Goulds Pumps XHD Extra Heavy
Duty Metal and Rubber Lined Slurry
Pumps are suited to tough slurry applica-
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ITT
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226
 Cover Series: PLANT OPERATIONS

SAFE SHUTDOWN
FOR A TURNAROUND PROJECT
25,000 individual steps in a tight schedule were completed
at a German Dow Chemical plant | By Dipl.-Ing. Olaf Fuchs, TV SD Chemie Service GmbH

n regular intervals, every process plant According to regulations, the turnaround takes Time is money

I needs to be shut down to carry out inspec-

tions, maintenance, repairs and safety
inspections. This is called turnaround
place every three to five years. The personnel required
and the logistical efforts are huge. In addition to the
approximately 900 Dow employees and external ser-
When the naptha cracker is not functioning, high
costs are incurred. During regular operation, the
plant generates a daily turnover in the amount of 1
or major shutdown.. The term shutdown, however, vice partners, approximately 1,200 other specialists million euros. The target is, therefore, to keep the
does not adequately describe this large-scale project. from different companies came to Bhlen for the shutdown as short as possible. This requires meticu-
The term turnaround is much better since this is companys last turnaround. They disassembled the lous planning for around 30 months to complete the
what is done: Every single part of the plant is turned plant step by step, inspected each component thor- turnaround in the tight timeframe of six weeks.
around once and is disassembled, maintained and oughly, cleaned each and replaced any if needed.
assembled again. The naphtha cracker, the heart of Sensors, measuring devices or pipelines belong, for Shutdown in 10 days
the Dow-Olefinverbund chemical plants in Germany, example, to the discarded components if they were The plant cannot be suddenly shut down. In order order
is just like compressors, pumps and turbines replaced. Heavy-duty cranes, rising into the sky by the to shut down the ongoing processes in a coordina at-
coordinat-
shutdown during the turnaround of the Bhlen plant. dozens among the plants and scaffolding, lifted and ed way, Im working with a team around the cloc clockck
However, a lot more people work in the plant during positioned the heavy components. To coordinate all in three shifts for nearly 10 days, says Jrg Friedrich,
Friedricch,
the turnaround than during normal operation. these tasks, Dow created a new, large car park with its naphtha
who was responsible for the operation of the naphth ha
own traffic light system as well as a container village. cracker at Dow. Many of the plants that depend on o
the Olefinverbunds heart also are maintained and annd
The plants core shutdown, but not all of them. This constitutes a spspe-e-
Via a 430-kilometer long pipeline, petroleum is cial challenge, particularly regarding safety.
brought from the harbor in Rostock to Bhlen where
it is further processed. The chemical plant close to Safety experts
Leipzig is part of Dow Olefinverbund GmbH, a sub- The operational
opep rati
tion
onal
al safety
saf
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com
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antt mu
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around 800C C, the
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oleu
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hydro- Decisive
Deci isiive for the ins
inspections
nspe ctions is the
pect he Industrial
th d strial Safety
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ca rbon
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carbon Regulation
Regu gula tion iincluding
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ctio
ion
n, wwhich
hicch
hi c
within the n apht
ap htha
naphthaha ccrackers
rack
ra cker
erss 1155 fu
furrnac
aces. This
furnaces. Thiis is
Th is the
th iiss now regulated in the Ordinance on Hazardou Hazardous us
basis for producing high-quality plastics in the Dow Substances. TV SD Chemie C em
Ch mie Service
Service GmbH
Gmb bH has
has been
beeen
e
plants in Schkopau
Schkop p au and Leuna. While Whililee the
th e naph-
naph
na ph-
ph involved
invo
in volv
vo lved
lv ed in
in Dows
Dow
Do
Dowwss safety
s fetty iinspections
sa nspeections for many years.yearrs.
tha
th
ha cracker
crac
cracke
ac kerr is the
ke the heart
heartt off the
thhe Olefinverbund,
O efinverbund, it also
Ol The experts are knowledgeable. One example exampl Peter
plee is Peteer
et e
assumes further tasks, such as providingg process pro
roce
cess
ss
steam m for
foor other
othe
ot herr parts
part
pa rtss of the
the chemical
chemicall plant.

22 Processing | NOVEMBER 2016

 Clockwise from top: Jrg Friedrich (left) and Reiko Hass during a tour of
the plant. They coordinated the turnaround, checking in daily to ensure every-
thing occurred according to plan. Using dye-penetrant testing and other
tests, the experts verify the integrity of the pipe welds. Hass showing the
plans of the plant in a turnaround container during a plant tour.

5
tips
for a
successful
turnaround
1. Occupational and operational safety are top pri-
orities. Only when these goals are clearly com-
municated by the companys management and
Goth, w who has worked in the plan plant for nearly 35 years implemented throughout the whole company is
and who
wh ho knows the cracker well. T Two other colleagues planning complex turnaround processes top-
also pe ermanently work in the plant.
permanently pl They combine down and realizing them successfully possible.
experie ence in the management, organization
experience org and logis-
tics of large-scale
l projects and the specific knowledge 2. Long-term practical experience is what
of the pplants on site. Employees fr from other chemical counts for everyone involved. Complex
sites, su
uch as Frankfurt-Hchst an
such and Leverkusen, came plants are often unique in terms of their spe-
to Bhl len for the safety installation
Bhlen installations. In total, 13 experi- cific configurations. Therefore, employees,
enced specialists
s worked on site to carry out the many suppliers and service providers who know
statutoorily prescribed inspections.
statutorily the plants, their components and their par-
ticularities in detail are of considerable value.
Long-term
Long-
-term practical experien
experience counts
The saf
safety
fety company inspects numerous
num components 3. Create a team with strong communication skills
and syssystems tightness of the pressure
stems such as the tightn that assumes responsibility. When unforeseen
vessels.
vessels s. Corrosion monitoring is aan important part of events or clashing interests (for example, budget-
safety
the saf fety inspections. Therefore, 100 vessel nozzles ing versus repair measures) occur, all involved par-
had to be replaced. ties coming to a practical agreement is important.
What
Wha chemical industry is long-
at is important in the chemi
term practical
prractical and professional exexperience. Goth uses 4. Consider both the target and actual situation
tthee exa
th example
ample of a welding seam to explain why experi- during the planning of the many work sequenc-
ence is important. He says, It might
en mig look a bit sloppy, es and the organization of the equipment, tools
butt th
bu craftsmanship and still
thee seam is high-quality craft and spare parts, professional software systems,
intact
inta
in ct after
tact a dozens of years of ope
operation. An observ- and databases that provide valuable assistance.
er, who
er who only knows the flawless w welding seams pro-
duced
duce
du cedd by
b modern, fully automatic
automati machines, would 5. Encourage the employees motivation, but at
surely
sure
su ly assess
rely ssess the situation di
ass differently.
fferen the same time, do not put them under too much
pressure. Stress means mistakes, and resulting
corrections may contribute to much higher costs
than a conscientious and calm process.
The
he Do
D
Dow w Chemical plant in Bhlen was covered in scaffolding during the
turnar
turnaroun
oundd. At the center is the cracker, the oldest parts
turnaround. p of which are around
yea
earss old,
40 years o and at the front is the naphtha pipeline.
pipelin
All im
images
maages courtesy of TV SD Chemie Service
Servic GmbH

NOVEMBER 2016 | www.processingmagazine.com 23

 Peter Goth, who has worked on site for 40
years, discusses possible solutions for a leak.
High Efficiency Submicron Filtration Systems
Get the most out of your water treatment process! Learn
how you can accomplish tomorrows water treatment
goals with Vortisands cross-ow microsand ltration
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242
24 Processing | NOVEMBER 2016
Costs that pay off
In total, we [invested] around 42 million euros in
this turnaround. In addition to the shutdown costs of
around 50 million euros resulting from turnover loss-
es. A high investment, but necessary for safe opera-
tion, says Dow shutdown manager, Reiko Hass.
The turnaround for Dow is about more than a
statutorily prescribed safety inspection. The inno-
vation cycles in this high-tech area become shorter
and shorter. At the same time, the requirements for
functional safety increase. This is why the time during
which the plant is out of operation is also used for the
renewal of plant parts.
Shortly after the restart of the plant, those respon-
sible start planning the next turnaround.
Dipl.-Ing. Olaf Fuchs studied thermal process engineering at the technical
university Otto von Guericke, Magdeburg. After his studies, he worked for
13 years in apparatus and tank engineering and was a production manag-
er for 10 years. Afterward, he worked many years for a technical inspec-
tion organization. Since 2007, he has worked at TV SD GmbH as an
expert witness in the area of plant safety and inspection. Since 2010 he
has been head of plant monitoring in central Germany. He may be reached
at olaf.fuchs@tuev-sued.de or +49 3461 49-2263.
TV SD Chemie Service GmbH
www.tuev-sued.de/chemieservice
217
 cover series: plant operations
Top
5
These systems streamline preventive
maintenance and workflow
omputerized maintenance management
C systems (CMMS) are transforming the
large and complex maintenance opera-
tions of every industry. A CMMS solution
is an advanced application designed to manage and
monitor every aspect of maintenance operations to
make the day-to-day job of facility managers easier
and more efficient. It empowers organizations to
manage and monitor everything from work orders
and inventory levels to preventive maintenance
and workflow.
With the proliferation of cloud computing and
the Internet of Things, businesses of every size
and scope are flocking to a CMMS for improved
efficiency and cost savings. From restaurants and
retail chains to municipal facilities and malls, every
industry is making the most of a CMMS solution for
smarter maintenance.
The need for CMMS
Maintenance departments often face costly repairs
and emergency replacements that disrupt operations.
These repairs and replacements can be prevented
26 Processing | NOVEMBER 2016
industries for
cmms
implementation
| By Lindsey Walker, NEXGEN Asset Management
with an efficient CMMS solution that offers end-to-
end visibility into equipment uptime, workflow man-
agement and maintenance costs.
Installations that involve customization and
deploy on-premise servers can benefit from a power-
ful CMMS, which keeps equipment up and running
smoothly by identifying bottlenecks instantly and
preventing maintenance problems before they dis-
rupt the production process.
A CMMS facilitates informed decision making,
gives real-time access to mission-critical mainte-
nance information, extends the service life of equip-
ment, reduces the cost of repairs and replacements,
and accelerates responsiveness to work orders.
Benefits of a CMMS for 5 verticals
CMMSs provide advantages for multiple industries,
including:
Allowing hotels to replace lighting before it goes out
Ensuring that hospital life support systems
work properly
Compiling and reporting school fire alarm
performance data
4x6/iStock / hh5800/iStock
Keeping airplanes up to date and running on time
CMMS solutions allow industries worldwide to
create safer, more efficient operations. Five process
industry sectors may benefit most from the opera-
tional improvement of using a CMMS:
Manufacturing
1 Manufacturing involves significant wear
and tear, which means work orders must be gen-
erated when parts and replacements are needed.
To gain maximum returns on investment, track-
ing an assets life cycle is required for maximized
uptime and productivity. Investments in plant
equipment and the expenses for preventive
maintenance determine the competitiveness of
a plant. A CMMS automates everything from
work orders and asset management to report-
ing and vendor management. This automation
increases operational efficiency and helps the
business achieve its goals.
Oil & gas
2 In the turbulent environment of a wellhead,
ensuring that everything remains organized,
 PVDF FLUOROPOLYMERS

Kynar
A mobilized CMMS is the best solution for
organizations in which employees are always on Kynar Flex
the go or for operations in remote locations.
even with constant movement and activity, is paramount. The maintenance Outstanding Chemical Resistance
team needs to verify that everything from the equipment and fleet to the
final product and essential assets is in top shape.
A CMMS captures every detail at a centralized location, which can be accessed
easily by multiple users from any device to prevent unplanned downtime and Proven performance
other delays. It streamlines the day-to-day maintenance tasks while ensuring
accurate recordkeeping. It keeps constant track of metrics that have a pro-
against chlorine,
found impact on the equipments performance, generating greater revenue as bromine, sulfuric
projects expand. acid, hydrochloric
acid, chlorinated
Food & beverage
3 The food and beverage industry must comply with stringent regulatory solvents and more.
requirements. Meeting tough standards during strict audits requires those in
the food and beverage industry to keep careful and constant track of every step
in the production process. Timely maintenance plays a pivotal role in keeping Use temperatures up
production lines fully functional around the clock. A CMMS is fully loaded to
accomplish everything needed to prevent downtime and other problems. It pro- to 150C, radia-
vides accurate reports on work orders, inventory levels, maintenance schedules tion resistant, meets
and allocated funds for operations without any interruption. many ame and
Energy
smoke ratings, and
4 Longevity, high-performance and uptime are the top concerns of any is abrasion resistant.
energy-intensive facility. A CMMS stores all the information on a centralized
dashboard so managers can stay on top of work orders, repair costs, availabil-
ity of spare parts and other maintenance functions. From condition monitor- You can build an entire
ing and compliance to document management and preventive maintenance, uid handling system
organizations can keep the pulse of each activity to ensure that operations run
safely and effectively.
with components made
of reliable Kynar
Municipal facilities uoropolymer.
5 A CMMS improves responsiveness to infrastructure failures and equip-
ment breakdowns by updating the team about inspection schedules and pre-
ventive maintenance. Municipalities use CMMS to manage workflows, prevent
critical breakdowns, ensure the timely performance of maintenance tasks, and
implement timely planning and scheduling. This improves transparency, pro- Versatile Kynar
motes accountability and aids in achieving regulatory compliance. uoropolymer is
used extensively
in general chemical
processing, high-purity
semi-conductor,
pharmaceutical,
MOBILE CMMS pickling/steel industries
and pulp & paper
Using a mobile CMMS empowers maintenance teams to: industries.
Schedule, allocate and accomplish work orders faster and
800.596.2750
with complete precision
www.kynar.com
Manage the spare parts inventory efficiently so repairs
are performed quickly Kynar and Kynar Flex are registered trademarks of Arkema Inc.
Copyright 2016. All rights reserved.
Keep constant track of equipment parts, maintenance
procedures and inventory levels to avoid delays and
interruptions
Reduce machine downtime that leads to lost revenue
Ensure strict adherence to safety regulations and meet-
ing safety standards to prevent workplace hazards and
machine failures
Minimize overtime by saving the time traditionally wast-
ed on searching for information in folders and files 201

NOVEMBER 2016 | www.processingmagazine.com 27

 Scheduled maintenance
is the key to performance
Prasit Rodphan/iStock optimization, and a mobile
CMMS solution helps
keep up with standardized
procedures even with
massive inventory levels.

Government and private organizations use asset

RIBBON/PADDLE/PLOW
BLENDERS HANDLE
POWDERS TO PASTES
MUNSON Ribbon,
Paddle and Plow
Blenders force
agitators through
stationary materials,
imparting shear
needed to reduce
agglomerates and
blend pastes and
slurries. Low cost industrial units to
state-of-the-art designs of 304/316
stainless and exotic alloys with heating/
cooling jackets, liquid spray additions,
high-speed choppers/intensiers, and
nishes to USDA Dairy and other
standards. Minimum heel of residual
following discharge. Heavy- and extra-
heavy-duty batch and continuous models
in capacities from 1 to 1000 cu ft
(.03 to 28 cu m).
WORLDS FASTEST
BLENDING AND CLEAN UP
No other bulk solids mixer delivers this
unique combination of benets:
100% Uniform blending and/or
liquid additions to 1 ppm in
2-1/2 minutes
Total discharge with no segregation
Ultra-gentle tumbling action
(versus blades forced through batch)
Fast yet gentle 4-way mixing
action: fold/tumble/cut/turn
+1-315-797-0090 USA: 1-800-944-6644 INFO@MUNSONMACHINERY.COM
VEE-CONE BLENDERS FLUIDIZED BED MIXERS management and employ a CMMS solution to
SANITIZE ULTRA-FAST, BLEND ULTRA-FAST, streamline operations, save time, lower mainte-
THOROUGHLY GENTLY
nance costs and improve work efficiency. A CMMS
MUNSON Vee-Cone Unlike Ribbon
Blenders feature and Paddle improves transparency, ensures the accurate mea-
smooth internal Blenders with a surement of performance, enhances compliance
surfaces free of single agitator
bafes, shafts and shaft, MUNSON
standards and facilitates precise adherence to stan-
bearings, allowing Fluidized Bed dard operating procedures. A ready-to-implement,
unobstructed Mixers feature two easy-to-use CMMS solution is making predictive
material ow, shafts with paddles
plus complete that counter-rotate and preventive maintenance safer and smarter by
discharge through a gate valve for rapid at higher speeds to uidize material, leveraging the agility and accessibility of mobile
cleaning or sanitizing of the easy-access achieving homogeneous blends in 10
interior. Uniform blends typically achieved seconds to 2 minutes. Low shear forces technology. Mobile CMMS technology is gradually
in 5 to 15 minutes at ll volumes from minimize friction with little degradation. becoming a must-have in every industry.
100% to 25% of capacity. Ideal for dry Drop bottom gates provide rapid discharge
and granular materials. Gentler than with no segregation. Ideal for short cycles
machines that force agitators through and gentle handling of low- to medium- Mobile CMMS is the future
stationary material. Options include spray density powders and fragile akes. By enabling daily engagement in the blink of an eye
bars for liquid additions, Clean-In-Place Capacities from 265 to 28,660 lb
(CIP) systems, abrasion-resistant steel (120 to 13,000 kg). across the globe, mobile technology has become the
construction and ASME-coded jackets. undisputed king of communication, and the same
ROTARY LUMP BREAKERS stands true for businesses. A mobilized CMMS is the
REDUCE AGGLOMERATES, best solution for organizations in which employees
FRIABLE MATERIALS are always on the go or for operations in remote loca-
tions. The power and portability of a mobile CMMS
Remove lumps
and agglomerates
from bulk foods,
allow technicians to stay on their toes and save tre-
pharmaceuticals mendous time and cost.
and chemicals, or Below are seven ways mobile CMMSs have revolu-
break down glass
and other friable tionized the way technicians work and why this tech-
materials. Dual nology will have a long life in the process industries:
rotors with three-
Ultra-low energy usage point, single-piece breaking heads rotate
with minimum clearance inside a curved, Real-time access to information
Equal efciency from 100% perforated bedscreen. On-size material 1 One of the biggest benefits of a mobile
to 5% of capacity exits through bedscreen apertures from
Unlike other rotary mixers: 1/32 to 2-1/2 in. (0.8 to 63.5 mm) in CMMS is its portability, which facilitates instant
No internal shaft or seals diameter. Low prole design ts tight access to work orders even when technicians
spaces. Side-removal bedscreens allow
contacting material fast, in-place sanitizing. Inlets range from are in the field. For maintenance technicians
Every internal surface accessible 15 to 48 in. (38 to 122 cm) in width who are always in the field, this technology will
Signicantly faster washdown classifying screen apertures from 1/32 to
2-1/2 in. (0.8 to 63.5 mm) in diameter. improve efficiency and reduce downtime. A
Seal changes 10x to 20x faster
mobile CMMS solution enables instant notifica-
PIN MILLS REDUCE FRIABLE tions for upcoming preventive maintenance and
SOLIDS IN CONTROLLED work orders to ensure that equipment operates
SIZE RANGES efficiently and effectively.
Also known
as Centrifugal
Impact Mills, Improved responsiveness
these MUNSON 2 With a mobile CMMS, workers can eas-
ROTARY machines deliver
BATCH coarse to ne ily access pending work orders, track assets and
MIXER grinding of friable browse through the inventory from any device.
powders, akes
and granules into A mobile version keeps technicians on top of
controlled particle sizes at high rates equipment performance to prevent breakdowns.
per hp/kw. High-speed rotation of the
inner disc creates centrifugal force that
It eliminates the possibility of delays and makes
accelerates bulk material entering the completing all the reactive repairs and replace-
central inlet of the opposing stationary ments on time fast and easy.
disc. As material travels from the center to
the periphery of the discs at high speed, it
passes through a path of ve intermeshing Instant communication
rows of rotating and stationary pins, with 3 With on-the-spot communication from
the desired tight particle size distribution
obtained by controlling the rotor speed. any device, managing workflow and accelerating
EE-0696

MUNSONMACHINERY.COM
responsiveness during emergencies becomes easy.
2016 Munson Machinery Co., Inc. MUNSON is a registered trademark of Munson Machinery Co., Inc.
It keeps the entire crew updated and informed at
241 all times so operations remain up and running

28 Processing | NOVEMBER 2016

 around the clock. With end-to-end visibility into
the entire maintenance operation, closing work
orders on time while ensuring regulatory com-
pliance is simplified. Real-time reporting of what
went wrong and how soon the maintenance or
repairs will be accomplished occurs seamlessly
and quickly, minimizing the chances of important
details being missed or forgotten.

Reduced transit time

4 With a mobile CMMS, photos are easily
shared and videos are easily uploaded from any
device. The maintenance team is always aware of
the actual issue saving time, improving accu-
racy and increasing work efficiency because every Yamac Beyter/iStock
member knows exactly what needs to be done.
The portability of a CMMS plays a crucial role
in preventing breakdowns because technicians
always have instant access to critical information.

Enhanced precision
5 A mobile CMMS solution empowers main-
tenance technicians to shift the focus from reac-
tive problem solving to improving uptime and
reducing errors. It eliminates paperwork so that
technicians can concentrate on optimizing equip-
ment performance and ensuring that operations
remain on track without spending hours recording
work and searching for old records.

Faster workflow
6 When a mobile CMMS solution is paired
with barcode scanning, it simplifies inventory
management. This enables the technicians to
act immediately and find replacement parts and
assets in an instant. It automates the workflow
for faster turnaround and boosts overall pro-
ductivity. Since a CMMS does not keep the tech-
nician tied to a desk, accuracy is improved and
errors are reduced.

Improved coordination
7 A mobile solution allows technicians to
place orders from any location. When they can
connect with vendors at any time without reach-
ing out to a PC to look for vendor information,
they save time and ensure the receipt of the
correct parts at the earliest time possible. This
reduces overall downtime and prevents errors.

Scheduled maintenance is the key to performance

optimization, and a mobile CMMS solution helps
keep up with standardized procedures even with
massive inventory levels. It allows for the manage-
ment and monitoring of everything including ser-
vice contracts, specific work orders and inventory
levels by making information readily available at
any location. Overcome many maintenance issues
by streamlining predictive and preventive mainte-
nance schedules on the spot with this solution that
keeps the entire maintenance team informed and
on track.

Lindsey Walker is marketing manager for NEXGEN

Asset Management. With a bachelors degree in
business information management, she excels at
business development, project management and
asset management. Walkers passion for writing
allows her to find time to share her knowledge on asset management,
geographic information systems, software implementation, training cur-
riculum development and similar topics.

NEXGEN Asset Management 221

www.nexgenam.com
NOVEMBER 2016 | www.processingmagazine.com 29
PLANT
OPERATIONS PRO D UCT SPO T LI GH T
1 | Mining network
The Connected Mine from Rockwell Au-
tomation helps mining companies across
the globe maximize yield and improve
operating efficiencies while meeting regu-
latory requirements and maintaining safe
working environments. Operators benefit
from increased operational flexibility, using
data to make critical adjustments to their
processes anywhere from extraction to
processing. Using a single, unified network
infrastructure allows for seamless con-
nectivity and information sharing across
the mining enterprise.
Rockwell Automation
www.rockwellautomation.com
514
30 Processing | NOVEMBER 2016
2 | CAE software
EPLAN Software & Services' ePLAN
Platform version 2.6 that includes ad-
ditional productivity-enhancing features
for terminal design and project data
management, the representation of piping
in fluid power engineering, and optimized
IT integration. With the addition of Turkish,
the suite of computer-aided engineering
(CAE) products supports 18 languages,
an advantage for global project collabora-
tion and customer support. For electrical
design, these enhancements simplify and
accelerate project tasks.
EPLAN Software & Services LLC
www.eplanusa.com
515
3 | Control loop monitoring system
Metso Expertune PlantTriage, a control
loop monitoring system, oversees process
control loops night and day, diagnoses and
prioritizes opportunities for improvements,
and pinpoints major economic paybacks.
As a tool of the digital world, the system
leverages Metso's expertise in automa-
tion and control valves. It gathers process
data from many different control systems
and monitors thousands of control loops.
Metso's understanding of smart position-
ers and valve position feedback systems
has been incorporated into the system
to meet customers' needs for improved
reliability.
Metso Corporation
www.metso.com
516
4 | Asset monitor & analyzer
SCADAware Inc.s StatusWatch production
intelligence and plant efficiency product
line now includes StatusWatch Live, which
monitors asset use and analyzes plant ef-
ficiency. The Andon-based system consists
of visual products and systems that interact
to alert management, maintenance and
operators of a quality or process problem
within a facility. StatusWatch has consis-
tently helped manufacturers achieve a 20
percent or more increase in overall equip-
ment effectiveness by maximizing plant
efficiency through real-time data collection,
timely decision making, improved account-
ability and continuous improvement.
SCADAware Inc.
www.scadaware.com
517
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Trade shows & events
NEW TRENDS IN
POWER
ore than 20,000 attendees and 1,400 exhib-
M iting companies are expected to convene
at the world's largest power-generation
event, POWER-GEN International, Dec.
1315, in Orlando, Florida.
Displaying a variety of products and services,
POWER-GEN International represents a horizontal
look at the industry with key emphasis on new solu-
tions and innovations for the future, according to
event organizers.
More than 300 industry experts will present new
solutions and technology in more than 70 conference
sessions across 11 tracks during three days at the
Orange County Convention Center. Through these
sessions, attendees have the opportunity to earn 10
professional development hours.
POWER-GEN International full-conference attend-
ees gain access to the conference sessions for not only
POWER-GEN International, but also for Renewable
Energy World International, NUCLEAR POWER
International and COAL-GEN.
A new conference track this year is the Digital
Power Plant, with sessions aimed at teaching
attendees about the Industrial Internet of Things
and the opportunities to exploit data and make
sense of information to trim costs, increase sales
and boost efficiency.
Other track topics include:
Energy storage
Emissions control
Gas turbine technologies
Industry trends/competitive power generation
On-site power
Plant performance
Power project financing
32 Processing | NOVEMBER 2016
Exhibition info
Orlando, Florida
Orange County Convention Center
North & South Halls
Tuesday, Dec. 13
11:30 a.m.6 p.m.
Wednesday, Dec. 14
9 a.m.5 p.m.
Thursday, Dec. 15
9 a.m.2 p.m.
The opening keynote session, themed The Power
to Change, will take place from 9:30 to 11:30 a.m.,
Tuesday, Dec. 13, featuring speakers Alex Glenn, pres-
ident of Duke Energys utility operations in Florida;
Rick Halil, senior vice president and general manager
of Burns & McDonnells Energy Global Practice; and
Willi Meixner, chief executive officer of the Power and
Gas Division at Siemens AG.
The exhibit hall will open Tuesday after the keynote
session and will allow attendees to explore the latest
products and services and see the newest in technol-
ogy all under one roof.
For more information, to view the show schedule
or to register, visit power-gen.com.
ATTENDEE BENEFITS
Insight into the latest technologies, innovations
and trends from more than 1,400 exhibitors
Knowledge for successful implementation of these
innovations into operations to cut costs, maximize
efficiencies, improve visibility and reduce risk
Networking opportunities with thousands of other
professionals within the industry
Practical solutions to complex problems including
valuable skills to better perform their jobs
Innovative ways to tackle the latest industry
challenges delivered by powerful speakers
Real-world case study investigations
aottke/iStock
Aeration Solutions
Proper design, maintenance and operation
contribute to an efficient system

+ Submersible slurry pumps

eliminate scale
Wedge wire benets &
applications

NOVEMBER 2016
www.processownetwork.com
Table of Contents | November 2016

Features
SS-6 Aeration equipment for
energy efciency
By Chris French
Lower costs and increase efciencies across
applications with the right system.

SS-10 Wedge wire considerations

By E. Marvin Greenstein, Newark Wire Cloth Co. Inc.
This lter design benets media bed ltration processes
in water and wastewater treatment.

SS-12 Keeping pace with progress

By Jim Neville, MPW Industrial Services

Cover image courtesy of Landia Inc.

Submersible slurry pump with auger enables a steel plant
to achieve higher production rates.

Cover Image: Aerator systems with chopper pumps cre-

ated energy savings of 30 percent for a manufacturer of
starch products, syrups and sugar alcohols.
Image courtesy of Newark Wire Cloth Co. Inc.

Departments
SS-4 Ask Dan, the
Wastewater Wizard
By Daniel Theobald
SS-10 Troubleshooting one industry that required
multiple procedure modications

Image courtesy of Greenshoots Communications/Alamy

SS-12

SS-2 | November 2016 Process Flow Network

Write in 307 or request info at fcm.hotims.com
Special Section: Wastewater Processing

Ask Dan, the Wastewater Wizard

Troubleshooting one industry that required
Dan Theobald multiple procedure modifications

aintaining consistent, compliant wastewater dis-

M charge at all times is vitally important since waste-

water treatment plants operate 24 hours per day,
seven days per week.
Official discharge permit sampling is required periodically,
but it is equally important to maintain consistent wastewater
discharge compliance at all times.
Wastewater treatment procedures may also need to be modified
from time to time in response to instantaneous changes of the
incoming untreated wastewater. This is extremely important for
an operator to achieve. However, permanent changes sometimes
affect the quantity and the quality of the untreated wastewater, and
they may require permanent procedure changes to satisfy discharge
permit limits. Ongoing procedures may also need to be changed.
An industrial customer recently asked me to monitor the sig-
nificant changes of untreated wastewater and report the impact,
cost, procedures, treatment requirements, etc., to management.
This article covers the data utilized to analyze the untreated
wastewaters changes, and it identifies some of the required
procedure modifications to respond to those changes while
taking into account the maintenance required to consistently
comply with the wastewater discharge permit.

Examples
When we started receiving the untreated wastewater, the first
issue we identified was a substantial reduction in the volume
of untreated influent.
As it worked out, the volume of water decreased almost 50
percent. This reduction was also important in terms of flow rate
fluctuations. Because we were operating without an equaliza-
tion tank, we had to react quickly to current rate changes and
to the instantaneous changes during the treatment cycle.
The next obvious issue was that the absorption of the pol-
iamfat42/iStock

lutants in the untreated wastewater was also diminished.

Decreases in volume and decreases in concentrations can
show how wastewater treatment procedures and the individual
process units work in physical/chemical wastewater treatment.
Changes in operating procedures would probably need to
be linked with chemical setpoint changes and perhaps the
unique chemicals used.
Current procedures
An analysis of current operating procedures for untreated
wastewater would help operators understand how to modify
any existing wastewater treatment process units operating
procedures to meet untreated wastewater treatment volume
and concentrations.
To better interpret the circumstances behind changes to
these procedures, it is beneficial to understand the cur-
rent wastewater treatment operating procedures before the
changes take place.

SS-4 | November 2016 Process Flow Network

 For the current procedures, the incoming untreated waste-
water flows through a circular screen. After a couple of pH
adjustment locations, a polymer solution flocculant is
injected into the flow stream before entering a solids separa-
tion process unit. The effluent treatment process concludes
with a pH adjustment procedure to satisfy discharge permit
compliance as effluent flows to the sewer collection system.
Procedure modifications
After the alterations to the untreated wastewater occurred,
we determined that we could reduce the amount of chemi-
cals for treating each gallon of wastewater.
We used three basic chemicals for treating wastewater.
After the changes, we were able to decrease the intensity
of each chemical by approximately 60 percent, which was
larger than the 50 percent reduction in the mass amount of
untreated influent.
An analysis of the sludge generated from the decreased
volume of untreated wastewater revealed a substantial
reduction in sludge volume. The mass of sludge decreased
by more than 65 percent. Perhaps this significant decrease
of sludge volume was caused by a 50 percent decrease in
untreated wastewater and a 60 percent decrease in chemi-
cals used with the untreated influent. The reduced mass
E
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IA
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of sludge allowed for significant modifications to the solids
handling processes.
In summary, we found that we could convert the pH setpoints
throughout the treatment process and reduce the mass of
chemicals used at each of the chemical injection locations, which
afforded us these decreases throughout the treatment procedure.
Conclusion
Measurement of the wastewater treatment operating proce-
dures and wastewater treatment solutions revealed that, with
decreased quantity and quality of untreated wastewater, it was
advantageous to control with fewer chemicals. Laboratory analy-
sis results were essentially equal to the results achieved before
the untreated wastewater changes. Ultimately, consistent qual-
ity wastewater discharge was maintained at a reduced cost per
unit of untreated wastewater because each gallon of untreated
wastewater had a reduced waste load.
Known in the industry as Wastewater Dan, Dan Theobald,
proprietor of Environmental Services, is a professional waste-
water and safety consultant/trainer. He has more than 24
years of hands-on industry experience operating many variants
of wastewater treatment processing units and is anxious to
share his knowledge with others.
HEAVY DUTY
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November 2016 | SS-5
Special Section: Wastewater Processing

Aeration equipment
for energy efciency
Lower costs and increase efficiencies
across applications with the right system.
By Chris French

f engineers want to prove to their and an ejector system aerate the sludge Weve recently completed a similar

I customers they are providing the

best possible long-term solutions,
then they need to look further than
in the main 500,000-gallon lagoon and
mix the wastewater. A separate inlet la-
goon also benets from a 5.5 kW aerator
installation for a guar gum producer in
Texas, said Rasmussen, where sludge
was settling out on the bottom of their
mere conventional aeration, according to that points directly at the inlet pipe. Set efuent lagoon. The consultant had advised
Soren Rasmussen, director of Landia Inc. up to work at night or whenever liquor the owner that oating aerators were best
In fact, they may only have to pick strengths require it during Camstars 24- and had adhered to the tried and tested
up the bad odors emanating from an hour operation, the aerators have to be textbook calculations but the oating
industrial plant to know that something rugged and reliable for an installation in aerators could not reach the depths
somewhere isnt right, Rasmussen said. which up to 35,000 gallons of water can where the sludge was accumulating. The
A rotten egg smell of hydrogen sulde be processed per day. [submersible aerators], which recirculate
that may be wafting its way up from a
storage lagoon will almost certainly have
developed and quite quickly from
an anaerobic environment caused by
dead particles falling to the oor because
the oxygen transfer is not great enough
for the type of sludge.
At Camstar Herbs, Landia solved just
such a problem where, during the long
harvest season from May to November,
unpleasant odors were emanating from
the lagoons at the 500-acre site, caused
by fermenting wastewater from herbs
such as chamomile, parsley, coriander
and chervil. Now, two 7.5-kilowatt (kW)
An aerator with chopper pump and ejector system provides simultaneous aerating and mixing.
aerators consisting of a chopper pump

SS-6 | November 2016 Process Flow Network

 Roquette, where aerator from 2 to 5 percent solids. It is not just the
systems have created energy
savings of 30 percent solids content though that seems to be
overlooked. Efuent laced with chemicals,
sugars and starches will always present
challenges.
He says that, for example, a brewery
with relatively low solids in its wastewater
will have to deal with high biochemical oxy-
gen demand (BOD) from all the sugar and
alcohol that need to be reduced before dis-
charge to the sewer network. If large blow-
ers are employed to aerate wastewater with
high BOD, one outcome is always certain:
eye-watering energy costs. This, stresses
Rasmussen, is just one area where it is
time to move into the 21st century.
Going back as we do at Landia to
1933, were all proponents of engineered,

Youve tried the rest,

All images courtesy of Landia Inc.

now go with the best...

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productivity! Superior designs,
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A food processor, dairy or chemical
workmanship, engineering
company might look at all the surface
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apparent aeration activity, but achieving Stay away from the junk yard
optimal conditions for a tank or lagoon is choose A-T Controls!
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in the textbook. An optimal solution for
anyone dealing with a difcult wastewater
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is better given by manufacturers who can
provide a harmonious system that not only
aerates and mixes, but also reduces the
particle sizes without getting clogged up. 9955 International Boulevard
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All too often, claims Rasmussen, a (513) 247-5465
system that has been used in a municipal FAX (513) 247-5462
e-mail: sales@atcontrols.com
plant with less than 0.5 percent solids, is www.atcontrols.com
somehow judged to be able to manage a
tank with industrial efuent with anything
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www.processownetwork.com November 2016 | SS-7

Special Section: Wastewater Processing
tried and tested solutions, he said. But
environmental concerns are very differ-
ent these days not to mention prot-
zapping energy bills. More nutrients in
wastewater mean more aeration, mean-
ing more expense. Brewery efuent, like
many industrial wastewaters, can also
be quite corrosive with high or low pH
wastewater as well as hydrogen sulde,
3030 mFlow magnetically
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SS-8 | November 2016
which will eat away at equipment un-
less, as we insist upon, it is made from
stainless steel. For Hook Norton Brewery,
our chopper pump, which forms part of
[our aerator], aerates wastewater at a
loading rate of 10 kilograms chemical
oxygen demand per cubic meter. The
knife system on our chopper pumps
ensures that solids cannot get into the
www.gemu.com
pump and clog it up, so there is no
downtime. The specially designed pump
casing and impeller also protect it from
impurities.
Aerator design &
maintenance
Even if an aeration system is working ef-
ciently, its type and design may prove
too much of a costly maintenance head-
ache, involving far too much downtime.
This and energy bills were the case at a
major manufacturer of starch products,
syrups and polyols (sugar alcohols). Lo-
cated in Keokuk on the Iowa/Illinois bor-
der, the heart of corn production coun-
try, Roquette America previously utilized
oor-mounted air diffusers powered by
large blowers and several surface mixers
to try to aerate and mix its primary and
secondary oxidation tanks.
However, this standard industry
practice meant constant cleaning and
replacing of diffuser membranes. Since
Roquette operates 24/7, the process
could not be suspended to drain the
tanks. This resulted in the substantial
outlay of having to hire divers to enter the
tanks and carry out maintenance.
Rob Decker, senior project coordinator
at Roquette, was searching for new tech-
nology to reduce maintenance time and
costs associated with his aeration tanks.
A design for the installation of nine aera-
tor systems and the addition of one mixer
per tank reduced maintenance to a simple,
economic annual requirement, while as a
bonus, energy costs have been lowered by
30 percent.
If the situation demands it, con-
tinued Rasmussen, we will sometimes
supplement the operation with propeller
mixers, which again, are low-energy and
low-maintenance. Taking an aeration ba-
sin ofine, or having to send in divers as
they used to have to do at Roquette, is
very costly and labor-intensive.
Paper mill maintenance
Maintenance was not at the top of the
agenda at the Skjern Papirfabrik paper
mill. Odors had become so bad that local
residents and the media had mounted a
campaign for the plants closure.
Process Flow Network
 A treatment plant we were working
with just recently gave us gures theyd
been advised to use for over 1,500 hp
of mixing energy specied by a con-
sultant whod gone no further than the
old textbook approach. We questioned it
and we were able to show that we could
help provide better, more comprehen-
sive mixing for just one-fth of the power.
Installing aeration equipment requires se-
rious thought for any plant wanting to drive
towards becoming energy neutral.
Chris French is a freelance journalist
who specializes in wastewater/biogas.
Landia Inc. is a subsidiary of Landia A/S,
established in 1933. For more informa-
tion, visit landia.co.uk.

Externally mounted chopper pump aeration

system at Gun Barrel City
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Toughest Applications
Lene Lange Andersen, head of labora- Flex-Pro Peristaltic
tory operations at Skjern Papirfabrik, said, Metering Pumps are
capable of handling the
The situation was completely precarious, aggressive, and often
but within just a few days Landia produced high viscosity fluids used
in Processing and Water
and supplied two pumps with jet aeration Treatment applications.
equipment. The design allowed installation A wide range of feed
to be carried out in full tanks so we were capabilities and materials
options are available.
able to start right away. The following day, Patented Tube Failure
the stench had been reduced consider- Detection.
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OW
OWN

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cient aeration of the tank contents, it also

brought about additional benets, which
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The wastewater for our treatment
plant has become signicantly cleaner and
Superior Chemical Resistance
we do not have to use as much energy and Precise Metering
as we used to when preparing it for nal When your system
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treatment at the towns treatment plant, high quality chemical
Baek said. By pointing one of the aera- metering injector pump,
Choose Chem-Pro.
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OWN
water process and reduced maintenance
costs have all begun to stack up as rea-
sons to introduce mechanical mixers for
optimum aeration, but as Rasmussen
5300 Business Dr., Huntington Beach, CA 92649 USA
concludes, the willingness to reduce pow-
714-893-8529 sales@blue-white.com www.blue-white.com
er still seems to have some way to go.
Write in 302 or request info at fcm.hotims.com

www.processownetwork.com November 2016 | SS-9

Special Section: Wastewater Processing
Wedge wire considerations
This filter design benefits media bed filtration processes
in water and wastewater treatment.
By E. Marvin Greenstein, Newark Wire Cloth Co. Inc.
any industries use media-bed filtration. This
M use may take the form of ion exchange for
water softening/demineralization, sand filtra-
tion, activated carbon or other media bed fluid treat-
ment processes. However, no matter if the application
is in a water utility, a power utility, pulp and paper, steel,
or any other industry, problems tend to be similar. Time
and again, the same common complaints arise in the
media bed filtration process: leaking resin or media, exces-
sive pressure drop, screen clogging and excessive backwash/
rejuvenation requirements. These problems can be solved by
the use of properly designed and specified equipment and
equipment internals (arguably the most important investment
in media bed filtration). Unfortunately, most new equipment
and retrofit inquiries do not include enough hard and specific
data to ensure the proper product selection.
Understand the system
To ensure a proper design outcome, a design engineer needs to
know the system pressures. ls it designed to avoid clogging? In the
event of hydraulic failure, will it withstand the strain it is likely to
experience and yet still retain the media? ls it sized to retain the par-
ticles in normal use? Will it pass the desired ow? ls it designed to
provide a pressure differential to ensure uniform ow? Has corrosion
been considered? Are proper alloys available and specied? Can it
be successfully backwashed on a repetitive basis without clogging?
A typical inquiry to the ltration product manufacturer might
ask for a set of header laterals to form a distribution system
for an activated carbon column or demineralizer tank. The manu-
facturer may be supplied with a request for a lateral distribution/
collection system. Given the ow data and vessel particulars, this
data can certainly be used to produce a set of header laterals. ln
fact, a great variety of header laterals might be produced that all
conform to these specications. The question is: Which design
would do the best job for the specier? Although the term header
lateral is commonly used, the process may be better served and
more economical with other congurations such as a hub lat-
eral system, drop-leg nozzle congurations as well as others. In any process where a uid is distributed through media, chan-
In the ideal situation, the manufacturers application engineers
will return to their customer with a set of questions designed to
elicit more specic information about the customers overall re-
quirements. For example, they may want to discuss the media
bed ltration process to make certain the process is understood
SS-10 | November 2016
All images courtesy of Newark Wire Cloth Co. Inc.
Wedge wire pipe-based header lateral system
and the critical areas are fully considered. Initial understanding of
the process particulars like these are paramount to reduce overall
maintenance and costs and obtain an optimal product.
Wedge wire benefits & applications
Wedge wire is often recommended for its strength and clean-
ing ease. It can be supplied in many forms used in distribution/
collection systems, nozzle and lateral congurations being the
most common. Laterals can be supplied with many end con-
gurations to suit. Commonly, wedge wire is applied over a
drilled pipe. This design offers improved support and allows for
engineered drill patterns that ensure the best possible distribu-
tion and collection, affording maximum bed utilization.
All of the above is based on an accurate determination of the
media retention requirements. The slot size of the wedge wire prod-
uct is crucial to ensure all of the efforts of analysis, design and
methods of fabrication are realized. Many of the wedge wire prod-
ucts on the market are still based on the original well drilling usage
as far as tolerances are considered. They are often manufactured
with a retentive slot size tolerance of +/- 0.002 inch or greater.
The results are obvious when trying to retain ion exchange media
of 0.010 inch. Modern Computer Numeric Control (CNC) machin-
ery and International Organization for Standardization (ISO) quality
procedures can result in tolerances of +/- 0.001 inch and better.
Channeling is the enemy
neling must be eliminated. It is important to retain the uniform
distribution as stated above, directing the uid to ow uniformly
through the bed and to maximize the media contact. Channeling
is always the enemy. Channeling leads to premature media ex-
haustion and a need for premature regeneration. Vessel internals
Process Flow Network
therefore determine ow characteristics
and the ultimate performance of the pro-
cess. Technology-oriented manufacturers
use electronic design automation (EDA)
to supply the answers. Specic consid-
erations such as screen opening size in
water treatment processes, as in ion ex-
change, are crucial. The function of the
screen is to keep the resin beads in place
while facilitating uid ow through the bed.
Materials of construction
Materials of construction need to be
addressed as well. The typical liquid
seen by a ltration system is water.
It can be wastewater or boiler feed wa-
ter, river water, brackish water, seawa-
ter or ultrapure water. In the process
industries, ltration may also involve a
variety of chemicals. Fortunately, most
of these uids can be handled by ele-
ments made of the appropriate stain-
less steel, nickel alloy or duplex alloy.
The customer should make sure the
supplier can provide a material that
functions well with the specic system
uid used. Filtration systems are also
supplied with PVC laterals slotted to re-
tain the media. PVC offers good corro-
sion resistance but poor structural sta-
bility. Pressure variations tend to cause
the plastic to ex, altering slot size and
conguration. PVC is also subject to
abrasion altering retention, which can
result in media loss or even total failure.
Wedge wire lter nozzle
www.processownetwork.com
Wire cloth screening is also often
used with good results in ltration ap-
plications, but it does not provide the
reliability of wedge wire. Because the
cross section of wires that makes up the
mesh is round, a tendency for particles
to lodge and clog always exists. Wedge
wire is fabricated using a triangular-
shaped wire wrapped continuously over
longitudinal support wires. The wires are
welded at each intersection. The trian-
gular, cross-section wedge wire with
a at retention surface is more easily
and more effectively cleaned and back-
washed. ln addition, water pressures,
system stresses and careless handling
can cause abrasions or tears in the wire
cloth. For these reasons, many engi-
neers prefer the strength, clog-resis-
tance, ease of backwashing and dimen-
sional stability of wedge wire.
Many systems also employ down-
stream protection in the form of basket
strainers or resin traps. Wedge wire is
also an ideal lter media for this ap-
plication. Strong and rigid, retention is
maintained as process conditions vary.
The nature of wedge wire construction
lends itself to scrubbing, cleaning and
washing without damage. Baskets can
be designed to accommodate line size,
pressure drop requirements, varying con-
gurations and process conditions.
The result is that wedge wire has pro-
vided engineers a superior retention me-
dia with which to design and manufac-
ture vessel internals, resin traps as well
as other ltration products with long-term
savings and efciencies.
E. Marvin Greenstein is director of
engineering at Newark Wire Cloth Co.
Inc. He is considered an expert in engi-
neered filtration products serving the
water, waste, utility and power genera-
tion industries. He has published articles
on the design of vessel internals for
media bed filtration. Greenstein holds
a Bachelor of Science in chemical
engineering and is a member of the
A.I.Ch. Engineers. He may be reached
at emgreenstein@newarkwire.com. For
more information about wedge wire
products, visit newarkwire.com.
Write in 304 or request info at fcm.hotims.com
November 2016 | SS-11
Special Section: Wastewater Processing
Keeping pace
with progress
Submersible slurry pump with auger enables
a steel plant to achieve higher production rates.
ince continuous casting was introduced in the steel
S manufacturing industry in the 1950s, engineers have
continually perfected the process. A tweak here, some
new technology there, and over time manufacturers are mak-
ing steel with more efficiency and at greater rates than few
thought possible 60 years ago.
All of this, however, has placed a signicant strain on the
treatment of cooling water for reuse in the casting process.
Simply using municipal water to meet ever-increasing produc-
tion requirements is impractical for nancial reasons because
thousands of gallons per minute are required. Recycling process
water is critical to the economics of steel manufacturing. Miss-
ing just one day of production every six or seven weeks while the
water recycling system catches up with demand can result in
millions of dollars in lost revenue annually.
SS-12 | November 2016
Image courtesy of Greenshoots Communications/Alamy
End of continuous casting process
for steel showing the solid steel
being cooled by water
By Jim Neville, MPW Industrial Services
Eliminating scale
The primary requirement for the recycling of cooling water to the
casting process is to eliminate the scale and other total sus-
pended solids (TSS) that accumulate during the cooling of mol-
ten steel. Scale is produced when the heated steel is exposed
to oxygen, creating a tough gray or black coating on the surface.
To remove the scale, a Midwestern steel manufacturer sends
its process water to a large pit where the oxidized metal can
settle to the bottom. The water is decanted and then sent to
sand lters to remove any residual scale and TSS. The water is
then sent to cooling towers and back to the caster spray water
cooling process.
Increased production rates at the plant, however, mean that
water is being sent to the settling pit at an increased ow rate.
Therefore, scale is accumulating at the bottom of the scale pit
Process Flow Network
Write in 308 or request info at fcm.hotims.com
Special Section: Wastewater Processing
much faster than the original design rate, compromising the ef-
fectiveness of the settling process.
The plants settling process was designed for water entering
the pit to take approximately 35 minutes to travel the length
of the 80-foot tank before entering the sand lters. This would
provide enough time for the scale to react with a occulent and
fall to the bottom of the 12-foot-deep tank.
Today water travels from one end of the pit to the other
sometimes in as few as six or seven minutes because scale
accumulations at the bottom of the tank often exceed 9 feet, ef-
fectively reducing the capacity of the settling pit. Optimal settling
occurs when scale accumulations are 5 feet or less.
To address the scale buildup, workers periodically dug scale
out of the pit with a clamshell excavator while the plant was in
operation. Though successful in dredging the pit, this technique
created an increase in the amount of scale and TSS overowing
the pit and being sent to the sand lters, effectively negating
the settling process. The turbidity during the excavation was as
high as 200 to 500 Nephelometric Turbidity Units (NTU), placing
an unacceptable burden on the sand lters. This also resulted
in TSS levels that had the potential to damage the caster spray
water cooling process.
Next, plant management turned to its water treatment sup-
plier, which recommended a change in chemistry that enabled
the TSS coagulation to occur at a faster rate. This, however, only
increased the volume of scale in the pit.
The consequences of water with higher TSS levels being
sent back to the casting process are signicant. Cooling wa-
ter is sprayed on the molten steel exiting the caster mold with
ne-tipped nozzles. Any buildup in the nozzles could limit the
ow and proper distribution of the cooling water, resulting in the
inadequate cooling of the molten steel. This has the potential to
disrupt the manufacturing process.
To prevent this from happening, production is halted on a
regular basis so workers can excavate the settling pit with a
clamshell. Time spent waiting for the pit to be cleaned has the
impact of negating the process improvements made throughout
the years in other parts of the steelmaking process.
A submersible solution
As a result, plant management and the water treatment com-
pany turned to MPW Industrial Services for a solution. Engi-
neers from the companys industrial cleaning and water puri-
cation divisions evaluated the plants production requirements
and the settling process.
Working as a team, the services provider, the steel com-
pany and the water treatment company quickly determined
that a submersible slurry pump lowered into the settling pit
could remove the scale. This slurry pump includes an auger
that loosens up the scale lumped at the bottom of the pit and
pulls it toward the pump without kicking up any appreciable
scale in the pit.
The pump and auger are lowered into the pit with a crane on
average three days per week depending on the plants production
SS-14 | November 2016
Graphic courtesy of MPW Industrial Services
Figure 1. Impact of submersible pump with auger
rates and the grade of steel being manufactured. The goal is to
pump a 50-to-50 mix of water and scale to an adjacent dewa-
tering pad while generating less than 50 NTU in the pit. In one
eight-hour shift, the pump and auger can remove approximately
30 percent more scale than the plant generates in a typical 24-
hour period.
Steelmaking production is now interrupted only when the
continuous caster process requires routine maintenance, which
is generally every ve to seven weeks. Since the introduction
of the pump and auger as well as the improved occulent from
the water treatment rm, no production delays have occurred
because of excessive scale in the pit. Furthermore, the services
provider is developing ways to automate operation of the pump
and auger and its engineering team is designing the next phase
of the project to include an overhead gantry that will allow for a
more continuous scale removal process. The goal is to eliminate
the scale as an interference to steel production as well as the
need for the clamshell excavation of the pit.
In addition to scale, cooling water from continuous cast-
ing contains oil and grease, both of which need to be removed
before re-entering the process. Previously the plant used rope
skimmers to rid the process water of oil and grease. Recently,
the services provider has worked with plant management and
the water treatment rm to evaluate alternative, more efcient
skimming technologies.
No doubt the individuals who pioneered the continuous cast-
ing of steel would be hard-pressed to recognize some of the
technology in todays mills. Nonetheless, they would applaud the
commitment to continuous improvement in all aspects of the
process, including the recycling of cooling water.
Jim Neville is executive vice president for MPW Industrial
Services. With nearly 3,000 employees and 72 locations
in the U.S. and Canada, MPW provides industrial cleaning,
water purification, facility management and environmental
management services to customers in the power genera-
tion, primary metals, chemicals, refining, oil and gas, auto-
motive, food and beverage, and pulp and paper industries.
MPWs headquarters is in Hebron, Ohio. For more informa-
tion, visit mpwservices.com.
Process Flow Network
 Advertiser Index

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A-T Controls Inc. SS-7 300 Gemu Valves Inc. SS-8 305

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Write in 303 or request info at fcm.hotims.com

261
 MOTORS & DRIVES

THE

DC MOTOR
A D VA N TA G E
These motors continue to be the best solution for many industrial applications, particularly
those requiring constant torque across the motors entire speed range | By Joe Kimbrell, AutomationDirect
hile some may claim that direct-current
urrent the current-carrying coils being integrated into the

W (DC) motors are no longer relevant, t, that

rs and
is definitely not the case. DC motors
DC converters/drives are alive and well in
spinning rotor, the coils are located in the fixed sta-
tor. Instead of the permanent magnets mounted to
the stationary stator, as in a DC motor, the magnets
industry, driven by many applications in which h they are mounted in the rotor.
are the best option (see Image 1). This design eliminates the need to provide electri-
Alternating-current (AC) motors have certainly tainly cal connections through brushes in both AC induc-
decreased DC motor sales, and they do confer advan- tion motors and DC brushless motors because the
tages in some applications. Understanding the differ- magnetic field is rotated instead of the current-
ences between AC and DC motors reveals wheree each carrying conductors. The rotor with the permanent
cation.
works best and helps guide selection and specification. magnets is forced to move by the current and related
magnetic field generated by the AC voltage fed to the
DC motor designs stator windings.
Popular DC motor designs include:
Permanent magnet
Brushless
Shunt
Series
Compound wound or stabilized shunt
The basic operation of all these designs is similar.
imilar.
A current-carrying conductor is placed in a magnetic
gnetic
field, and applying power through these conductorsuctors
causes motor rotation. The difference among ng the
designs is how the electromagnetic fields are gener-
ated and where in either the rotor or stator.
In a permanent-magnet motor, the stator is sta-
tionary and mounted to the motor frame (see Image
2). It holds permanent magnets mounted in proxim-roxim-
ity to the spinning current-carrying conductors in the
rotor. Applying a voltage through brushes contacting
acting
the armature on the rotor induces the current need-
ed to produce mechanical force, which is rotation. ation.
Connecting two wires to the motor and supplying ng the Image 1. Despite encroachment from AC designs, DC mo-
proper DC voltage will cause the motor to run. tors remain the best choice for many industrial applications.
Shunt, series, and compound-wound or stabilized-
ilized- All graphics courtesy of AutomationDirect
shunt motor designs have a rotor with electrical al con-
nections through a brush and commutator arrange- range-
ment. The brush/commutator acts as a switch tch to
apply voltage to different coil segments of the rotor
as it spins.
This configuration is different in AC induction
on and
DC brushless motors. In these motor types, thee mag-
netic field is generated in the fixed stator. Instead
ead of

34 Processing | NOVEMBER 2016

Brushing up on DC motors
AC motors and DC brushless motors are popular
and dominate many applications formerly occupied
by standard DC motors. Although many reasons
explain this change, one of the most notable is that
AC motors require less maintenance.
All motors require at least some minimal mainte-
nance such as keeping the fan and motor clean or
greasing non-sealed bearings. However, DC motors
also require monitored and scheduled replacement
of the internal brushes. This is simple to perform on
small motors. However, on higher horsepower (hp)
DC motors, brush installation procedures are more
complex and must be carefully followed.
On smaller, permanent-magnet DC motors, brushes
easily and quickly can be changed. They are inexpen-
sive and only take minutes to replace. A good rule of
thumb is to replace the brushes once they reach one-
third of their original length or every 2,500 hours of use,
whichever comes first. This will ensure the brushes are
always within specification.
Although brush maintenance is often seen as a dis-
advantage compared to AC motors, brushes in DC
motors continue to improve. Designs that reduce
brush wear, such as smaller diameter commutators,
extend motor operating time between brush replace-
ments. The design of the brush including the sur-
face area, shape and contact pressure can also
extend brush change g intervals.
Why DC?
DC motors are often selected instead of AC motors
mot
for many reasons (see Table 1). DC motors and con-
co
compared
trollers are often the low-cost option when compar
to inverter-duty AC motors and drives. This is espe-
esp
cially true for fractional hp applications.
Table 1. Advantages of DC motors
Form factor
1.00
1.05
1.35
1.90
Table 2. DC motor form factors
DC motors have been around for more than 140
years, so they have a large installed base and corre-
sponding widespread familiarity with their operation
and maintenance. For existing installations, replacing
a DC motor with a new one as opposed to redesign-
ing the motor circuit to use an AC motor and drive
is almost always less expensive, quicker and easier.
Along the same lines, the simple design of DC
motors makes service, maintenance and control well
understood and easily supportable. Field excitation is
not required, and brush replacement and motor ser-
vice are well understood by the typical industrial elec-
trician. Even speed control is simple: Just adjust the
terminal voltage, often using a local potentiometer.
Additionally, until the late 1980s, when the vari-
able frequency drive (VFD) was fully developed, DC
motors were the best choice for variable speed con-
trol, and this remains a well-supported option.
Often the lower cost option
Large installed base
Simple, efficient design
Easy to service and maintain
Easy to vary the motor speed
Full torque at zero speed
Higher motor power density
Less inertia
Smaller converters and drives
DC voltage source
Battery (pure DC)
Pulse-width modulation (PWM)
Full-wave rectification (single phase)
Half-wave rectification (single phase)*
* Not recommended for use with most DC motors
Image 2. Permanent magnet motors are among the simplest in terms of
design, installation and operation and operate well in fractional hp applications
such as this zero-pressure, 24-volt, DC, live-roller conveyor.
Torque at low speed
While the ease of controlling motor speed was a
big part of its early success, several other DC motor
characteristics make them the best choice in certain
applications. DC motors develop full torque at low
speed and across the full operating range from zero to
base speed (see Figure 1).
This makes DC motors a good choice for driving
constant-torque loads such as conveyor belts, ele-
vators, cranes, ski lifts, extruders and mixers. These
applications are often stopped when fully loaded, and
the full torque of the DC motor at zero speed gets
them moving again without the need for oversizing.
DC motors have a higher power density and are,
therefore, smaller than an equivalent AC motor.
They have no field coil in the stator, so the field coil
space is saved, reducing the overall motor size. This
becomes a substantial benefit in some space-con-
strained applications.
Smaller form factors also mean DC motors have
less inertia than AC motors, offering quicker accel-
eration and deceleration times. This can result in a
quicker cycle time on production machines that start
and stop often.
Although not often needed, DC motors can be
manufactured to motor power ranges of more than
4,000 hp, whereas standard low-voltage induction
motors do not go above 800 to 1,200 hp. Above that,
higher voltages are needed, which can greatly compli-
cate installation and maintenance.
Modern AC motors and drives have narrowed
the performance gap with their DC counterparts,
but general-purpose DC motors still outperform
general-purpose AC motors by many measures. To
obtain comparable low-speed performance from an
AC motor, much more expensive AC-inverter duty
motors and VFDs must be used.
Motor control
Less electronics and rectification are required to build
a DC-converter drive when compared to building an
AC-inverter drive. With an AC drive, the incoming
AC power must be rectified to create DC that is then
converted back to AC to power the motor. DC drives
need only to rectify AC power before passing it to the
DC motor. DC motors can be directly fed from differ-
ent power sources, even batteries.
Depending on the type of DC drive, the quality
of the output power varies dramatically and is
typically measured by how much ripple current is
produced by the drive. The ripple current is des-
ignated by a drives form factor, which is the rela-
NOVEMBER 2016 | www.processingmagazine.com 35

Figure 1. Unlike an AC motor, a DC motor delivers constant torque across its
entire speed range.
tionship of the ripple current caused by rectifi-
cation relative to a pure DC current. High ripple
current results in increased motor heating and
possibly premature brush failure. Limiting the
form factor to 1.40 or less in continuous-operation
applications is good practice.
36 Processing | NOVEMBER 2016
A battery is an ideal current source because its
form factor is 1.0 (see Table 2), which provides con-
stant voltage and current to power a DC motor. A
pulse-width-modulated DC drive emulates pure DC
closely with a form factor of 1.05, meaning only a 5
percent ripple.
A single-phase, full-wave rectified DC drive is the
most common form of DC drive used in the 0.33- to
2-hp range. This drive takes an AC voltage and pass-
es the positive half of the waveform and rectifies the
negative part of the waveform to produce a wave-
form with a form factor of 1.4, or a 40 percent cur-
rent ripple. These drives are commonly referred to as
silicon-controlled rectifier (SCR) drives. Many motors
are SCR-rated, meaning their full-load torque and
power are produced even when using an SCR drive,
as opposed to a more pure power source.
A simple, single-phase, half-wave rectified DC drive
has a much worse form factor. These drives only pass
the positive half of the AC sine wave and have a form
factor of 1.9. These half-wave DC drives are not rec-
ommended for use with most DC motors.
Applications
DC motors are suitable for many applications
including conveyors, turntables and others for which
adjustable speed and constant or low-speed torque
are required. They also work well in dynamic brak-
200
ing and reversing applications, which are common in
many industrial machines.
Their quick acceleration, stopping and reversing
along with their linear-speed torque curve make
the DC motor a popular choice in many new designs,
particularly for fractional hp applications.
Joe Kimbrell has been a product manager for Drives, Motors & Motion
Control at AutomationDirect since 2004. He graduated with a Bachelor
of Science in electrical engineering (BSEE) from Georgia Tech in 1993.
He started his career with Rovema Packaging Machines as the electrical
engineering manager and worked there for seven years. He then moved on
to Automation Intelligence, a multi-axis motion controller developer/manu-
facturer and system integrator for the next five years where he was the
system integration engineering manager prior to joining AutomationDirect.
He may be reached at jkimbrell@automationdirect.com.
AutomationDirect
www.automationdirect.com
MORE Visit processingmagazine.com
ONLINE
for more articles on motors and drives.
240
MOTORS
& DRIVES P ROD U C T S PO T LI GH T

1 | Express Service
Control Techniques and Leroy-Somer (CT
& LS) launched a new service in Europe to
increase product availability and delivery
speed for Emerson Industrial Automations
motors and drives. The Express Avail-
ability service means a large range (0.09
up to 500 kW) of motors, servos, geared
motors, drives, options and accessories
are now available to be shipped directly
to customer premises quickly and reliably.
The service is open to all customers, in-
cluding OEMs, distributors and end users.
Emerson Industrial Automation
www.emersonindustrialautomation.com
519
2 | Control Software
ABB released the first variable speed drive
control software that uses Model Predic-
tive Control to regulate the drives torque.
When power supply disruptions happen,
protection systems quickly shut down the
compressors. Installed in the MEGADRIVE-
LCI, the software uses a control algorithm
based on Model Predictive Control that
ensures the operation of the drive during
power and grid disturbances in order
to provide the compressor with partial
torque, preventing the compressor from
going into surge.
ABB Drives and Controls
www.abb.com
520
3 | OEM Variable Frequency Drive
Eaton expanded its line of PowerXL
Series DG1 variable frequency drives to
include a more powerful Frame 6 option.
Designed for global commercial, industrial
and original equipment manufacturer cus-
tomers, the new Eaton-engineered drive
increases available power from 150 to
250 hp, providing greater agility, reliability
and safety. The drives reduce energy con-
sumption while helping customers reduce
energy costs.
Eaton
www.eaton.com/powerxldg1-p
521
4 | AC Variable Frequency Drive
Dalroad Norslo Ltd.s S100 is used to con-
trol the speed and torque of three-phase
motors. Simple to install and easy to oper-
ate, the variable frequency drive includes
a seven-segment LED programmer and
built-in RFI filters, ensuring compliance
with European EMC regulations.
The drive is available in IP20 form from
400 W up to 75 kW (up to 90 kW for fans/
pumps) for installing in an enclosure or for
wall mounting in a clean, dry plant room.
Dalroad Norslo Ltd.
www.dalroad.com
522

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NOVEMBER 2016 | www.processingmagazine.com 39

Level Measurement & Control

T h e n e x t g e n e r at i o n o f

level control
The same historic management provided by hydraulic altitude water control
valves can now be achieved with panels and instrumentation | By Ryan Spooner, Singer Valve

ater is an essential resource to everyday the same valve as the filling cycle. In this case, the With zero differential pressure, the system essen-

W life, and having a way to store and dis-

tribute water is important. Water storage
tanks have been designed to compensate
altitude water control valve still will close when the
maximum of hydraulic control pilot is met but then
will re-open when the differential pressure in the line
tially sits at a static flow and pressure, and therefore,
no water will flow in or out of the tank, which means
there will be no tank turnover.
for varying water demands during high- and low- is reversed, allowing the water to distribute in the To fix this situation, the set maximum of the
peak periods, as well as for firefighting, power out- opposite direction. hydraulic control pilot needs to be adjusted and set
ages and other emergency demands. Water can be Ideal operation is not always easily achievable to the correct tank level, or the system inlet pressure
stored in many ways in a distribution system, but because system characteristics can change con- needs to be increased above the desired tank-level
the control system must ensure that water storage is tinuously and affect the system. As system demand maximum setpoint. Adjusting the hydraulic con-
accomplished correctly. changes, so does the pressures in the system. trol pilot entails a site visit to adjust the set screw of
Common practice is to use different hydraulic alti- Commonly, incoming pressure to an altitude water the altitude water control valve, which can be quite
tude water control valves. These control valves use control valve drops off, or the demand on the distri- cumbersome in remote sites when many changes are
hydraulic control pilots, depending on the applica- bution system pressure/flow demands change. needed to facilitate system changes. Increasing sys-
tion, to measure the tank levels and maintain or Altitude water control valves operate off differen- tem inlet pressure entails either ramping up pumps
adjust the water storage levels. The two key factors for tial pressure of the inlet of the valve to the tank-level in the system or adjusting the feeder zone pressures
water storage are to ensure that the tank maintains head pressure. Consideration needs to be taken to higher. Both situations add time and cost but can
the correct level and that water turnover occurs. ensure the inlet pressure of the altitude water control also increase water loss and add strain on the system
valve is always greater than the tank-level head pres- due to extra pressure, which could result in addition-
Turnover sure. If the system fails to have a greater inlet pres- al pipe breakages.
Water quality deteriorates with water age, so stag- sure, the system essentially equalizes es the inlet pres-
nant water in tanks severely reduces the quality of the sure of the altitude water control valve
water. Water quality deterioration can give rise to dif- and tank-level head pressure. With zero
ferent health risks. Poor water storage can have both differential pressure, the altitude water
chemical and biological impacts such as, disinfec- ating
control valve will essentially sit, floating
tant decay, microbial growth, tank corrosion, chemi- open, trying to fill the tank but never ever
cal contaminants, nitrification, pathogen contamina- reaching the maximum level setpoint. oint.
tion and sediment build up.
Another issue, less common but still a factor,
occurs in colder climates in which low tank turnover
can lead to the water freezing within the tank. Water
in motion during tank turnover is far less likely to
freeze. Freezing can cause an altitude water control
valve to lose the ability to sense a full tank and, there-
fore, can cause the storage tank to overflow.
Freezing also can cause internal and external
structural concerns. The ice expansion may put
pressure on rivets or on bolted or welded seams.
Additionally, freezing may lead to pipe breaks and Image 1. Hydraulic altitude water control valves
cause leaks if corrosion previously formed when ice All graphics courtesy of Singer Valve
pressure was produced.
In an ideal situation, the altitude water control
valve controls the tank water level to the set maxi-
mum of a hydraulic control pilot. Following this, the
altitude water control valve closes, and then the dis-
tribution line is opened. This allows the tank to drain
down to a satisfactory level so that enough water
turnover can be accomplished before the altitude
water control valve opens again to fill the tank to the
set maximum.
In a two-way altitude water control valve situation,
the same is true except the distribution is through

40 Processing | NOVEMBER 2016

 Altitude water control valves operate off differential pressure of
the inlet of the valve to the tank-level head pressure. Consideration
needs to be taken to ensure the inlet pressure of the altitude water
control valve is always greater than the tank-level head pressure.

Image 2. Image 3. Water storage tank

controlled by a control valve in Modesto, California

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NOVEMBER 2016 | www.processingmagazine.com 41


Image 4. Solenoid-operated control valve
Automation & solenoid control
Automation and instrumentation is a growing mar-
ket in the water industry and for good reason
since many systems are moving toward full, remote
autonomy and control. Hydraulic altitude water con-
trol valves have controlled tank levels for many years,
but now the same control can be accomplished with
control panels and instrumentation.
By replacing traditional hydraulic control pilots
used to sense level with electronic tank-level/pres-
sure switches or sensors paired with a control panel,
the level control process can be achieved electroni-
cally. The hydraulic water control valve still remains.
However, a complex hydraulic pilot system, as
described in the previous section, is not required. All
that is needed is a simple, single solenoid.
Level & pressure switches
Once automation control is installed, one of two
operational sequences can be used for the level con-
trol. The first sequence entails using one level/pres-
sure switch located at the maximum-level setpoint
and a second one at the tank-drawdown setpoint. If
the water level is located below the tank-drawdown
42 Processing | NOVEMBER 2016
By replacing traditional hydraulic control pilots used to
sense level with electronic tank-level/pressure switches
or sensors paired with a control panel, the level control
process can be achieved electronically.
switch, then the panel will open the control valve via
the solenoid and allow the tank to fill until the max-
imum-level switch is contacted. The panel will then
close the control valve using the solenoid.
The control valve will remain closed until the tank
level is once again drawn below the drawdown switch.
Although this is an effective technique and provides
more flexibility than the basic hydraulic altitude water
control valve, the maximum level and drawdown
switches still sit at a constant level. They would need to
be adjusted accordingly on site to allow for variations
of the setpoint, which must sometimes be adjusted to
accommodate changes in system pressures.
Level & pressure transmitters
A more versatile option, which is the second opera-
tion sequence, is to use a level/pressure transmit-
ter. These are available in all shapes and forms to
fit specific tanks. These level/pressure transmitters
offer a 4-20-milliampere (mA) feedback signal to the
control panel that gives the panel the exact tank
level. With a live feedback signal, the panel provides
many more options for determining the tank-level
setpoints. The level control panel can then calcu-
late a variable setpoint for both the maximum level
and drawdown, which easily can be changed with
the user interface on the panel. This eliminates the Image 5. Level control panel
need for a site visit to change any setpoints and
202 209
allows the system setpoints to be changed as need-
ed to ensure optimum operations.

New level control panel

The Level Control Panel with Touch Panel interface
designed by Singer Valve was created to accomplish
optimum level control feasibility and flexibility. This
level controller was designed to complement a single
solenoid-operated/override control valve and 4-20-
mA level sensor or high/low level switches. This com-
bination package is ideal for filling and controlling
any water tank that requires a filled, level setpoint
and a draw-down-level setpoint before activating
the fi
fill cycle again to ensure tank turnover.
Th system is easy to configure, read and com-
This
pare the level 4-20-mA signal to the desired set-
poin The setpoints can be set locally with an
point.
inte
interactive button display screen or remotely with
eith supervisory control and a data acquisition
either Figure 1.
Mo
Modbus or hardwired 4-20-mA, remote-setpoint 6ROHQRLG&RQWURO9DOYH Tank application example
sig
signals. If a high- or low-level switch system is
pr
preferred, this panel can switch the configura-
tio to allow for level switch inputs and regulate
tion optimally. This ability to take all the information and being over pressurized or the development of stag-
th control valve accordingly. Data logging is
the then easily adjust the tank setpoints is a benefit. nant water contamination, a common theme.
al a useful feature to log sensor feedback and
also Although the system does not eliminate tank turn- Electronic automation of level control means that
s
setpoint data with a time stamp, allowing for over issues because it still needs to be operated cor- gone are the days of relying on remotely located
s
system analysis. rectly, having access to all the feedback information hydraulic pilots with no way of telling what the sys-
The biggest benefits of this automated level should allow insight into setting the system to oper- tem is doing. The level control process now sits at an
controller are the flexibility and readability ate to ensure proper water turnover. For example, the end users fingertips, delivering accurate and safer
of the control. For the user who wants to set live, level feedback lets the system know when it is sit- water storage.
up a full communication network that can ting statically, which allows the user to easily rectify
access all the storage tanks and control them the issue and regain control of the system and pre-
remotely, this is easy to accomplish with vent the water from sitting stationary in any tanks. Ryan Spooner is an engineer and head of Automation and Instrumentation
Modbus and remote 4-20-mA communica- A remaining feature that fits into the readability for Singer Valve. He has a degree in mechatronics engineering from
tion options. For the user who has a remote of the system is alarm/notification output. Instantly Simon Fraser University and a deep understanding of electronics with a
site but wants to log data and analyze tank knowing if something goes wrong with the system solid background in valve mechanics. Spooner designs and builds cus-
turnover, the system offers a data logging allows procedures to be implemented right away in tomized control panels and does commissioning and valve integration. He
feature. Either option offers feedback and traceability order to rectify the problem. Not having access to also runs operator training sessions on-site as well as lab demos at the
of the sy
systems operation. Based on this information, these alarms could mean the system is assumed to be manufacturing plant.
the tan
tank level setpoints can be adjusted to match operating correctly until closer inspection occurs, or
nee and demands of the system with simple
the needs worse yet, until something goes drastically wrong Singer Valve
interact
interaction to ensure that the system can function such as tanks overflowing, pipes breaking, the system www.singervalve.com

203 224

NOVEMBER 2016 | www.processingmagazine.com 43

LEVEL MEASUREMENT
& CONTROL P ROD UCT SPO T LI GH T
1
1 | Magnetic Level Indicator
WIKAs WMI Series Magnetic Level Indica-
tors are suitable for most industrial and
commercial applications including the
refinery and chemical; energy and power
plant technology; feedwater heaters and
boilers; oil and gas; pulp and paper; food
and beverage; pharmaceutical and more.
The level indicators easily can be com-
bined with the WIKA WLC series chamber
for redundant level measurement. They
operate in temperature ranges from
-320F to 1,000F.
WIKA
www.wika.com
523
44 Processing | NOVEMBER 2016
2 | Noncontact Radar Level Sensor
The BinMaster NCR-80 noncontact radar
level sensor is designed specifically for
use with powders and bulk solids. It uses
an 80 GHz frequency that focuses the
signal in a narrow 4 beam angle for pre-
cise aiming to avoid flow stream, internal
structure, or sidewall buildup. This ensures
reliability at measuring ranges up to 393
feet and accuracy within 0.2 inches. The
sensor is designed for continuous level
measurement in tall and narrow vessels
where there is excessive noise or dust.
BinMaster
www.binmaster.com
524
3
3 | Radar Level Transmitter
Endress+Hausers FMR10 and FMR20
free-space radar level transmitters are for
measuring liquid levels in storage tanks,
open basins, open channels, weirs and
canal systems. The FMR10 measures
liquid levels at ranges up to 16 feet with
0.2-inch accuracy, while the FMR20
measures levels up to 66 feet with 0.08-
inch accuracy. The FMR10 has a 4-20mA
output and comes standard with Bluetooth
for configuration. The FMR20 features a
4-20mA HART smart output, which allows
for configuration from an optional remote
display.
Endress+Hauser
www.us.endress.com/bluetooth-radar
525
4 | Guided Wave Radar Level
Transmitter
OMEGAs LVRD10 Series of general
purpose, guided wave radar level trans-
mitters provide continuous level measure-
ment with a 4-20 mA signal output. The
transmitters are offered in three probe
(rod, coaxial or cable) configurations up to
3 meters (9.8 feet) for the rod and coaxial
and 5.5 meters (18 feet) for the cable
design. The sensor is configured using
easy, robust software.
OMEGA Engineering Inc.
www.omega.com/pptst/LVRD10.html
526
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251
 Energy Efficiency

GOING GREEN
1 m i l l i wat t at a t i m e
New energy-efficient meters use process energy for power.
By Otto Fest, Otek Corporation

n the past, we believed we had a nearly infi- 1980) has 300 to 800 individual meters per reactor.

I nite amount of natural resources with end-

lessly progressing technology that could be
used to create anything at our fingertips.
Most are still analog.
Replacement of analog meters would require
reworking of panels, new wiring and engineering
Now we know that we have limited natural resources, designs, agency approvals, and inspection and opera-
and some technologies, once cutting edge, are known tor training. Plants would have to supply additional
to be harmful to people and the environment. power for normal operation and emergency power
We have come a long way in our efforts to help pro- sources such as battery banks. Planning and imple-
tect the environment, but every little bit counts, and mentation for these replacements could take more
we can always do more. One way that Otek has taken than three years to complete. If approximately 500
steps to help the environment came when it recon- analog meters were to be replaced with traditional,
sidered the powering of the digital bar meter. digital units, assuming they only require the average
5 W to operate, the new power source would have to
Analog equipment produce and store more than 2,500 W per hour. The
Analog meters are the industrys most energy-effi-
cient meters. They function using the energy in the
signal that they measure. However, they are sensitive
to wear and tear, shock, and vibration. The meters,
although inexpensive, can be inaccurate and unreli-
able. These deficiencies may cause problems when
used in airplanes, ships and nuclear power plants.
When they read zero, operators cannot tell if the sig-
nal is dead or if the needle is stuck. As a result, opera-
tors may ignore a meter at zero. Because they are
inexpensive and easy to connect, many industries still
rely on them.

Digital meter power consumption

The digital counterparts of analog meters, digital
panel meters, make up for most of the analog equip-
ment's deficiencies. Not having moving parts, digi-
tal panel meters are more durable and reliable. They
have high digital accuracy and are easily read by oper-
ators using human machine interfaces. Some units
can communicate with supervisory control and data
acquisition/distributed control systems via serial
input/output (I/O) (machine-to-machine interface).
Some units are available, which control the process
they measure. These meters require external power,
on average at least 2 to 10 watts (W). For the last sev-
eral years, digital bar meters have been consuming
more and more energy in proportion to this increase
in functionality.

Nuclear power plant conversion

The digital meters had all the benefits the industry
was looking for, but at what cost? The meters did
not conform to pre-existing equipment, requiring A digital panel meter with alphanumeric display
a more complicated installation. A typical nuclear This meter features automatic signal fail-detection
power plant built during the last century (1960 to Images courtesy of Otek Corporation

46 Processing | NOVEMBER 2016


typical cost of the conversion was estimated to be
more than $20,000,000.
When told this by a nuclear expert, Otek experts
decided to make developing an alternative for ana-
log-to-digital conversion its priority. While design-
ing the industrys first 100 percent signal-powered
[alternating-current (AC) or direct-current (DC)]
digital meter, the development team thought of a
barge going downstream using the energy of the flow
of water and realized a lot of free energy flows all
around us. Even the water flowing from a garden hose
generates energy. Processes inherently have their
own energy, typically about 100 milliwatts (mW). This
energy is wasted because most meters require 1 to 10
W to operate, so power had to be drawn from another
source. A way to apply this wasted energy needed to
be discovered.
The goals were simple. The new meters need-
ed to be signal driven, like an analog meter, and
to reproduce the needle of the analog units. The
design also had to be something that was easy to
mount and connect by incorporating a mechanical
design that was a drop-in replacement for either
analog or digital meters.
The units would also need to be interference free
and computer compatible (isolated serial I/O), all
while maintaining accuracy, reliability and durability.
This technology needed to include the benefits of the
two existing technologies, be plug and play, and add
something innovative.
100 percent signal power
Current loop (4-20 and 10-50 mA DC)-powered digi-
tal panel meters had been developed and patented by
Otek in the 1970s and incorporated in the new design
of the New Technology Meters (NTM) series. The
challenge was to signal power the units with the AC
signal just like the analog meters.
The team needed to design an ultra-efficient cur-
rent transformer (CT) so that the meter could use
the free energy for power without saturating the
customers CT and thereby eliminate the need for
external power. A typical 5 amp CT is used to mea-
sure AC/power along with volts AC. By designing a
THE ECONOMICS
highly linear and efficient miniature CT, the meter The nuclear industry has approximately 300 reactors
could extract the power of the AC line to power the operating worldwide. Each reactor control room uses
electronics for volts, amps, watts and frequency. about 500 meters (approximately 150,000 meters
The team began additional development of this in operation globally). If all were digital, they would
new technology only to be brought to a standstill. consume about 750,000 W per hour, and the heat
Certain components it needed to accomplish this they generated would require additional energy to
goal simply were not yet available. keep them cool. In addition, if emergency, battery-
backup power were required, an additional cost
The new technology would be associated with producing and storing the
As a result of new developments and inventions emergency power supply. The total annual savings
from other creators, NTM was designed using ultra- per signal-powered meter in the nuclear industry is
efficient, custom LEDs that require about 1100 of the approximately $500 per meter, amounting to about a
energy that a standard LED uses. The team included a $250,000 in savings.
parasitic, application-specific, integrated circuit that These meters consume 1 percent of the energy of
uses approximately 1 percent of the energy of a regu- comparable digital meters but harvest and use exist-
lar microcontroller. The engineers developed soft- ing energy produced by the signal. Additional power is
ware to efficiently share the 10 to 100 mW of power not required, and excess energy is no longer wasted.
available. This is a 99 percent reduction in energy use. Every milliwatt counts.
With all these new innovations, the NTM uses exist-
ing energy to operate (provided the
signal can produce more than 10 mW).
The team was able to accomplish the
same objective as Sir R. Weston when
he created the analog meter in 1893
but for modern applications. Imagine
if the footprint could be reduced by
99 percent.
With the puzzle of how to use less
energy to operate the meters solved,
the team needed to design needle rep-
resentation. When stopped at a traffic
light, the lead engineer had an epiph-
any: Why not copy the universally
accepted red, yellow and green traf-
fic light standard? Red was known to
imply danger, yellow inevitably stood
for caution and green represented safe-
ty. This design was incorporated into a
bar graph for the meter that would dis-
play color setpoints and alarms.
The new technology design was
already a superior alternative, still the
A one-channel digital panel meter
Image courtesy of Otek Corporation
259
NOVEMBER 2016 | www.processingmagazine.com 47
 A typical nuclear power plant built during the last century has
300 to 800 individual meters per reactor. Most are still analog."
lead engineer felt that more could be added. The
team included an alarm to notify operators when
the signal failed. How can a dead meter detect and
record the occurrence? A battery was considered.
However, this would limit the meters practicality. In
certain segments of the market, a battery could be
hazardous. Approximately 100 mW of energy were
needed. This energy would last long enough to visu-
ally display a message while sending serial data to
the central computer. A new energy storage device
was designed. With it, excess energy from the signal
detects when the signal goes dead and enables the
alarm to indicate an input fail.
The end result of approximately 40 years of persis-
tence is new technology that replaces the fit, form
and function of the 1893 analog meter and the 20th
century digital meter. Most importantly, the meter
will ensure added safety with built-in input failure
detection. Operators will no longer have to guess the
Volt meter (circa 1803) status of their processes or the status of their meters.
Image courtesy of Hannes Grobe own work, Schulhistorische With a meter capable of so many things, it could help
Sammlung Bremerhaven prevent additional accidents.
Dr. Otto Fest was born on a banana plantation in
Mexico and graduated from the Teachers College of
Columbia University with a degree in electrical engi-
neering. He obtained master and doctorate degrees
in electronics at I.I.T., after which he worked for the
NASA/Apollo program until 1972 when he founded
OTEK Corporation. He holds several patents in different subjects. Fest is
79 years old and very active in research and development and pursuing
his latest goal of making Otek a full Appendix B-qualified supplier for the
nuclear industry.
Otek Corporation
www.otekcorp.com
MORE Visit processingmagazine.com
ONLINE
for more articles on energy efficiency.

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247
ENERGY
EFFICIENCY P RO DUCT SPO T LI GH T
1 | Stator
NETZSCHs iFD-Stator 2.0 delivers energy
efficiency and reduces energy costs due
to reduced starting and running torque.
Designed for difficult pumping applica-
tions, the stator features a two-part, reus-
able housing and replaceable stator and
is compatible with NEMO NM progressing
cavity pumps. Speed and pressure are
not limited with the stator, and the axial
mobility of the elastomer extends the
service life. Stator replacement costs are
lower, and replacement is more environ-
mentally friendly because the housing can
be reused.
NETZSCH Pumps North America LLC
www.pumps.netzsch.com/en
527
50 Processing | NOVEMBER 2016
2 | Direct-drive motor
Electric Torque Machines M-Series direct-
drive motors reduce energy costs by 60
to 80 percent compared to conventional
motor-and-gearbox combinations. The
motors also provide 80 to 90 percent
operating efficiency over conventional
configurations using patented electromag-
netic motor technology. Available with ad-
justable speeds up to 1,800 rpm, output
torque ranges from 40 to 1,800 pounds
per inch, and 0.71 to 2.2 hp ratings, the
direct-drive technology results in approxi-
mately $1,350 in savings each year over
conventional combinations.
Electric Torque Machines
www.etmpower.com
528
3 | IIoT software
Honeywell UOPs Connected Performance
Services offers software-based services
designed to address critical challenges
for refineries and petrochemical and
gas processing plants. With applica-
tions to improve energy efficiency, limit
unplanned downtime, better utilize assets
and eliminate expertise gaps, the services
belong to Honeywells larger IIoT ecosys-
tem. The cloud-based software service
continuously monitors streaming plant
data and uses that data to find and predict
underperformance and make operational
recommendations, which are displayed on
a user-friendly dashboard.
Honeywell UOP
www.uop.com
529
4 | Energy savings estimator
Rittal Corporations ChillZone app provides
energy savings estimations for the compa-
nys Blue e and Blue e+ lines of industrial
enclosure solutions. The app is available
from the Google Play and Apple stores
and offers inputing of five variables to
receive accurate energy- and cost-savings
calculations. The companys enclosure
units offer advanced energy conservation
and cost-effectiveness due to speed-
regulated components and patented heat
pipe technology. Input voltages range from
110 V to 480 V at grid frequencies of 50
or 60 Hz.
Rittal Corporation
www.rittalenclosures.com
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229
 TANKS & VESSELS
MODERN TANK
TECHNOLOGIES
Storage tanks have evolved to meet the highest standards
for safety, quality, corrosion resistance and longevity.
By Wayne B. Geyer, Steel Tank Institute-Steel Plate Fabricators Association
ank storage has come a long way since wood-
T en oil storage tanks were used in the early
20th century. From its founding in 1916, the
Steel Tank Institute (STI) has developed tank
designs according to concepts that are now common
requirements in all national tank standards and regula-
tions: corrosion control for underground tank systems
(USTs), secondary containment for USTs and above-
ground tank systems (ASTs), and fire protection for ASTs.
These technologies evolved in response to regulatory,
fire, environmental and safety codes developed by govern-
mental oversight agencies and standard-setting organiza-
tions. STI is in its 100th year as one of those standard-set-
ting bodies, having developed standards and specifications
for nine different tank technologies to meet the needs of
the industry and consumers.
Most owners and specifiers prefer purchasing tanks
that are built to national standards. These standards have
been developed through a consensus process among
industry and regulatory experts. Their goal is to create
tank technologies that are safe, high quality, corrosion
resistant and long lived.
52 Processing | NOVEMBER 2016
Storing flammable & combustible liquids
This article discusses only metallic atmospheric storage
tanks for flammable and combustible liquids. They are
either shop fabricated, meaning completed in a manufac-
turing facility, or field erected, meaning components are
delivered to a site at which the tank is constructed.
The following are the primary tank standards used
in the U.S. Purchasers should seek tanks that meet
these standards.
Atmospheric flammable & combustible
liquid storage USTs
UL 58 applies to single- and double-walled USTs, usually
cylindrical in shape. These tanks are commonly used to
store fuel at retail stations.
UL 1746 specifies that underground tanks must be pro-
tected to prevent corrosion damage that could lead to
fuel leaking into the soil. Methods include a jacketed tank
[(interstice layer and coating of fiberglass reinforced plas-
tic (FRP) or high-density polyethylene (HDPE)]; compos-
ite tank (FRP bonded to steel); and cathodically protected
 More than 350,000 STI-labeled USTs have been installed worldwide.

ASTs built to UL 142 and UL 2085 likely number in

the millions since welded tank technology began
in the 1930s.

tanks [more easily corroded anode (of zinc or magne-
sium) sacrifices itself to protect steel from corroding
at flaws in the coating on the tank surface].
UL 1316 is the comparable standard for tanks
made from FRP.
Atmospheric flammable & combustible
liquid storage ASTs
UL 142 covers tanks that are single- or double-walled,
wrapped or diked, vertical or horizontal, and cylin-
drical or rectangular. Vertical tanks are often seen at
bulk plants and tank farms. Most large fleet storage
uses horizontal, cylindrical tanks. Rectangular tanks
are most often used for lube oil, generator base tanks
and work benches.
UL 2085 covers double-walled tanks only (the
inside tank is built to UL 142). UL 2085 tanks must
be insulated to withstand a temperature of 2,000F
for two hours, comparable to the insulation provided
Old wooden storage tanks by the soil for an underground tank. Some fire codes
Nearly 100,000 STI-labeled, secondary containment ASTs have been installed. mandate the use of this type of tank for aboveground
All photos courtesy of STI-SPFA motor vehicle fuel storage.
Non-STI labeled, double- and single-walled
Materials
Carbon steel is the most abundantly produced of all
steel products and the most commonly used tank
material. Stainless and duplex steels are metal alloys
of steel with varying amounts of chromium, nickel
and other elements added. Unlike other metals, stain-
less steel does not rust or corrode in most applica-
tions. It is used primarily in pressure vessels, chemical
processing, petroleum refining and any application
for which sterile conditions are needed such as for
food, ethanol and biodiesel processing.
FRP is a composite material made of a polymer
matrix reinforced with fibers, usually of glass. FRP is
used primarily for USTs that store motor vehicle fuels.
It is also used to wrap steel tanks for corrosion pro-
tection and secondary containment.
Current issues pertaining to fuels
& atmospheric tanks
The fuel storage tank industry is exploring two impor-
tant issues of which prospective buyers should be
aware: biofuels and compatibility as well as ultralow
sulfur diesel and corrosion.
Biofuels & compatibility
Since the advent of ethanol-blended gasoline, con-
cern has existed regarding the compatibility of tra-
ditional steel storage tanks with ethanol and newer
fuels. Biofuels have significantly different characteris-
tics from petroleum gasoline and diesel. Noteworthy
are their higher solubility and water-absorption
capacity compared to conventional fuels.
Blended gasoline and ethanols higher solubil-
ity can mobilize sludge in tanks, clogging filters and
other equipment. Higher solubility can also allow

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215 230

NOVEMBER 2016 | www.processingmagazine.com 53


Corrosion in an STP sump
ethanol and biodiesel to degrade hoses, gaskets and
seals made from elastomerics and plastics under
prolonged exposure. For older FRP tanks, its impor-
tant to verify with the manufacturer that the resin
used is compatible with todays higher-concentrated
ethanol-fuel-blended gasoline, such as E15 and E85.
Ethanol and biodiesel also have the capacity to
absorb more dissolved water than conventional gaso-
line or diesel. This property can lead to phase sepa-
ration, which occurs when alcohol (ethanol) exits
the fuel phase and enters the aqueous phase. The
separated water can increase the activity of microbes
whose byproducts accelerate pitting corrosion.
Ultralow sulfur diesel & corrosion
Corrosion related to ultralow sulfur diesel has been
an ongoing source of concern since 2007. From 2014
to 2015, the U.S. Environmental Protection Agency
(EPA) conducted a field study1 of 42 in-service tanks.
The study assessed tanks constructed of both steel
and fiberglass located throughout the U.S. Based
on a scale developed by the Coordinating Research
Council, extreme corrosion was seen in 11 FRP and
seven steel tanks; moderate corrosion was seen in
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nine FRP and eight steel tanks; and minimum corro-
sion was seen in four FRP and three steel tanks.
Until recently, whether corrosion was also attack-
ing metallic components inside steel tanks, in addi-
tion to inside FRP USTs was uncertain. Documented
incidents previously were entirely of corrosion that
occurred on components inside tanks, and usually
inside fiberglass tanks. The EPA study, however, used
a video camera to go inside in-service tanks. The
video revealed this corrosion is a much more wide-
spread problem than first thought.
The corrosion of metal equipment inside USTs,
regardless of tank material, is unique in that it
appears to first develop in the vapor area of the tank
and then continues into the fuel space and into the
water on the tank bottom as well. This matter is still
being researched to better understand the cause.
Water
Finally, all fuel storage tanks, no matter what their
material of construction or what they store, must be
kept free of water. This point must be emphasized.
Not only does water oxidize steel and create rust, but
it is also a breeding medium for microbes that create
waste products detrimental to internal tank equip-
ment. In addition, water and microbial byproducts
contaminate the stored product, with consequent
economic impact.
STI developed the R111 Recommended Practice
for Storage Tank Maintenance2 for UST owners and
operators as well as a brochure3 emphasizing the
importance of keeping water out of underground
tank systems. Both are available for download from
the STI website.
For AST systems, STI provides the SP001 AST
Inspection Standard. Developed through a consen-
sus process by industry experts and stakeholders,
SP001 is widely used by AST petroleum storage tank
owners to help them comply with EPA regulations
for spill control.4
References
1. EPAs Investigation of Corrosion-Influencing Factors
in Underground Storage Tanks with Diesel Service,
www.epa.gov/sites/production/files/2016-07/
documents/diesel-corrosion-report_0.pdf
2. STIs R111 Recommended Practice for Storage
Tank Maintenance, www.steeltank.com/
Portals/0/Shop%20Fab/R111%20%20with%20
updated%20cover.pdf
3. STI UST maintenance brochure, www.steel
tank.com/Portals/0/Shop%20Fab/2016%20
4%20fold%20UST%20maintenance%20FOR%20
WEB%202.pdf.pdf
4. STI SP001 Standard for the Inspection of
Aboveground Storage Tanks www.steeltank.com/
SP001StandardFAQs/tabid/463/Default.aspx
Wayne Geyer is executive vice president of the Steel
Tank Institute-Steel Plate Fabricators Association
(STI-SPFA) and has been employed by STI since
1985. Geyer participates regularly in conferences
addressing underground and aboveground stor-
age systems for hazardous liquids. He is a professional engineer and a
member of the National Fire Protection Association's 30 Flammable and
Combustible Liquids Code Committee. In addition to STIs own standard-
setting efforts, he is active in other organizations standards development
processes. Geyer expands his advocacy role by participating in state
and national regulatory rule-making programs and code development.
STI-SPFA is a not-for-profit trade association representing fabricators of
steel construction products and their suppliers. The association is cel-
ebrating its 100th anniversary in 2016. Member companies produce
steel storage tanks, field-erected water tanks, pressure vessels and heat
exchangers, and pipe and pipelines. Their customers are from the petro-
chemical, power generation, food, pharmaceutical, fuels, wastewater and
water transmission industries. For information about STIs tank technolo-
gies, visit its website or email info@steeltank.com.
STI-SPFA
www.steeltank.com
MORE Visit processingmagazine.com
ONLINE
for more articles on tanks and vessels.
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54 Processing | NOVEMBER 2016

TANKS &
VESSELS P ROD U C T SP OT LI GH T
1 | Tank washing head
KAMATs TWK200/1500 air tank washing
head includes vertical and horizontal rotor
arms that direct high-pressure water onto
inner walls of tanks, containers and large
pipes. For use in chemical, petrochemical
and other industries, the washing head
includes an active pneumatic drive and
controllable speed and rotation direction
via remote control. Adaptable to differ-
ing degrees of soiling, this washing head
offers targeted cleaning of severely soiled
areas, which saves time and energy be-
cause the head is not removed from tanks
for speed or rotation adjustment.
KAMAT
www.kamat.de
531
2
2 | Custom tank fabrication
Ross Engineering accepts custom fabrica-
tion projects. Its large-scale elliptical head
pressure vessels for use as carbon filter
tanks are available sized up to 100,000
gallons in materials including carbon steel,
stainless steel, aluminum, titanium and
others. Other customizable options are:
heating and cooling jackets, internal coils,
electrical heat tracing or heat exchanger;
sheathing and insulation; sanitary design
and finish; special coatings and tank
liners; and agitators and mixer control-
lers. Construction to meet ASME, USFDA,
BISSC, ABS, API 650/620, UL 42 and
other codes is also available.
Charles Ross & Son Company
www.mixers.com
532
3 | Corrosion prevention preparation
Rugged Coatings CleanWirx decon-
taminates surfaces and eliminates a
range of micro-contaminants that remain
after conventional cleaning. The product
also removes mill scale, flash rust and
other interference materials, preparing
surfaces for advanced corrosion preven-
tion. Real-world applications include a
petroleum storage tank that failed to pass
pre-coating inspection because of high
contaminant levels but, within four days of
product application, passed inspection and
inspected brine pit pipes that revealed no
corrosion (even on bolt threads) on pipes
10 years after treatment with the product.
Rugged Coatings
www.ruggedcoatings.com
533
NOVEMBER 2016
4 | Scrubber system
Bionomic Industries Inc.s ScrubPac
VentClean System removes more than
99 percent of storage tank and rail car
vent emissions caused by breathing and
filling operations. The scrubber system
is a compact, highly efficient, packaged
system that uses triple-action scrubbing
technology and features corrosion-resis-
tant construction for long-lasting, in-field
operation. Available in two configurations
and four model sizes for gas capacities up
to 1,500 actual cubic feet per minute, the
systems applications include HCl recov-
ery, acid gas removal, alcohols, formalde-
hyde, amines and others.
Bionomic Industries Inc.
www.bionomicind.com
534
| www.processingmagazine.com 55
 WEIGHERS & FEEDERS
Bulk solids
handling system design
Measuring flow properties leads to proper equipment
selection and process reliability
ost engineers and operators involved in
M processing have dealt with bulk solids
handling at some point and, therefore,
understand that getting solids to flow in
a controlled manner is much more difficult than liq-
uid or gas streams. On many occasions, the problems
with bulk solids are baked into the design, resulting
in stark performance differences when compared to
fluid lines. Why is that? The science underpinning
bulk solid flow is dominated by frictional consid-
erations and is different from that associated with
fluids. While this difference is well established, it is
generally not covered in depth in undergraduate engi-
neering courses. As a result, many processing systems
are designed with little consideration of the flowabil-
ity of the material.
Beyond the lack of knowledge, bulk solid flow prop-
erties change depending on the particle size and dis-
tribution, the moisture content, temperature, time
of storage, and chemical composition, just to name a
56 Processing | NOVEMBER 2016
| By Carrie Hartford, Jenike & Johanson
few. Problems with handling solids can have a signifi-
cant impact on product quality, process productivity
and safety. Many bulk solids handling problems can be
avoided by using a proven scientific approach based
on the flow characteristics of the material. This article
discusses critical design parameters required for a reli-
able storage vessel (such as a silo, bin, tote, intermedi-
ate bulk containers, hopper, bunker, stockpile reclaim
system, self-unloading ships hull, etc.) to provide con-
sistent feed to the downstream handling system.
Basic differences between liquid & bulk solids
Fundamentally, a bulk solid can be defined as a group
of discrete particles of any size or shape in which stress
is transferred between particles and the containing bin
through frictional forces rather than by viscous forces.
Because of this internal friction, bulk solids can form
piles. Liquids are completely different because they
have no internal friction and cannot form piles. Liquids
are not sensitive to pressure and are incompressible,
Image 1. Sugar samples
All graphics courtesy of Jenike & Johanson
whereas the bulk density of a mass of discrete particles
typically changes as a function of consolidating pres-
sure (and particle size distribution).
Knowing the chemical makeup of a fluid allows
engineers to know the flow properties as a function
of temperature and pressure, whereas that is not pos-
sible with bulk solids. For example, all sugar has the
same chemical, sucrose, but the flow properties of
powdered sugar versus granulated sugar will ll be sig-
nificantly different. Image 1 shows different samples
of sugar.
g
aterials
Bulk solids include a wide range of materials
that can behave differently. Fine powders, rs, such
ocrystal-
as cornstarch, titanium dioxide and microcrystal-
ractions
line cellulose, may exhibit solids-gas interactions
that make them prone to flooding, fluidizationdization
or a reduced feed rate. Large particles par-
ticularly those that are irregularly shaped, d, such
as wood chips, switch grass or wheat-midds dds
may form interlocking structures, or align in a
bin, making discharge difficult. Some materi- eri-
als, such as cement, cocoa powder and fine ne
limestone, are prone to arching or rathol-
ing as a result of their cohesive strength.
Pharmaceutical powders and glass batch
blends often have a tendency to de-mix
(segregate or stratify) during storage and
transfer. These bulk solids follow fun-
damental behaviors that, when under-
stood, can be used to design equipment
that will function reliably, eliminate
stagnant regions and minimize prod-
uct degradation.
Flowability
The flowability of a bulk solid is a func-
tion of the material and the equipment
 rathole forms, resulting in a no-flow condition. In this
stagnant region, material can gain strength over time,
cake, and oxidize. It also limits the live storage capaci-
ty of the bin1 and can create cross-contamination and
microbial growth issues.
In addition to flow stoppages resulting from rat-
holes, funnel flow can cause material degradation,
results in a first-in, last-out flow sequence, and
increases the extent to which sifting segregation
(separation of large and small particles) impacts the
uniformity of the discharging material. In these cases,
the material exiting storage can be functionally differ-
ent from what entered.
While funnel flow bins and silos may be problem-
atic, problems are not a universal truth, and a large
class of bulk materials is quite well-suited to being
handled in these structures. These generally have the
following characteristics2:
Coarse particles usually a quarter inch in size
and larger
Free flowing materials composed of particles
that do not stick to each other
Figure 1. The two flow patterns that can occur in a bin: funnel flow (left) and mass
flow (right) Non-degrading particles materials that do not
cake, spoil or oxidize when sitting for long peri-
handling it. An easy-flowing bulk solid placed in the ods of time without movement
wrong piece of equipment can become difficult to han- Segregation not a concern either the mate-
dle, but the material only appears to be hard to handle. If rial is non-segregating or, if it does segregate, will
it is placed in the correct equipment, it can flow reliably. not affect downstream processes ( for example, if
When working on the design of a handling system, the
engineer must be aware of the material flow properties
and choose the appropriate equipment for reliable flow. Even the most carefully designed hopper can discharge in
funnel flow if the feeder does not provide uniform withdrawal
Flow patterns
Material will move through a bin in one of two ways: of material from the entire hopper outlet.
funnel flow or mass flow (see Figure 1).
In funnel flow, an active flow channel forms above
the outlet, with non-flowing material at the periph-
ery. As the level of material in the bin decreases,
layers of the non-flowing material may not slide
into the flowing channel. When the bulk solid has Image 2. Combustion ash is similar
to dry sand at ambient temperatures
sufficient cohesive strength, the stagnant material (left). The same material, after being
does not slide into the flow channel, and a stable heated to 1,400F, is sintered (right).
operated on a batch basis)
Provided that the bulk material meets all four char-
acteristics, a funnel flow bin is the most economi-
cal storage device. One reason is the sloping hopper
walls can be shallow, which results in savings in over-
all headroom for the bin. In addition, by not having
particles sliding along the hopper walls, no abrasive
wear occurs.
However, if the four criteria above cannot be satis-
fied, a funnel flow pattern is no longer suitable, and a
mass flow discharged pattern should be used. In mass
flow, all the material is in motion whenever any is
withdrawn from the hopper. Material from the center
and the periphery moves toward the outlet. A mass
flow discharge pattern provides a first-in, first-out
flow sequence that maximizes the control of the resi-
dence time in the bin, uses the full bin capacity, and
eliminates ratholing and the associated problems of
the flooding of fine powders.
Mass flow bins provide other benefits over fun-
nel flow hoppers. A mass flow discharge pattern will
eliminate stagnant regions and diminish the effects
of sifting segregation that may have occurred as a bin
is filled. Caking, spoilage and oxidation of the bulk
material is minimized because of the first-in, first-out
flow pattern. Mass flow also provides a steady dis-
charge at a consistent bulk density and a flow that is
uniform and controlled. For these reasons, mass flow
NOVEMBER 2016 | www.processingmagazine.com 57

Figure 2. Comparing a constant pitch screw feeder to a mass flow screw feeder
Bulk solids handling systems are often the weakest links in
the process plant, and their performance can dictate the perfor-
mance of the entire operation.
is advantageous for material that is cohesive, fine,
will degrade over time, or in which sifting segregation
is a concern.
Achieving mass flow requires:
Sizing the bin outlet large enough to prevent
arching
Ensuring hopper walls are sufficiently smooth
and steep enough to allow for the flow of the bulk
solid along them
Ensuring withdrawal of material from the entire
outlet area
These requirements can be met by using a mean-
ingful method of quantifying the properties of the
bulk solid that dictate its behavior and applying the
measured properties of the material as the basis for
the design.
Flowability tests required for design
To design for the appropriate parameters, flowabil-
ity tests need to be conducted on a representative
sample of material. Key tests required are3:
Wall friction provides mass flow hopper angles
using a shear tester in accordance with American
Society for Testing and Materials (ASTM)
Standard D 61284.
A cohesive strength test provides opening sizes
to avoid flow stoppages caused by cohesive arch-
ing and ratholing. It is measured as a function of
consolidating pressure in accordance with ASTM
Standard D 6128.
Compressibility gives the bulk density of a bulk
solid as a function of consolidating pressure.
It is used to determine the storage capacity of
equipment and to calculate material-induced
loads. It is measured in accordance with ASTM
Standard D 6683.
Permeability is the measurement of the resis-
tance to gas flow through the bulk solid. When
material contains a significant portion of fines,
permeability is particularly important. The data
obtained from this test are used to calculate the
critical, steady-state flow rate of the material that
can occur during discharge as a function of outlet
size and consolidating pressure.
Testing conditions must match the process con-
ditions because temperature, time at rest, moisture
content, chemical composition and particle size dis-
tribution directly affect a materials flowability, which
will affect the outcome of the tests. For example,
some material may be relatively free flowing at ambi-
ent temperatures, but when heated to about 1,400F,
it can sinter together (see Image 2), becoming pro-
gressively stronger at temperatures in between.
Another material may experience plugging issues
with the wet material in the rainy season and dusting
issues with the same material when dry unless the
design has accounted for both conditions. Humidity
can be a factor with hygroscopic materials during
processing, storage and shipment, causing material
to cake together. If material is allowed to sit in a pro-
cessing bin for some period of time before discharg-
ing, then the same conditions need to be matched in
the laboratory. Missing any of these conditions may
cause the design data to be flawed.
Feeder below hopper
Even the most carefully designed hopper can dis-
charge in funnel flow if the feeder does not provide
uniform withdrawal of material from the entire hop-
per outlet. This problem frequently comes up when a
gate or valve is used at a hopper outlet in an attempt
to regulate flow. To use a gate to regulate flow, it must
be operated partially closed. This is detrimental to
reliable flow because it prevents discharge from a
portion of the hopper outlet, potentially resulting in a

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58 Processing | NOVEMBER 2016

 Application Parameters to
Maintain During Bulk Solid
large volume of stagnant material in the hopper. 123, University of Utah Engineering Station, 1964 Flowability Tests
Ultimately, a feeder should accomplish the following:5 (revised, 1976).
Provide reliable and uninterrupted flow of mate- 4. ASTM D-6128, Standard Test Method for Shear
rial from the bin above Testing of Bulk Solids Using the Jenike Shear
Control the discharge rate from a bin, achieving Cell. ASTM International, 2006.
the required rate while preventing flooding 5. Carson, J.W. Step-by-Step Process in Selecting
Remove material from the entire cross section a Feeder. Chemical Processing. Powder & Solids
of the hopper outlet to avoid interfering with the Annual, 2000, 38-41.
mass flow in the bin above MOISTURE CONTENT
Seal against a gas pressure gradient (in some
applications) As a senior project engineer in Jenike & Johansons
For screw or belt/apron feeders, this means the office in California, Carrie Hartford has been involved
capacity must increase along the length of the hop- in troubleshooting and recommending corrective
per outlet to allow material to be activated along the actions for material flow problems and providing rec-
entire hopper area (see Figure 2). ommendations to avoid material-flow-related prob-
lems in new installations worldwide in many indus-
Conclusion tries such as chemical, cement, food, biomass and mining. Typical TEMPERATURE
When designing a liquids processing plant, the den- projects include the analysis and design of transfer chutes, stockpiles,
sity and viscosity of a liquid is looked up or tested bins and feeders. From 2012 to 2014, Hartford opened and established
and used as a design parameter. With bulk solids, the an engineering office and laboratory facilities in Perth, Western Australia.
design process is similar except the friction, cohesive Internationally she publishes technical papers, participates in conferences
strength, compressibility and sometimes permeabil- and presents numerous short courses in the field of bulk solids flow. She
ity need to be measured for the material. Many plants received her Bachelor of Science in mechanical engineering from the
use a copy-and-paste technique with little consider- University of California, Santa Barbara. Subsequently, she received her
ation of the materials flow properties. MBA from Azusa Pacific University in California. Hartford is a licensed pro- TIME at REST | IN STORAGE
Bulk solids handling systems are often the weak- fessional engineer in mechanical engineering in California. She may be
est links in the process plant, and their performance reached at chartford@jenike.com or 805-541-0901.
can dictate the performance of the entire operation.
Therefore, they deserve special attention. Jenike & Johanson
Measuring flow properties and applying them cor- www.jenike.com
rectly will reduce project risk, potentially save a sig-
nificant amount of capital and provide a peace-of-
mind solution. CHEMICAL COMPOSITION
References
1. Clement, Scott A., Paternina Gonzalez, Jairo A.,
and Hartford, Carrie E. Designing Hoppers to
Prevent Spoilage. Food Technology, April 2010.
2. Marinelli, J. and J. W. Carson. Solve Solids Flow MORE Visit processingmagazine.com for
Problems in Bins, Hoppers, and Feeders. Chemical ONLINE
Engineering Progress, May 1992, 2228.
more articles on weighers and feeders. PARTICLE SIZE
3. Jenike, A.W., Storage and Flow of Solids. Bulletin

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NOVEMBER 2016 | www.processingmagazine.com 59

WEIGHERS
& FEEDERS P RODUCT
ODUCT SPO T LI GH T
1 | Flexible screw conveyors
Spiroflow flexible screw conveyors provide
dust-free, low-energy, low-maintenance
and low-cost conveying solutions. Simplic-
ity of operation is the key element of the
flexible screw conveyors. The motor-driven
spiral, which is the only moving part,
rotates within a sealed tube, moving mate-
rials with its Archimedean screw action.
The design eliminates additional operating
equipment such as filters or bearings.
They are easy to clean, have low installa-
tion and maintenance costs, and provide
efficient performance.
Spiroflow Systems Inc.
www.spiroflowsystems.com
535
60 Processing | NOVEMBER 2016
2 | Weighing & dosing system
Volkmanns sensitive weighing and dos-
ing systems can accurately weigh and
dose powders, granules, food particles,
pellets, capsules, tablets and other bulk
materials being transferred into and out
of product pickup, through vacuum con-
veying and into the final unit. These units
provide a closed system with dust-free
feeds to protect employees and the work
environment and meet ATEX certification
standards for explosion protection. Volk-
mann equipment can handle contained
powder transport from the receiving area
through final packaging.
Volkmann
www.volkmannusa.com
536
3
3 | Pharmaceutical custom
lump breaker
Ajax Equipment developed a custom pow-
der sifter for pharmaceutical applications.
The rotary lump breaker unit is made of
a screw feeder with sifting screens and a
collecting conveyor. The unit gently breaks
lumps in pharmaceutical powders. Powder
agglomerates enter the highly polished
sifter from a feeding screw, and a rotating
paddle forces the powder through the
sifter grille and into a collecting conveyor.
The sealed unit provides effective sifting
action and controlled feed.
Ajax Equipment
www.ajax.co.uk
537
4 | Weigh batching system
Flexicon Corporation's automated Bulk
Bag Weigh Batching System meters in-
gredients into a FLEXI-DISC tubular cable
conveyor that transports batches of a
specified weight to downstream process-
ing equipment, dust-free. The BULK-OUT
BFC Series Bulk Bag Discharger features a
cantilevered I-beam with electric hoist and
trolley for loading and unloading without a
forklift. FLOW-FLEXER bag activators raise
and lower opposite bottom edges of the
bag at timed intervals for continuous and
complete discharge of the materials.
Flexicon Corporation
www.flexicon.com
538
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253 255 260

NOVEMBER 2016 | www.processingmagazine.com 61

INFO CENTER
Model BR Back Pressure
Regulator
Cashco's new Model BR back
pressure regulator is for use with
a range of gases and liquids.
With the appropriate options,
applications include upstream
over-pressure regulation of cryo-
genic liquids, sour gas, industrial
gases and chemicals, water, oil,
steam and compressed air.
Cashco Inc.
785-472-4481
www.cashco.com
400
HRS Series Quarter Turn
Electric Actuators from
Hayward
These new actuators bring
high performance and ease of
use to the market. The HRS
series provides highly efficient
multiplication of motor power
to produce uniquely compact
torque ranges.
Hayward Flow Control
One Hayward Industrial Drive
Clemmons NC 27012
336-712-9900
www.haywardflowcontrol.com
403
Epoxy Offers Superior
Acid Resistance
Two-component Master Bond
EP21ARHT is a high strength
coating, liner, adhesive and
sealant that is widely used in the
chemical processing and metal-
working industries.
Master Bond
Hackensack, NJ
201-394-8983
technical@masterbond.com
www.masterbond.com
406
62 Processing | NOVEMBER 2016
Line of Check Valves Gentle Pneumatic
Since 1958, Check-All Valve Conveying Systems
Mfg. Co. has manufactured a Dry, granular materials can be
complete line of in-line, spring- moved gently, reliably and with
loaded, piston-type check significant reduction in prod-
valves. With worldwide service, uct degradation and/or system
Check-All Valve serves many wear with a Dynamic Air
industries for practically every pneumatic conveying system
service application. designed from one of 16 differ-
ent conveying concepts.
Check-All Valve Mfg. Co. Dynamic Air Inc.
www.checkall.com 651 484-2900
info@dynamicair.com
401
www.dynamicair.com
402
Kason Launches Dry Run Protection
Centrifugal Screen The PMP-25 Pump Load Control
Replacement Program guards against dry running,
K-SERIES Replacement Screens cavitation and overload. It moni-
Program for centrifugal sift- tors true pump power for maxi-
ers offers: K-Centri screen mum sensitivity while displaying
cylinders utilizing durable wire power, trip points and delays.
or synthetic screen for general The 4X-enclosure is small
applications, and K-Duracyl enough to fit on size 1 starters
screen cylinders of heavy duty and can be door-, panel- or wall-
wedgewire or perforated plate. mounted.
Kason Corporation Load Controls Inc.
973-467-8140 888-600-3247
info@kason.com www.loadcontrols.com
www.kason.com
405
404
Low Headroom High-Intensity
Material Master Continuous Blender
Patented system promotes ma- HIM-306-SS High-Intensity
terial flow, features a dust-tight Continuous Blender imparts
material discharge, a bag spout shear required for blending,
access chamber for easy operator homogenizing, de-dusting and/
access, and includes a stainless or de-agglomerating dry ingre-
steel discharge hopper with bolt- dients, slurries, pastes and diffi-
on top cover. cult-to-blend materials. Uniform
blends achieved in as little as 20
seconds residence time.
Material Transfer & Storage Inc. Munson Machinery Company
1214 Lincoln Road 800-944-6644
Allegan, MI 49010 info@munsonmachinery.com
269-673-2125 www.munsonmachinery.com
sales@materialtransfer.com 408
www.materialtransfer.com
407
Industry Insights
The worlds nine largest operating power plants are
hydroelectric facilities, according to a report by the U.S.
Energy Information Administration (EIA). Four of the
worlds 10 largest power plants are located in China,
and all four of those plants began operating during the
past 13 years. Hydroelectric power is the second-largest
source of electricity in China after coal.
Graphic courtesy of EIA
index Find company websites and product information
at processing.hotims.com.
advertisers
Aplus Finetek Sensor Inc...................................36
Arkema Inc.......................................................27
Assured Automation .........................................42
Atlantic Coast Crushers.....................................43
AutomationDirect ................................................1
Baldor Electric Company ..................................IFC
Benko Products Inc...........................................58
Blue-White Industries........................................48
Boerger LLC .....................................................13
Bola-Tek Mfg Co. Ltd........................................42
Brennan Industries............................................19
Camfil Air Pollution Control..................................3
Charles Ross & Son Company .................... 18, 61
Dynamic Air Inc ..................................................5
Evoqua Water Technologies ..............................24
Flowrox ............................................................54
H-P Products ....................................................25
Halogen Valve Systems .....................................54
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representation
Hapman ...........................................................15 Rice Lake Weighing Systems ...........................IBC
Heinkel Filtering Systems Inc .............................61 Rosedale Products Inc ......................................49
Kemutec ..........................................................29 Schenck Process ..............................................12
michael c. christIAn
publisher
Lewco Inc.........................................................58 SEEPEX Inc.......................................................38 PH | 908-507-5472
fax | 205-408-3797
Li Xiang Mach. & Elec. Co. Ltd. .........................61 Silverson Machines ...........................................45 mikeC@grandviewmedia.com
Load Controls Inc..............................................43 SLY Incorporated ................................................4
Magnatrol Valve Corporation .............................48 Specialty Equipment ...........................................7
Magnetrol International .....................................21 Spencer Strainer Systems .................................61
Magnum Systems .............................................39 Spiroflow Systems Inc .......................................11
jay haas
Material Transfer & Storage Inc. ........................31 Valve-Tek Mfg. Co. Ltd. ....................................61 districT manager
PH | 205-572-1058
Midwestern Industries .......................................51 Vanton Pump & Equipment Corp. ......................10 fax | 205-408-3797
jay@grandviewmedia.com
Monitor Technologies LLC .................................53 Vesco Plastics Sales .........................................61
Morris Coupling ................................................37 Wilden Pump, a division of PSG ........................14
Munson Machinery ...........................................28 Winsted Corporation (WIN) ................................47
Paul O. Abbe ....................................................59 Xchanger Inc ....................................................61
Plast-O-Matic Valves Inc. ................................. BC Yaskawa America Inc........................................33 JIM SEMPLE
national accounts manager
Posi-flate..........................................................53 PH | 908-963-3008
fax | 205-408-3797
Red Guard ..........................................................9 jsemple@grandviewmedia.com
LISA WILLIMAN
SOUTHEAST accounts manager
PH | 908-332-5915
fax | 205-408-3797
lwilliman@grandviewmedia.com
ADDISON PERKINS
ACCOUNT EXECUTIVE
PH | 205-861-5303
APERKINS@grandviewmedia.com
NOVEMBER 2016 | www.processingmagazine.com 63
 THIS MONTH ON
ProcessingMagazine.com
FROM OUR TWITTER FEED
ONLINE ProcessingMag
EXCLUSIVE Oct 5, 9:35 am
Processing plants are not immune
to #cybersecurity attacks. #Manufacturing
was 2nd most targeted industry in 2015:
ow.ly/tmbm304Syy
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ProcessingMag
Oct 7, 9:50 am
No #manufacturing process is com-
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TrendMiner CEO Bert Baeck discusses the importance of data so26304XsyC
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Why the process industries are in need of and prepared for the Industrial Internet of Things, among other
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Top articles on level measurement

Image courtesy of Emerson Process Management

Graphic courtesy of Dust Control Technology

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Level measurement system yields Whats in my bin? Safeguarding waste oil transfer
greater accuracy With any monitoring method for bin, tank or with multipoint level measurement
silo inventories, a first question invariably asked is,
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