Processing magazine

July 2015

www.ProcessingMagazine.com

Weighers & Feeders

Manifold Instrumentation Valves

Brennan Industries, Inc., a supplier of hydraulic fi ttings and adapters, has expanded its line of instrumentation valves by introducing manifold valves. The valves are offered in three valve confi gurations: two valve manifolds for use in pressure instruments; three valve manifolds, used

in differential pressure instruments; and fi ve valve manifolds, which are normally used with differential pressure instruments where drain valves are required on the instrument side.

Brennan manifolds are available in

four different types of designs.

Brennan Industries, Inc.www.brennaninc.comWrite In 502

Dual Bulk Bag Filling System with Pallet Dispenser

A Dual Bulk Bag Filling System from Flexicon integrates two Swing-Down Bulk Bag Fillers with a Flexicon Pallet Dispenser and Powered Roller Conveyors, allowing safe, high capacity fi lling of bulk bags of all popular sizes. Programmable controls allow the fi llers to operate separately or simultaneously, fi lling bags of the same size or two different sizes. The system is offered with the company's own mechanical or pneumatic material delivery system integrated with the user's upstream process equipment or other material

source. For more on bags, bagging & packaging,

turn to page 22.

Flexicon Corp.www.fl exicon.comWrite In 501

The Power of Plus

Rice Lakes new 880 Plus indicator/controller is built for communication and packed with power. Onboard connectivity includes RS-232 or 485, USB, Ethernet TCP/IP and installable protocol options to offer versatility for a wide range of applications. The 880 Plus incorporates a universal mount with numeric keypad to simplify the user experience, making operations more convenient and fl exible. NEMA Type 4X/IP69K-rated gaskets effectively keep internal components out of harms way. The 880 Plus features next-level performance and can be used as a batch-ing indicator, with 20 time- and weight-based setpoints to handle process-control requirements. For more on weighers & feeders, turn to page 30.

Rice Lake Weighing Systemswww.ricelake.com/880PlusWrite In 500

Featured ArticleDont let water & steam issues hurtcombined heat & power efforts

Electric-power and process steam co-production has proved economical at refi neries, petrochemical plants and pharmaceuti-cal facilities. Net effi ciencies up to 80 percent are said possible. However, if water & steam treatment is mishandled, plants instead face outages and unit shutdowns. Combustion turbines with heat-recovery steam-generators (HRSGs) for CHP steam gen-eration are increasingly common. Read more on page 6.

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Compact Scotch-Yoke Valve

Actuators

The Remote Control RCI200 pneumatic actuator features a scotch-yoke drive mechanism. Unlike rack-and-pinion designs with a fl at torque output, the scotch-yoke provides a higher start- and end-torque output that matches the torque demand

profi le of most valves. RCI200s have the lowest weight and the smallest external dimensions of any actuator with an equivalent torque output. The optional integral declutchable manual override eliminates the

need for a separate override.

REMOTE CONTROL, Inc.www.rciactuators.comWrite In 503

the #1 value in automation

Order Today, Ships Today!* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

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Variable speed drives can improve your bottom line by reducing

your motors energy consumption. An investment of as little as

$59 can start paying off immediately.

GS1 AC drives (1/4 to 2 hp) offer simple Volts/Hertz

control for general purpose applications. Built-in I/O,

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With a huge selection of high-quality industrial electric motors

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GS2 AC drives (0.5 to 10 hp) feature built-in PID control,

dynamic braking and Modbus communications.

DuraPULSE AC drives (1 to 100 hp) add sensorless vector control,

a removable keypad that stores up to four different application

programs and built-in discrete and analog I/O. Communicate via

built-in Modbus or an optional Ethernet connection.

Ironhorse DC drives can accommodate 1/50 HP @ 12VDC all the way up

to 3HP @ 240VAC. These drives deliver excellent low speed control and

stability and are easily confi gured for your application.

Ironhorse AC motors are available in rolled steel (1/3 to 2 hp),

stainless steel (1/3 to 2 hp), cast iron (1 to 300 hp) and farm

duty (2 to 5 hp) 1800 RPM models. 1200 and 3600 RPM units

are also available in the most popular horsepower ratings. Our

premium ef ciency models meet current NEMA standards

from 1 to 150 hp, and start at $155.

Ironhorse DC motors are available in TENV and TEFC rolled

steel enclosure styles. Their space-saving designs feature a

NEMA 56C ange and removable mounting base.

Marathon Electric inverter-duty motors have been carefully

selected to be performance matched with our DURApulse

and GS series AC drives. They are available in 1/4 to 100 hp with 1200

and 1800 RPM base speeds. Dual 230/460V and 575 VAC models are

available and factory-mounted encoders are offered on select models.

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Write In 100

Less degradationMove your dry granular materials gently, reliably and with significant reductions in product degradation and/or system wear.

Proven capabilityDynamic Air dense phase pneumatic conveying systems have been proven in over 15,000 installations worldwide. They handle a wide range of materials and bulk densities at rates from a few hundred pounds to 400 tons per hour, over distances exceeding 5,000 feet.

Sixteen conceptsEach Dynamic Air system is custom designed from one of our sixteen different conveying concepts. So you get a conveying solution that fits your process perfectly, without compromises.

Cost effectiveOur high material-to-air ratios reduce energy and compressed air requirements. Our low conveying velocities provide significant process savings in both operation and

maintenance. Initial cost is surprisingly affordable too, thanks to our modular design concept and ease of installation.

Write or call us today with your questions, or for detailed information on our system applications.

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BulkBusterTM Bulk Bag Unloader Bella Twin Shaft Fluidized Zone Mixer

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Write In 101

4 Productivity Perspectives

14 Size Reduction

22 Bags, Bagging & Packaging

30 Weighers & Feeders

34 Piping, Tubing, Hoses & Fittings

36 Industry Briefs

37 Info Center

38 Classifi eds

40 Index

In This Issue2 July 2015 volume 28, number 07

July 2015 www.ProcessingMagazine.com

6 Dont let water & steam issues hurt combined heat & power efforts

Chemistry, corrosion and other stuff to consider for CHP plants,based on two decades plus experience.

16 Closed-system dispensing is better for bulk-chemical applications

How to better transfer chemicals from bulk containers toprocess equipment or other vessels.

24 Verify continuous-weighing instrument accuracy

Material tests compare belt-scale and weighfeeder output to a trusted source.

32 Innovation & production line unifi cation Sensors, remote diagnostics and track and trace technologiesblur line between processing and packaging. 24

Explosion Vent

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Write In 102


Immediately after the opening keynote address at most any automation-platform user conference comes the roadmap session, in which the event sponsor reveals its product development plans for the immediate future. In effect, theyre telling you how some knowledgeable odds-makers had bet their budget.

The gambling analogy may be especially apt for events held in Las Vegas, as was the recent 20th annual Siemens Automation Summit.

Its said that an almost ungodly amount of installed industrial automation is nearing end of life $65 billion worldwide. Yet, some plants are interested to keep what they have running, while others incrementally beneit from Internet-based and other advances accrued in recent years.

Processing pragmaticsThe roadmap presented for process control

system Simatic PCS addresses some of the most entrenched challenges and frustrations faced by automation users.

Leaving aside acronyms, model numbers and release dates, the following includes recent advances with some available in the immediate future.

Production problems related to nuisance alarms and personnel responses to alarms are rampant. They can be addressed by an alarm management system that includes six customizable alarm classes and priority-based

alarm views, with pending alarms being one possible view. The ability to hide alarms manually is by authorization, and easy reference can be made to see exactly what alarms are hidden. Alarm acknowledgement can be automated or manual. Alarms can be locked based on any number of parameters area, loop and machine among them.

Seeing it simple Software upgrade downloads are simpliied

and operating system security patches are supported. For software purchases, the idea is that the software is downloaded and the back-ofice software licensing process is completed in one day, i.e., when it is needed.

Downloads are simpliied with persistence of user changes. Property conigurations, overview attributes and other set parameters are not erased to default upon upgrade.

More and more installations are said to be taking advantage of economically available, very large display screens.

For engineering, its all about the process model, which is top-down, collaborative and on-line, with views that include the plants technological hierarchy and simulation embedded in the engineering worklow.

4

Reader Advisory Board

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 Stansield, Plant Manager, Accelerated Curing Inc.

Dr. Jesse Yoder, President, Flow Research

Robert M. Donnelly, Vice President of

Marketing, Flo-Tite Valves & Controls

Kevin Parker, Editorial Director

[email protected]

Productivity Perspectives

Write In 103

Use-of-automation challenges comprehensively addressed Editorial Director, Kevin Parker

Email: [email protected]

Managing Editor, Nick Phillips

Email: [email protected]

Copy Editor, Christy UnderwoodEmail: [email protected]

Art Director, Ryan CarlsonEmail: [email protected]

Group Publisher, Michael C. Christian

Ph: 908-507-5472, Email: [email protected]

Advertising Sales Assistant, Cookie RayfordEmail: [email protected]

Marketing Director, Annee Cook

Digital Operations Manager, Mary Beth RomanoEmail: [email protected]

Audience Marketing Manager, Anna Hicks

Audience Marketing Analyst, Stacy Barnes

Administrative Team:Group President, Vicki Denmark

Chief Revenue Oficer, Chris DolanChief Marketing Oficer, Mary Beth ShaddixVP, Audience Marketing, Delicia Poole

Interim Chief Technology Oficer, Carin ObadFinancial Director, Randy Lyle

Production/Business Director, Michael Humber

PROCESSING (Pub.#ISSN 0896-8659)

PROCESSING Magazine 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: Non-qualified domestic subscriptions: one year, $57; two year, $99; single issue, $10. Canadian and foreign surface subscriptions: one year, $93; two year, $162. Air mail subscrip-tion: one year, $203; two year, $355. Grand View Media Group, 2015. PROCESSING Magazine assumes no responsibility for validity of claims in items reports.

For Subscription Questions/Inquiries:U.S. 866-721-4807 Outside U.S. 847-763-1867E-mail [email protected] / Renew / Change of Address:www.processingmagazine.com/subscribe

Write In 104


Interest in combined heat & power (CHP) keeps growing. Electric-power and process-steam co-production has proved economical at reineries, petrochemical plants and pharmaceutical facilities. Net eficiencies up to 80 percent are said possible.

However, if water & steam treatment is mis-handled, plants instead face outages and unit shutdowns.

Combustion turbines with heat-recovery steam-generators (HRSGs) for CHP steam gen-eration are increasingly common, e.g., replace-ment of coal-ired electricity generation.

Combustion turbines, like jet engines, exe-cute a fundamental thermodynamic cycle, the Brayton Cycle.

Inlet air is compressed and injected into the turbine. The compressor is attached to the tur-bine shaft, and thus the compressor and turbine rotate in unison.

Fuel, typically natural gas but occasionally fuel oil, is injected and ignited in the compressed air stream.

The expanding gas drives the turbine.Hot exhaust, at 850 F or higher, exits the

turbine.Key advantages for power industries include

fast start times, especially during peak power periods; low capital cost compared to coal or nuclear; simplicity of fuel feed; and minimal operations and maintenance issues. For wind and solar power production, fast-start backup helps when temporal conditions limit renewables supply.

Combined-cycle energy generationA stand-alone combustion turbines net efi-

ciency is at most 30 to 35 percent, with much energy loss from the turbine exhaust. This is where the combined-cycle design helps. A heat-recovery steam generator (HRSG) placed at the turbine exhaust produces steam using waste heat. The most common HSRG design is the multi-pressure, drum-type unit.

The condensate is split between circuits, with relatively small low to the low-pressure (LP) steam network and the bulk to the intermedi-ate- (IP) and high-pressure (HP) circuits. Steam extraction may be taken from any circuit, or, as is most eficient, from a non-condensing tur-bine.

For straight steam production with no steam power generation, a less complex scenario is perhaps better, encompasing a combustion tur-

bine and a single-pressure HRSG. Net eficiencies of combined-cycle units for

power production today may reach 60 percent, while up to 80 percent eficiency is reportedly possible for co-generation.

However, the authors experience at facilities where power production is only part of the process reveals that water & steam treatment and chemistry monitoring are too often neglected. This inadvertent negligence will haunt operators and technicians once water & steam side upsets either short- or long-term lead to corrosion, scaling, and fouling failures of potentially enormous cost.

Write In 105 Write In 106

Chemistry, corrosion and other stuff to consider for CHP plants, based on two decades plus experience

By Brad Buecker

Dont let water & steam issues hurt combined heat & power efforts

Combustion turbines, like jet engines, execute a fundamental thermodynamic cycle, the so-called Brayton cycle, which describes the workings of a constant-pressure heat engine.

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8

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Sometimes troublesome condensersRegarding water/steam chemistry in dedicated

power-generating units, the condenser is typical-ly the most troublesome source of contaminant in-leakage. Impurity introduction via condenser tube leaks can cause boiler tube failures within weeks, days or hours. Most notorious is chloride, which in the steam generator concentrates under deposits, causing acidic corrosion and hydrogen damage.

On-line monitoring of condensate chemistry is essential to detect impurity ingress.

Unless a steam generators condensate/feedwater system contains copper alloys, oxygen scavenger use is highly discouraged. These are now known to propagate low-accelerated corrosion (FAC) in feedwater systems, economizers and low-pressure HRSG

evaporators, amongst other locations. Within the last three decades, FAC-induced failures have caused power plant fatalities. Up-to-date programs use ammonia or sometimes an amine for pH control, but allow oxygen leaking in through the condenser to remain. This oxygen, when chemistry is carefully controlled, causes the carbon-steel feedwater piping to develop a protective oxide layer.

Still popular for boiler-water treatment, espe-cially in high-pressure units, are tri-sodium phosphate (Na3PO4) and caustic, which boost alkalinity and help neutralize bad actors such as chlorides. However, overfeed can lead to other chemistry problems, including under-deposit caustic corrosion. Careful attention must be given to steam chemistry. Even trace amounts of impurities can damage downstream equipment,

particularly turbines. Common limits for chloride, sulfate, and sodium in steam that supplies a tur-bine may be as low as 2 parts-per-billion (ppb).

Condensate return chemistryFor CHP plants distributing steam to process

heat exchangers, district heating, or other similar applications, condensate return chemistry is critical. First, some boiler-water chemistry programs particularly in low-pressure units with relaxed chemistry requirements allow CO2 to carry over with steam. This CO2 then condenses with water in the condensate return system, generating corrosive conditions, as will any oxygen carried over or otherwise entering the condensate return system.

Crosslow, offset and vertical lutes are shown. The ilming mechanism maximizes liquid surface area.

1-800-472-6703

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Write In 109

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