Reducing CO2 through air leak detection
Carbon dioxide (CO2) is a gas essential in the production of many everyday products, as well as being a key raw material in the fertilizer industry.
Much is spoken about the CO2 emitted by vehicles in the automotive sector; however, the main culprits are the energy and heat generation segments. In 2020, electricity and heat production accounted for > 15 B tonnes (t) of CO2 emissions, with transportation in second place at > 7 Bt.
When it comes to reducing energy use within a large industrial complex, low-hanging fruit such as low-energy light bulbs and movement sensors have already been initiated. The more difficult areas are associated with the production itself: elements that require elevated temperatures can be better insulated, as can refrigerated areas, but mechanical machines themselves can prove difficult to improve in terms of efficiency without affecting production.
One common element of most manufacturing sites is the need for compressed air. Pneumatics are a common theme and used in all sorts of industrial applications. To deliver the compressed air, a compressor or number of compressors are employed, and the resulting air is delivered throughout a site by a system of air lines. These pipes are often above ground to improve the logistics and ergonomics of production; however, over time they can degrade and give rise to leaks. Elbow joints, reducers, condensers and other fixtures all have the potential to leak air under pressure. With hundreds of meters of pipework, these leaks can often be difficult to detect.
Teledyne FLIR is a global producer of high-quality analytical handheld devices, including both thermal and acoustic imaging cameras.
The company’s FLIR Si2-LD acoustic camera (FIG. 1) makes light work of identifying leaks in pipework, even those elevated air lines that are difficult to access. By simply pointing the camera at an airline, leaks of 0.05 liters per minute (l/min) can be detected from 10 meters (m) away. At 2.5 m, leaks as little as 0.0032 l/min can be detected. These may not seem like significant volumes, but over the course of a year the loss can be considerable. On the FLIR Si2-LD, air leaks are displayed on the high-definition 5-in. color screen by simply pointing the handheld device at the air line.
Teledyne FLIR produces a wide range of high-quality cameras and provides the associated software to facilitate the collection and analysis of data. The FLIR Si2-LD camera is loaded with such software. Using a system termed industrial gas quantification, the camera can calculate the monetary loss incurred for each leak identified. As well as air, the software can also calculate losses for a variety of other gaseous systems, including ammonia (NH3), helium (He), hydrogen (H2), argon (Ar) and CO2.
For more information, visit https://www.flir.com/browse/industrial/acoustic-imaging-cameras/.
Compact triplex diaphragm pump for smooth metering and unique power output
For applications in process technology with medium hydraulic outputs, the question often arises as to whether the pulsation of an oscillating pump with only one plunger is too high. It is not uncommon for a less-expensive, single-head pump to be used in this transitional area. However, their high residual pulsation can be the deciding factor for switching to a three-headed pump, which only has ~20% residual pulsation due to the superimposition of flowrates.
LEWA has added a new size to its portfolio of triplex process diaphragm pumps. The LEWA triplex G3E (FIG. 2) is the smallest of its kind to date. With a hydraulic output of 10 kW, it offers a low-pulsation alternative to single-head pumps in the medium output range. Compared to a three-headed pump with a modular design, the G3E also requires a footprint that is ~30% smaller.
In principle, three-headed pumps can be built in a modular or monoblock design. The combination of several individual units in a modular design requires more space as well as additional couplings and gaskets, which comes at the expense of simplicity and robustness. So far, the lower costs of the modular solution have compensated for the disadvantages of this design. For this reason, LEWA generally met requests for particularly low-pulsation pumps with a three-pump combination of modular LEWA ecoflow drive units. With the new LEWA triplex G3E, the pump manufacturer is ushering in a new era for process technology applications with medium hydraulic outputs.
As with all models in the LEWA triplex series, the three plungers are housed in a common crankcase. The monoblock design not only makes the unit more compact than comparable modular solutions, but it also has fewer individual components (e.g., gaskets, couplings), which makes the machine extremely robust. Thanks to this design, the LEWA triplex G3E can also be operated with stroke frequencies that are not possible with modular pumps. The design also makes maintenance extremely easy for specialist personnel: for example, the gearbox is very easy to inspect even when it is installed.
Due to its robustness, the LEWA triplex G3E can run significantly faster than modular three-headed pumps. It has a permissible stroke frequency of up to 350 spm, which is very high for this size range. It achieves a maximum flowrate of ~20 m3/hr at 16 bar; however, pressures of up to 400 bar are also possible at lower flowrates. With these technical specifications, the new development also closes a crucial gap in terms of overall project costs. With the new triplex process diaphragm pump, a jump to the next larger machine can often be avoided, reducing investment costs for users.
In several respects, the LEWA triplex G3E is more efficient than modular variants. As already mentioned, the monoblock design is more compact from the outset since additional connecting elements are unnecessary. The vertical design of the motors reduces the footprint by a total of 30%. In addition, the new triplex process diaphragm pump achieves extraordinarily high efficiencies of between 80% and 90% over a very broad operating range. For example, in a fuel gas supply system on a very large gas carrier (VLGC) with a cargo volume of ~90,000 m³, the energy costs would be reduced by €20,000–€30,000 per year compared to another pump technology with significantly lower efficiency. In combination with the low wear of the few wear parts, this economic advantage is multiplied by the life expectancy of 20 yr–40 yr.
For more information, visit https://www.lewa.com/de-DE/pumpen/prozesspumpen/lewa-triplex-prozesspumpe.
Gas chromatograph for natural gas, biogas, renewable gas measurement, H2 applications
Emerson has released its Rosemount™ 470XA gas chromatograph, designed to simplify natural gas analysis in custody transfer and other process applications.
As natural gas sources have evolved to include sustainable and renewable sources—such as landfill gas and biogas—the need to provide greater gas chromatograph flexibility has accelerated. Existing designs provide the needed capabilities, but a smaller form factor and a more cost-effective solution are needed.
The Rosemount 470XA (FIG. 3) addresses these and other needs with an analyzer design based on the versatile and industry-proven Rosemount™ 770XA gas chromatograph, known for its robustness and wide variety of applications. This opens a wider range of use cases for a product in this segment, such as for carbon capture utilization and storage (CCUS), renewable natural gas (RNG) and custom applications.
The 470XA provides the same reliable and accurate C6+ BTU/CV measurement that users have come to expect from decades of traditional Rosemont gas chromatograph technology, but now with the added benefit of being a more economical solution for a wider variety of emerging applications.
A full-color LCD local operator interface and easy-to-use software reduce the need for specialized training by guiding operators through common operational and maintenance functions. Preinstalled Rosemount MON2020 software simplifies analyzer configuration, maintenance and data collection.
The 470XA does not require a shelter for operation in most environments, lowering total cost of ownership. A fully serviceable module combines all critical functional parts in one assembly, allowing for quick and easy field replacement or repair.
For more information, visit https://www.emerson.com/en-us/catalog/rosemount-sku-470xa-gas-chromatograph.
Pipeline protection in extreme cold environments
Denso Inc., a global leader in corrosion prevention and sealing technologies, presents Protal 7125, a high-build liquid coating specifically formulated for use in low-temperature environments (FIG. 4). Tailored to meet the needs of the oil, gas and natural gas industries, this innovative solution offers superior pipeline protection even in the most challenging climates.
Engineered for application on substrates at temperatures as low as –20°C (–4°F), Protal 7125 is designed to extend the working season for pipeline construction and maintenance. Its advanced formulation ensures that the coating remains effective on surfaces below 0°C (32°F), maintaining integrity in sub-zero conditions. This high-build coating achieves up to 50 mils (1,270 microns) in a single coat, significantly reducing application time and labor costs. Protal 7125’s fast-curing properties allow for quick handling and backfilling, even in extreme conditions, ensuring seamless project timelines.
Additionally, Protal 7125 offers exceptional adhesion that complements fusion bond epoxy (FBE) coatings, making it a versatile choice for pipeline operators. For enhanced operational efficiency, the product is available in repair cartridges (50-ml and 825-ml), facilitating easy onsite touch-ups.
Protal 7125 is ideal for a range of applications, including girth welds, tie-ins, push racks and repairs to FBE-coated pipelines. Its versatility also extends to in-service pipeline maintenance in cold environments where preheating or post-heating is not an option.
Denso specifically designed Protal 7125 to tackle the challenges posed by cold weather pipeline operations. This innovative solution aims to provide consistent protection for pipelines throughout the year, even in low-temperature conditions. Protal 7125 demonstrates Denso's ongoing dedication to creating cutting-edge, high-performance products tailored to meet the needs of the oil, gas and natural gas industries.
Denso continues to set the standard for corrosion prevention and pipeline protection with products like Protal 7125, designed to improve efficiency, reduce downtime and provide long-lasting durability.
For more information, visit Protal 7125™ - Denso.
System health monitoring offering delivers industry-spanning operational insights
Control Station has launched its System Health Monitoring (SHM), a tiered service offering that leverages intelligence captured by the company’s PlantESP Loop Performance Monitoring solution. The service enables proactive monitoring of PlantESP deployments, facilitating rapid response to system resource issues and guidance for achieving world-class control. Dozens of PlantESP licensees and the associated production facilities enrolled in the service offering prior to the 2024 launch.
Control Station’s PlantESP Loop Performance Monitoring solution (FIG. 5) capitalizes on a facility’s existing historical process data to assess proportional-integral-derivative (PID) controller performance on a plant- or enterprise-wide basis. The software uncovers a range of common mechanical, tuning and process interaction issues that undermine productivity and can contribute to unplanned downtime.
PlantESP’s library of metrics automates the identification of controller-related performance issues, and its portfolio of advanced forensic tools simplifies the isolation of root causes. Historically, monitoring systems like PlantESP could falter due to natural disasters and other unexpected events, and process manufacturers lacked a common method for assessing performance. The introduction of SHM ensures that deployments operate effectively while also providing a benchmark of performance and facilitating the pursuit of world-class production.
Intelligence derived by PlantESP is transmitted daily via a compact and encrypted machine-readable file. The captured information equips Control Station with timely awareness of:
Server health: Basic evaluations of the system, including verifying a server’s status (i.e., on vs. off), calculating engine status and access to required databases.
Infrastructure analysis: Assessments of system functionality and architecture, including available server and database hard drive space; the identification of misconfigured and/or invalid loops and tags; and the documentation of “dead loops.”
Control benchmarking: A singular value for assessing a plant’s regulatory control performance and indicating net changes in performance over time.
Control Station’s SHM offering utilizes a variety of metrics and other intelligence to calculate an Overall Controller Effectiveness™ (OCE) value. OCE is a normalized measure for control loop operations based on the methodology for calculating overall equipment effectiveness, and provides a simple, quantitative means for benchmarking various levels of control within a plant. Through receipt of periodic scorecards, subscribers to the SHM service offering can establish plant or even corporate performance standards. The tiered service offering can provide a list of priority recommendations that aids customers with the targeting of PID-related issues that offer the greatest impact on control and production performance.
PlantESP has been successfully deployed at manufacturing facilities both globally and spanning all major segments of the process industries. Information provided for analysis is restricted to a PlantESP server’s available resources and aggregated values of the software’s metric calculations. No proprietary process data is transmitted. All comparisons within SHM assessments are anonymized to ensure that data cannot be traced to any individual source. For more information, visit www.controlstation.com. GP&LNG