Small Valves, Big Impact

Given that power plants can comprise hundreds of these components, flow control is a critical starting point for any plant manager looking to increase efficiency and uptime. These valves operate in a highly hazardous environment, handling high pressures, temperatures and erosive risks during daily operation. As such, resilience is expected as standard.

Yet as hardy as they are designed to be, both wear and tear and maintenance and replacement works are built into day-to-day plant operations. However, at a time when process costs are rising, any factor that increases the rate of deterioration must be identified and addressed. Most prominent among these is the issue of wet steam.

Otherwise known as flashing condensate, wet steam occurs when saturated steam and condensate water molecules combine. This is often the result of insufficient plant drain arrangements, incorrect bypass operation, improper valve calibration or inadequate pre-warming processes. Regardless of its origin, the effect of wet steam remains the same – the erosion of trim components used in critical service applications, hampering productivity.

Domino Effects

Flashing condensate can damage the component’s plug and seat sealing surfaces. This ensuing erosion is a significant cause of steam leakage. In turn, this sees rising downstream temperatures, with spray water valves operating at lower openings and water valve trims becoming eroded. Downstream pipe cracking occurs as a result.

Alongside physical damage, the consequences of steam leakage can include a loss of operator control – a potentially catastrophic situation in power plants reliant on unchanging conditions during production. Similarly, flashing condensate may lead to excessive noise and vibration that can increase energy loss and heat rate, further driving up consumption.

The shift of sustainability from a preference to a priority further underlines the impact of wet steam erosion across power plants. With some nations now obligated by law to hit net zero emissions within a certain timeframe, the issue of damaged valves, magnified at scale, may have an outsized effect on carbon footprints if not addressed quickly.

Taking Remedial Action

Remedial action for damaged components has often involved removing the valve’s cover and replacing its internal parts. Yet this puts the plant back at square one if underlying processing issues are not addressed. This fix is also expensive, as key plant machinery may have to be taken offline for repairs and maintenance.

The ensuing lost productivity and cost of replacing parts may actually be more expensive than keeping the initial, inefficient valve operational. Indeed, repeated at scale over an entire facility, single incidents like these can add up to significantly impacting the company’s bottom line. Accounting for the fact that major works to address these site problems – including adding drains to existing pipework – are also often ruled out due to costs and logistics concerns, more innovative strategies are required.

Minimising Sealing Surface Contact

One effective way of doing so is to ensure that any condensate has minimal contact with sealing surfaces. It is this thinking that led to the development of IMI Critical Engineering’s (IMI) EroSolve Wet Steam, which upgrades the valve’s plug-stem assembly, cage and seat ring. The solution’s use of specially engineered sealing surfaces and erosion-resistant hard-facing materials allows it to minimise the impact of wet steam droplets while enhancing trim life.

Crucially, this technology can be easily implemented in any make of control valve. While EroSolve Wet Steam’s wide-ranging applicability is a key strength – it can be implemented without changing the component’s body, bonnet or actuator – it is still highly recommended that facility managers work with suppliers to most effectively deploy the solution within the plant environment.

In fact, considering the increasing pressure on industry to do more with less, stakeholders should be leveraging supply chain expertise more than ever. Conversely, suppliers must be able to provide increasing levels of support, training and development to help unfamiliar maintenance and repair teams develop a deeper understanding of critical components, including valves.

For example, by deploying technical experts on-site such as IMI’s Valve Doctors to analyse ongoing operations, a more granular, tailored approach to maintenance can be established. Ultimately, more effective troubleshooting can result in greater insight into how to alleviate issues such as condensate flashing.

Simple Solutions to Complex Problems

Most traditional solutions to the problems posed by wet steam do not provide any added long lasting benefits, as erosion will remain a constant, cyclical concern if the true cause is not properly addressed. Additionally, fully replacing valves within a demanding production environment poses its own problems, with the downtime required often proving more expensive than the hardware itself.

The difficulties and costs posed by this strategy make inaction too risky for most to consider. Welding the valves inline also creates similar problems, as there are substantial additional costs incurred through the engineering, scheduling, cutting and re-welding process, as well as during post-weld inspection. However, replacing the trim with an innovative solution, such as EroSolve Wet Steam can delay degradation and extend valve lifetimes in conditions where erosive wet steam is common.

For more information on EroSolve Wet Steam, click here.

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The proven design of the Capanivo^® has been significantly improved.  As a result, the CN 7120 point level sensor from UWT meets the standards of the EHEDG (European Hygienic Engineering & Design Group). This approval authorises the sensor for use in hygiene-relevant applications such as pharmaceuticals, the food industry and other sectors that demand the highest standards of cleanliness and safety in their processes. The CN7 can be used as a full, demand or empty detector in containers, pipes or bypasses as well as for leakage detection in all liquids.

Ensuring hygiene standards

The EHEDG specifies basic requirements for manufacturers of food and pharmaceuticals to ensure clean and contamination-free design of equipment and production facilities. This includes protection against contamination by dirt, chemical substances, viruses, foreign bodies and toxins. This is achieved with UWT sensors through the use of food-safe materials, as well as the integration of high-quality surfaces and gap-free designs of the sensor arms that come into contact with the product. The EHEDG conformity of the UWT level sensors offers additional safety in industries that require sensitive production environments. This EHEDG version of the Capanivo^® level indicator opens up possibilities for optimising processes while taking the highest hygiene standards into account.

Insight into EHEDG-certified revision

With the redesign of the Capanivo^®, a further version of the capacitive point level indicator is now available. The EHEDG version differs fundamentally from the standard version.  

In order to comply with the EHEDG guidelines, the contour of the process connection and the flush-to-wall weld-in socket, both made of stainless steel, were optimised.

The probe is made of the high-performance plastic PEEK, which is ideal for food processing, production and biotechnological applications due to its chemical stability and thermal safety. The material is also ideal for CIP (clean-in-place) and SIP (sterilisation-in-place) cleaning and sterilisation processes up to 150°C / 302°F.  

EHEDG certification guarantees compliance with the strictest hygiene regulations, a decisive factor in ensuring consistent product quality and safety.

Versatile mounting options for a wide range of applications

The CN 7 capacitive sensor is characterised by its compact design with 1/2″ process connection, which makes it ideal for use in small containers and pipes Its versatility is highlighted by the different installation options: it can be installed vertically as a full detector, horizontally as a demand detector, or from below as an empty detector.  This flexibility allows the sensor to be used in a variety of installation environments, including tanks, pipes in both horizontal and vertical orientations, as well as in bypass configurations, supporting precise measurements across a wide range of applications.

Explosion protection

The Capanivo^® is not only known for its hygienic design, but also for its safety in potentially explosive atmospheres. With approvals such as ATEX, IEC-Ex, INMETRO and UKEX, the sensor can be used globally in environments that must fulfil strict safety requirements. These certifications guarantee that it functions reliably and safely even under the most difficult conditions.

Communication and process efficiency

Another outstanding feature of the CN 7 is the IO-Link signal output, a globally standardised technology that enables simple and efficient communication between the sensor and higher-level control systems.

The potted electronics within the sensor probe protect against shocks and environmental influences, thereby improving measurement accuracy and extending the detector’s lifespan. Additionally, the sensitivity can be adjusted via a potentiometer directly on the sensor. This capability for seamless integration into modern automation systems facilitates process monitoring and control, enhances operational efficiency, and reduces maintenance costs.

The integrated “Tip Sensitivity” also guarantees that the sensor reacts highly sensitively to the smallest changes, while the “Active Shield” actively protects the sensor from interference, which ensures a high level of functional reliability even with products that could cause caking or adhesions on the probe.

Game changer in the field of capacitive point level measurement

Overall, the capacitive level sensor of the Capanivo^® series from UWT is an outstanding solution for companies that require reliable, safe and hygienic level monitoring in their production facilities. The combination of advanced technology, comprehensive approvals and certifications as well as versatile application possibilities makes the CN 7120 a valuable tool in the modern process industry.

The post UWT’s Capacitive Level Sensor for the Highest Hygiene Level appeared first on Fluid Handling Pro.

The new CIP package is a highly versatile and easy-to-maintain clean-in-place solution, designed with mobility and hygiene at the forefront of its design. Fully customizable with options ranging from manual to automatic, the system can be adapted to include an integrated control unit via a panel-mounted touchscreen HMI and PLC. With remote monitoring and ongoing technical support available if required, the system can be programmed to record historic data, accessible on site by an operator, or remotely by one of Axium’s own engineers.

Developed with decades of hands-on experience across multiple process applications, Axium’s new Mobile CIP System offers an advanced alternative for sanitary maintenance.

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“The enhanced features of the Generation IV will make our DFplus valves market leaders not only in terms of dynamics and flow. They now also offer the easiest way to enter Industry 4.0 without high investments and without changing the machine control strategy”, says Frank Henschke, Product Manager Proportional Valves at Parker’s Industrial Systems Division Europe.

There are more innovations that provide added value. One of these new features is an integrated near-field communication (NFC) chip that allows users to obtain all status information in the field or in service situations – even when the valve is not actively powered. A 360° LED at the top of the electronics box ensures that the basic status data is immediately visible in the application by different colors or flashing frequencies. Parker’s ProPxD parameterizing software has been fundamentally revised along with an improved oscilloscope function, permitting adjustment to the application-specific parameters quickly and easily.

The new electronics are perfectly complemented by the mechanical characteristics of the DFplus^®valves. The unique VCD with its highest resolution integrated linear variable differential transformer (LVDT) provides elevated force drive without the need of strong active return springs, resulting in real servo valve performance. Together with the high robustness, which has been proven by vibration tests with up to 60 g and 10 billion endurance test cycles, the valves have already demonstrated their suitability for numerous demanding applications.

With the innovations of DFplus Generation IV, Parker is ideally positioned for working with engineers facing the challenges of the future in industrial hydraulics, in particular the increasing digitalization of processes. The valves are also suitable as a 1:1 replacement for DFplus Generation III valves in existing applications.

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Recently, a system integrator approached Bürkert to supply a valve for a water conductivity blending application, with the objective of achieving water quality with a conductivity level of 10µS (microsiemens). Their process design schematic included a ball valve that would isolate the flow of softened water, while a control valve would modulate the flow of deionized water. By controlling this media combination, once blended, the customer’s expected outcome was water production at the desired conductivity level. With this plan, the system integrator requested a control valve that would regulate the deionized water flow. 

To calculate the size of control valve required, it is important to understand the required flow rate and pressure. The integrator suggested that upstream pressure was 4 bar, with 3 bar pressure downstream. Moreover, they suggested a total flow rate of 1.5 m^3//h. Even at this stage, Bürkert suggested a review of this input data because the suggested flow rate appeared to be inaccurate. Furthermore, using the pressure and flow data, the calculation generated a requirement for a 1” diameter valve, which would likely be too large for this application. However, the integrator was satisfied with the validity of their initial input data, and they confirmed the resulting valve specification, supported by the fact that they had used this size of valve on a similar project with the same input data. 

Oversized valve specification

The Bürkert team remained unconvinced and they sought wider input data to help confirm the specification. The integrator reported that when installed, the previous valve project would operate at 10 to 20% of its total capacity. However, the reverse situation should ideally apply, sizing a valve to operate at 70%-90% of its capacity would enable the use of a smaller, more cost-effective valve, that could also achieve more efficient operation. 

Burkert decided to recalculate the valve size, based on optimising 80% capacity. This time, to ensure a comprehensive approach, the input data was reconfirmed. With a reading from the system’s pump, the upstream pressure was confirmed. Thanks to an installed flow meter, the flow reading was also verified. Using these input data, it was possible to work backwards and determine the actual downstream pressure. 

This highlighted that the downstream pressure was significantly less than the figure initially provided. Instead of the suggested 3 bar, the new calculation was just 0.1 bar. Based on this new data, it was realised that the customer’s desired, repeatable, and controllable flow range could not be achieved. 

Optimising control accuracy 

On further investigation, the customer revealed that an open tank was positioned downstream of this system, which both explained and confirmed the almost 0 bar downstream pressure reading. As a result, the customer agreed to resize the valve, sufficient to handle a difference from 4 bar upstream pressure down to 0 bar downstream. 

By this stage, the system integrator was working more closely with Burkert, and as a result, were also able to challenge a fundamental assumption about the system’s design. Although the conductivity value of the deionized water was very low, at 0.5 µS, the value of the softened water was very high, around 600 µS.

Without modulating the softened water flow, the resulting conductivity level after blending the media would be far higher than the objective of 10 µS. Bürkert advised that instead of regulating the flow of deionised water, by controlling the softened water, the desired conductivity level could be reached. 

Get it right first time

Switching the position of the control valve and resizing it accordingly enabled the integrator’s system to achieve the low, 10 µS water conductivity rating for their customer. Without assistance in making the correct calculation, the customer would have integrated a much larger – and much more expensive – control valve. Most significantly, the system would have been far less likely to have produced the desired quality of water. Had the system designer engaged with valve sizing and application expertise at the outset, they would also have avoided rework in design, instead achieving a faster time to market. 

Although this example demonstrates specific implications of incorrect specification, the same principles apply for any application that requires control valve modulation. The fundamental calculations to ensure correct control valve sizing are essential whatever the purpose and sector, from food & beverage, to pharmaceutical and life sciences. 

A crucial aspect for optimum sizing of control valves is achieving valid application input data. If the input application data is incorrect, or incomplete, then the type, position, and size of the control valve will be sub-optimal. While specifiers can make mistakes in calculations, valve specification errors can also have historic origins. If the original system wasn’t designed according to the right data, like-for-like replacement will also be sub-optimal. As technology has advanced, valves today are frequently more accurate, impacting open and close rates, and this means that smaller, less expensive valves can potentially be used instead. So, even when upgrading an existing system, the best practice is to recalculate control valve sizing each time.

Valve sizing

Bürkert’s process valve sizing tool, comprising control valve selection, helps designers and specifiers configure the right specification through a sequential set of application criteria. This tool helps to make control valve selection fast and simple, however, it’s imperative to remember that valve specification depends on valid input data.

Moreover, when used in an application like conductivity blending, Bürkert has additional internal tools to determine whether a complete system could achieve the desired outcome.

The surest way to achieve optimised valve specification, first time, is to involve a flow control specialist as early as possible in the process. Sharing access to details on the wider application enables an experienced valve provider to make an accurate specification based on all of the relevant criteria. This process might involve challenging the input data, but in so doing, a more effective outcome can be achieved. 

The post Optimising Control Valve Specification by Challenging the Input Data appeared first on Fluid Handling Pro.

The Type-21a SST PVC flow control ball valve provides a modified equal percentage flow control, with repeatable results across the span of travel. It is available in ½” – 2” true union sizes and features a precision-machined PVC ball with center provisions to support PTFE seats from zero to 100 percent of capable flow. The characterized ball valve requires directional installation and comes equipped with a flow direction label.

The Series 19 smart modulating actuator is capable of 0.01% accuracy of setpoint. It is a multi-voltage unit and operates at a 75 percent duty cycle for more frequent cycling of the valve. The Series 19 also features 4-20mA control, failsafe capability, an LED light to indicate valve position or fault, ISO mounting configuration, corrosion-resistant NEMA 4X enclosure, and a QR code for easy and instant access to user manuals. It comes standard with an OLED screen and fault contacts. All Series 19 actuators are CE labeled and compliant, and factory mounted and tested to ensure dependable operation.

Asahi/America Series 19 actuators mounted on Type-21a SST ball valves are available as package units and can ship within 24 hours of ordering from the company’s facility in Lawrence, Mass. The units can also be assembled on custom pre-fabricated skids to increase installation time and reduce overall project costs.

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The path to net zero

The ETP has aways generated energy from sewage gas, and the site houses seven power generators which are capable of running solely on biogas – produced through the anaerobic digestion of sludge during the first and second phases of water treatment. In 2020, Melbourne Water began a project with John Holland-KBR Joint Venture to upgrade the biogas handling system at the Eastern Treatment Plant to make it more efficient, resilient and future proof. Expanding capacity, preventing corrosion and sedimentation, and extending the working life of equipment were key aims, with specific requirements to remove liquid droplets and moisture and to minimise the size and cost of any necessary cooling system. 

An energy-intensive process, sewage transfer and treatment is responsible for around 85% of Melbourne Water’s total greenhouse gas (GHG) emissions, so contributing to the company’s Net Zero commitment was a main target for the project. “However, with existing assets nearing the end of their service life, ensuring that the new asset can service future production growth and plant upgrades was also essential,” says Nick Fung, Senior Project Manager at Melbourne Water. Increasing reliability for the operations team on site and improving safety across both operation and maintenance were further aims.

Energy-saving solution

Biogas contains hydrogen sulphide (H₂S) gas, which condensates out to form a highly corrosive liquid. Including a system to remove most of the moisture from the gas was therefore essential to minimise the amount of corrosion and degradation of the power station generators, while also limiting operational downtime and reducing the need to import electricity from the grid.

HRS Heat Exchangers were one of five companies invited to tender for the moisture removal equipment in the project. The HRS BDS removes water from biogas, protecting combined heat and power (CHP) engines and generator sets from corrosion and cavitation. It condenses more than 90% of the water present in biogas by reducing the temperature to leave a clean, green gas. The addition of heat regeneration technology means the cold biogas produced can be used to pre-cool the incoming warmer biogas. This reduces the load on the final cooling heat exchanger and saves valuable energy.

The BDS supplied as part of the project has a maximum capacity of 4,161 m³/hr (4,710 kg/hr), while the inclusion of an energy recovery section subsequently reduces the eventual chiller load by 30%, improving the overall energy footprint of the whole project. This BDS consists of two heat exchangers, a regeneration unit, and a final cooler, supplied on two skids. One skid – which is located in a hazardous area zone – contains the heat exchangers, a condensate knockout pot, a condensate drain line, and all the relevant IECEx-rated instrumentation. The second skid contains a buffer tank, standby and duty glycol pumps, and all the relevant glycol line process control valves and instruments. HRS also supplied an additional chiller and detailed process control descriptions, enabling the joint venture engineers to provide overall control and automation systems for the client.

Overcoming complex design parameters

Added design complexity came from the fact that the BDS needed to meet the requirements of two different operational stages, each of which contains four duty requirements. This meant a complex thermal design process was necessary to make sure that the supplied unit could meet all eight of the potential design scenarios.

Ella Taghavi, Project Manager and Technical Lead at HRS Heat Exchangers, explains: “Designing the BDS for the Melbourne Water project posed a significant challenge as it needed to cater to both current and future demands, with two very different conditions in each phase.

“The current first phase uses biogas supplied by the compressors and aftercoolers at an average pressure of 66 kPa. In the second (future) scenario, the gas is supplied following a number of additional treatments at an average pressure of 5 kPa and then supplied to the compressors. We therefore had to deal with two very different inlet conditions.

“The addition of heat regeneration added further complexity in terms of design. However, thanks to our cutting-edge technology, not only were capital costs reduced as a smaller chiller could be specified, but regeneration is also helping to lower ongoing operational costs.”

Robust and reliable

From being awarded the contract in July 2021, it took less than twelve months for HRS to install this bespoke BDS on site, with commissioning completed in June 2022.

“HRS have worked with the JH-KBR JV project team since 2020 and we were delighted when they asked us to bid on this project,” adds Ella. “Our experience in project management, construction and logistics enabled us to overcome early design challenges and respond to necessary changes during the design and construction process. As a result, we were able to deliver a high quality product that has performed to specification since its installation.”

The John Holland-KBR team noted that of the five tendered solutions, the technology of the HRS BDS stood out including excellent technical support to help develop the project further with Melbourne Water, from initial concept to a detailed, functional design. 

Since it was commissioned, the HRS BDS has been performing well and meeting its performance targets, with no breakdowns or interventions.

The upgrade project has improved the reliability and quality of the biogas supply to the power station at ETP, providing more confidence in its ability to provide more than 36,000 MWh (approximately 130TJ) of thermal energy for process heating. This means a reduced reliance on natural gas, making the overall operation more self-sufficient and reducing overall emissions.

Ella Taghavi, Project Manager and Technical Lead at HRS Heat Exchangers

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EXAIR carries a large selection of air and liquid atomizing nozzles in a variety of sizes, spray patterns, droplet sizes, and flow rates to meet your process-specific needs. All models come with our 5 year Built to Last Warranty and are CE compliant. FloodStream Liquid Nozzles start at $65.00. 

The post EXAIR’s New FloodStream Liquid Nozzle for Spray Applications in Tight Quarters appeared first on Fluid Handling Pro.

At the heart of fluid handling lies the need for adaptability. Whether it’s accommodating extreme temperatures, corrosive substances, or high pressures, stainless steel flexible metal hoses rise to the occasion. Their inherent flexibility allows them to bend and twist without compromising structural integrity, offering a reliable conduit for fluids in even the most challenging environments.

Unmatched Durability

Constructed from high-grade stainless steel, these hoses boast exceptional durability. Stainless steel’s resistance to corrosion, abrasion, and temperature extremes ensures longevity, reducing the need for frequent replacements and maintenance downtime. This resilience is particularly crucial in industries such as petrochemical, pharmaceuticals, and food processing, where hygiene and safety are paramount.

Versatility Redefined

From transferring water, steam, and chemicals to conveying gases and petroleum products, stainless steel flexible metal hoses are the Swiss Army knives of fluid handling. Their versatility extends to a myriad of industries, including manufacturing, automotive, aerospace, and beyond. Whether it’s mitigating vibration in machinery or accommodating thermal expansion in pipelines, these hoses offer tailored solutions to diverse fluid handling challenges.

Ensuring Safety and Compliance

In fluid handling, safety is non-negotiable. Stainless steel flexible metal hoses adhere to stringent quality standards and certifications, ensuring compliance with industry regulations. Their robust construction minimizes the risk of leaks, spills, and contamination, safeguarding both personnel and the environment. Additionally, their ability to withstand high pressures and temperature fluctuations adds an extra layer of reassurance in critical operations.

Embracing Innovation

As technology advances, so do the capabilities of stainless steel flexible metal hoses. Innovations in manufacturing techniques and materials continue to enhance their performance, making them even more indispensable in fluid handling systems. From advanced welding processes to novel alloy compositions, these hoses evolve to meet the evolving demands of modern industry.

The post Unraveling the Flexibility and Strength of Stainless Steel Flexible Metal Hoses in Fluid Handling appeared first on Fluid Handling Pro.

They are capable of handling fluids with suspended solid particles, corrosive fluids, and applications with high operating temperatures.

The operation is determined by the pneumatic actuation of a single-acting, spring-return piston actuator. Double-acting models without springs are also available.

The angle seat valves Series ASX are available in different versions depending on the nominal diameter, the fluid to be controlled, and the process connections. There are also specific models for installations with flow direction from under the seat, which help to eliminate or mitigate water hammer during the valve closing phase. For liquids, models with flow direction under the seat are recommended. For gases or steam, models with flow direction over the seat are recommended.

Angle seat valves – Series ASX

• HIGH FLOW
• LOW RESISTANCE OF THE FLOW
• ANTI-WATER HAMMER DESIGN
• COMPLIANT WITH DIRECTIVE PED 2014/68/UE
• COMPLIANT WITH DIRECTIVE ATEX FOR ZONES 1/21 – II 2G EX H IIC T4 GB AND II 2D EX H IIIC T135 °C DB -10≤ TA ≤+80 °C

Brochure and technical information

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