Watson Marlow - July 2010
Robust pump and tube combination solves sticky situation at adhesive firm
When Prelok encountered problems using both impeller and diaphragm pumps to circulate adhesive coating fluids at its Willenhall plant in the West Midlands, this specialist in the application of pre-applied locking and sealing processes for threaded components, turned to 521 Series pumps from Watson-Marlow. Used in combination with Gore Style 400 high resilience tubing, the solution overcame problems caused by previous pumps of damaging the fluid, or of the fluid damaging the pump. Prelok provides a range of high specification pre-applied thread locking and sealing products that are used throughout the automotive, IT, construction and telecommunications sectors. Established in 1969 in the West Midlands, Prelok now has additional facilities in France, Spain and Germany that help generate annual turnover in the region of £7.5 million. The company can process threaded components that range from miniature items for mobile communications through to M30 bolts used in bridge construction. "Our strengths lie in our ability to help customers source or manufacture quality components, quickly processing them and providing logistic solutions," says Andy Jones, Site Services Manager and Maintenance Co-ordinator at the 75-employee company. "When we have a problem in production we apply all our energies into finding a rapid and suitable solution." One such problem involved a process that re-circulates adhesive coating fluids prior to application. These fluids can be water- or solvent-based, with the exact make-up dependent upon customer requirements. "The problem focused on micro capsules that are suspended in the adhesive coating fluid," explains Mr Jones. "We found that impellor pumps damaged the capsules, while a subsequently installed diaphragm pump could not work with the sometimes small amount of fluid that is present. Furthermore it was hard to get the specific diaphragm material which is resistant to some of the aggressive chemicals we use." Fortunately Mr Jones recalled using Watson-Marlow peristaltic technology successfully in another process. In peristaltic pumping operations, nothing but the hose or tube touches the fluid, eliminating the risk of the pump contaminating the fluid, or the fluid contaminating the pump. Fluid is drawn into the pump, trapped between two rollers and expelled. The complete closure of the tube gives the pump its positive displacement action, preventing backflow and eliminating the need for check valves when the pump is not running. A Watson-Marlow 521 Series pump was duly installed at Prelok's Willenhall factory where it successfully overcame the previous problems encountered. So impressive was its performance that the company now has a total of four 521 Series pumps at Willenhall, with a further four dotted across its European operations. All of the units utilise an inverter to control speed, and all run continuously throughout the entire production period. Despite this demanding workload, Mr Jones says that maintenance tasks extend to no more than "spraying some lubricant on the rollers and springs every now and again". One final problem remained, however. The aggressive nature of some of the chemicals used within Prelok's adhesive coating fluids meant that the Marprene and Tygon tubing deployed initially exhibited short working life sometimes leading to ruptured tubes. "Since switching to the Watson-Marlow peristaltic pumps this at least meant it was easier to clean and get the process up and running again, however, it was still an issue we needed to resolve," says Mr Jones. "I contacted Watson-Marlow about alternative tube materials and our local sales engineer sent me a sample pack of different tubing material for me to immerse in our fluids to test for chemical compatibility. He followed up with a site visit and suggested we use a new type of pumphead (with quick release couplings) and Gore Style 400 tubing to trial. So far we haven't had a tubing rupture in the months it has been running." While chemicals will attack most other types of tubing, the secret behind the resilience of GORE Style 400 is Viton® GF-600S, a peroxide-cured fluoroelastomer based on DuPont advanced polymer architecture. Performance testing shows that Style 400 tubing offers greater than 50 times longer life than conventional non-reinforced extruded tube. Thanks to its expanded PTFE reinforcement, the new tubing also offers superior burst resistance to protect against the swelling effect produced when pumping aggressive chemicals using standard extruded tube.
Flowserve - July 2010
Flowserve Corporation (NYSE: FLS), a leading provider of flow control products and services for the global infrastructure markets, today announced it has opened an important test laboratory for compressor seals in Macaé, Brazil. The facility features the company's first dry gas seal testing capability in Latin America, expediting repair time for customers in the region. Part of a state-of-the-art Quick Response Center (QRC) that opened in 2009, the new test laboratory is designed to support compressor seal customers in a variety of industries including oil and gas, petrochemical and chemical. "Flowserve continues to make significant investments in personnel, cutting-edge equipment and expanded facilities in Latin America," said Tom Ferguson, President, Flowserve Flow Solutions Group. "With this new facility, we provide a full range of services in Brazil, ultimately helping our customers improve the reliability of their equipment and reduce costs." "We set an ambitious goal in building this laboratory to provide support to our local customers in Brazil and throughout the region," said Fabian Mamia, vice president and general manager, Latin America, Flowserve Flow Solutions Group. "Flowserve has established a leadership position in dry gas seal services for the Latin America market and we intend to gain our customers' confidence by providing outstanding customer service."
Facility Specifics
- More than 1,980 m2 (6,500 ft2)
- Dynamic test area allows customers to observe tests and seal repairs in real time via three LCD screens
- Full lifecycle equipment management capabilities, including Flowserve LifeCycle AdvantageTM programs to reduce the total cost of ownership and improve operating efficiency
- Overhang design test capability in Latin America for dry gas seals; test bench can reach speeds up to 23,000 revolutions per minute and pressures up to 250 bar (3626 psi); high-pressure air compressor can reach pressures up to 500 bar (7252 psi)
The Macaé QRC is part of the company's growing footprint of aftermarket service centers located near key customers around the world, offering a wide range of service and support to help customers maximize the effectiveness of their operations. The QRC network offers personal service, expertise and responsiveness to keep customers' equipment operating at peak performance.
CDR Pumps - July 2010
Silotank Ltd, the Leading UK manufacture of specialist thermoplastic, GRP and Dual Laminate Tanks , turnkey odour control and chemical scrubbing system based in Northern Ireland have recently installed CDR Pumps for Brine mixing systems at a food manufacturing companies plants in both England and Ireland. Silotank , engineered an automatic Brine mixing system to allow various brine solutions to be provided to fryer lines on demand. The scope involved the supply, Installation and commissioning of the mixing systems and controls, and included a 35 tonne and 23 tonne salt saturator, brine mixing tank and distribution pipework manifold for the fryers. At the heart of the system were two CDR Magnetic drive pumps from their ETN-L range of lined chemical process pumps, lined in Polypropylene, which allow long trouble free operational life of the systems with minimal maintenance requirements and eliminates corrosion problems. CDR Pumps have enjoyed a long association with Silotank, supplying pumps for bulk storage tanks, fume scrubbers and other installations falling within Silotank's scope of manufacture.
Sterling Fluid Systems - July 2010
SIHI have just launched a new web-based NPSHa calculator that is free of charge:
SIHIdeltaP - Pressure Loss Calculation Software. http://www.sterlingsihi.com/.
Determining the pressure (head) loss of fluid through pipe-work, bends, and other fittings can be undertaken very simply with SIHIdeltaP. This web-based application allows the pressure drop (∆P) and available NPSH(a) to be calculated for some complex systems together with a wide range of process fluids. The application is free to use, and has been launched as an investment for industry in which to reduce the number of cavitation-related pumping problems.
Introduction to SIHIdeltaP
SIHIdeltaP is an on-line adaptation of the proven "CAPRICE For Windows" software. Primarily, the tool is for piping and system Engineers to calculate the pressure losses through pipe-work, bends, and other fittings due to the friction caused by fluid flow.
Before the pipe layout is constructed, using the drag-and-drop system, the desired fluid is selected from the pre-installed database and its operating temperature entered. Subsequently, all relevant fluid properties are loaded in order to permit calculation. The next step is to enter the volumetric flow rate and nominal diameter of the suction and discharge piping. Subsequently, the user can drag-and-drop pipe-work elements from menu shown on the left-side and then advise the characteristics as requested. Roughness, diameter, and other values, can be selected from predetermined tables or entered manually. Nominal values will automatically reappear as a default for all later components. However, these values can be amended whenever necessary. Although there is an automatic refresh, it is wise to press "refresh" after all data has been input.
Finally, the user selects a System Configuration that represents the closest match to their own. The basic choice surrounds either flooded suction or self-priming. Options of open and closed-loop circuits are also given. Total (head) Pressure loss and available NPSH(a) can then be determined. The result can be printed and/or downloaded to Excel.
SIHIdeltaP allows:
- Pressure (head) losses to be calculated for industrial hydraulic pipe-work that is configured either in-line (open) or closed-loop.
- Liquid centrifugal pump optimisation, sizing & selection through the calculation of total manometric head.
- NPSH consideration and pump associated pump consideration
Armstrong - June 2010
INTEGRATED FUTURE FOR ARMSTRONG
Armstrong has announced the formal merger of its two key areas of operation in the UK. The off-site construction division of the company (Armstrong Integrated Systems based in Halesowen) and the HVAC equipment arm of Armstrong in the UK (headquartered in Manchester and Redhill) will now operate as a single company under a new legal framework. The move is expected to streamline and simplify administration and day-to-day contact for Armstrong customers who frequently require products and services from both divisions. Richard Strode, Armstrong's managing director, said, "For the last five years, both companies have operated side by side, offering distinct specialisms to the market. Armstrong Integrated Ltd will continue to leverage the strengths of our core product offering but with a greater emphasis on carbon reduction and whole life cost for the system, not just at a product level, but as a single provider of energy solutions and services to both the new construction market and the refurbishment/retrofit market." The integration of the two companies enables Armstrong to further strengthen and accelerate its product development activities in areas including:
- Low and zero carbon heating and cooling including the integration of renewable technologies such as biomass, heat pumps and solar thermal.
- Variable speed pumping technology and integrated control solutions.
- Fire, water supply, heat exchanger and sealed system expansion solutions.
The company will continue to operate using the well-known and respected Armstrong brand name. A new legal name has been chosen for the company however to recognise the merger of all operations - Armstrong Integrated Ltd. "The name ‘Armstrong Integrated Ltd' has been chosen to not only reflect the integrated design of our products and customer solutions, but also our desire to unify internally as a business and to communicate our ambition to form partnerships with our customers" explained Strode. "The move, in response to market feedback, will allow us to deliver an even better level of customer service providing enhanced customer access to our specialist teams across three centres of excellence. Our knowledge and capabilities enable us to provide customer support and services throughout the whole lifecycle of an installation from manufacture, to delivery, right the way through to service and replacement parts and products." The changes are designed to support Armstrong's continued growth in the UK market and do not involve any scaling down of activities. Operations will continue at all three sites - Halesowen, Manchester and Redhill - with the existing workforce and management structure. The changes are effective as of June 7th 2010.
Pipeflow - May 2010
New release of Pipe Flow Expert 2010 v5.12
PipeFlow.co.uk has announced the release of PipeFlow® Expert 2010 version 5.12, a major upgrade to the Microsoft Windows desktop application software for calculating flows and pressure drops in pipe systems.
Read the full story: http://www.pipeflow.co.uk/public/control.php?_path=/497/809/839
Pipe Flow Expert 2010 is a premier software application for designing and modelling fluid flow in a pipe network. It models both open and closed loop pipe systems, calculates flow rates, pipe pressure drops, friction losses, pump operating points and much more. BPMA members can get a 10% discount when purchasing online at http://www.pipeflow.co.uk/ by simply entering the promotion code BPMA10 before clicking on ‘Checkout'.
Axflow - May 2010
AxFlow introduces Wilden's Pro-Flo X air distribution system for hygienic pumps
AxFlow is now offering its UK customer the Wilden's Pro-Flo X air distribution system (ADS) for its stainless steel Wilden Hygienic Series pumps. This range of EHEDG certified, 3-A compliant air-operated diaphragm pumps is designed specifically to handle the most demanding sanitary and hygienic applications. "All our Wilden Pro-Flo X Hygienic Series pumps will now come equipped with the patent-pending Pro-Flo X ADS and include the Efficiency Management System that allows users to control both flow rate and efficiency," reports AxFlow's Wilden Pump Product Manager Peter Carfrae. "The Pro-Flo X ADS provides reliable operation, high flow rates, enhanced efficiency and anti-freezing characteristics." Wilden Pr-Flo X Hygienic Series pumps are highly flexible in terms of their suitability for a wide range of applications. The most basic configurations are a step up from the Wilden FDA Series, featuring polished 316L stainless steel surfaces of Ra 0.8µm, a flow-through liquid chamber design and a smooth flow path to enhance clean ability and prevent product entrapment. Both EHEDG and 3-A compliant models are configured with the integral piston PTFE diaphragm. The pumps can be supplied fitted on a swivel stand to permit draining without the need to disassemble the pump.
CDR Pumps - May 2010
CDR Pumps refine already successful STN ATEX pumps
The already successful STN series of magnetic drive pumps from CDR Pumps has undergone a series of design refinements to accommodate the ATEX certification requirements. Modifications include use of a heavy duty Cast Iron lantern and alloy feet to accommodate the heavier ATEX motors making the pumps far more robust. The ATEX pump comprises a Carbon filled ETFE casing for static energy earthing, while maintaining optimum corrosion resistance to the most arduous of chemicals. The bearing systems as standard is Glass loaded PTFE running against a stationery ceramic shaft and axial thrust shoes, with the option of upgrading to Silicon Carbide for solids handling. The nozzle connections allow for unions to be used directly onto the pump for easy disconnection, or alternatively flanged fittings to either ANSI 150 RF or BS4504 PN16 specification. Motor powers range from 0.75kw to 4kw to cover the complete hydraulic characteristics of the pumps with a single size mag drive coupling. The ATEX version complements the standard STN series, being manufactured for more than 8 years in standard Polypropylene and ETFE materials, and have been used widely in the chemical distribution industry, CIP applications, OEM installations as well as small scale chemical plants and transfer duties.
Armstrong - May 2010
ARMSTRONG GETS DOWN TO BUSINESS WITH PACKAGED PLANT ROOMS FOR LYDIARD FIELDS
Offsite manufactured plant rooms from Armstrong have reduced installation times for two top quality new office buildings at the prestigious Lydiard Fields Business Park. In addition to streamlining the schedule, the variable speed drive pumps at the heart of the HVAC systems will ensure long-term energy efficiency by automatically reacting to the heating and cooling requirements of each building. Washington House and Auckland House represent the second of three phases at the Lydiard Fields Business Park in Swindon, located adjacent to the M4 motorway. Developer BAM Properties purchased the site in May 2004 and has already let some of the previously completed buildings, including Canberra House and Kingston House. When planning the final two projects, BAM - which used the construction arm for the building - and its M & E contractor Renelec Building Services, decided that an offsite construction approach would have significant benefits and approached Armstrong to provide packaged plant rooms. Armstrong constructed the two plant rooms at its production facility in Halesowen, West Midlands. The plant rooms incorporate HVAC systems for chilled water, hot water and heating. Incorporation of variable speed drive pumps means that the site will be able to minimise energy consumption. The Armstrong IVS pumps have built-in inverters which automatically calculate the building load throughout the day and night, matching the pump speeds to the demand. These features, along with high efficiency low NOx boilers and a ‘Thermal Wheel' for ventilation heat and cool recovery have contributed to the offices receiving a ‘Very Good' rating from BREEAM. Manufacturing the plant rooms in the factory instead of at the construction site enabled the HVAC element of the project to progress concurrently with the build, rather than having to wait until the completion of the major works. On the date required, the plant rooms were delivered to site fully-assembled, in enclosures, requiring only final connections. This removed risks of bottlenecks such as adverse weather conditions and, as the work could be completed in the more easily controlled environment of a factory, the health and safety risks for the project could be minimised. The incorporation of variable speed drive technology has reduced the lifetime cost for the installation and enables BAM to offer the occupiers the benefit of reduced energy bills and improved carbon footprint. "Potential occupiers of office space are increasingly aware of the cost and CSR impacts of commercial buildings" said Steve Cooper, Director of Renewables and Sustainability at Armstrong. "The equipment choice for the Lydiard Fields office buildings established a long-term basis for reducing carbon footprint by eliminating wasted energy associated with fixed speed pump systems".
Mono - May 2011
NOV® MONO® CELEBRATES 75 YEARS
Flying the flag for UK manufacture for three-quarters of a century, NOV® Mono®, Europe's leading provider of progressing cavity pumps, parts, grinders and screens, will celebrate its 75th anniversary on May 13th 2010. Paul Naylon, Group Managing Director at NOV Mono, commented: "The progressing cavity (PC) pump has come a long way since its invention by French creator René Moineau in the 1930's and, as the UK's only licensee of this simple and effective pumping principle, we've taken a front row seat in its development over the past 75 years. "Originally the preserve of the water and wastewater industry, over the years Mono has introduced PC pump technology to a great many different sectors, revolutionising processes, minimising costs and improving efficiency. We are constantly striving to develop this technology to meet the changing needs of the many different markets in which we operate, which is why we have gone from strength-to-strength.
"Major innovations over the years have included the Mono Flexishaft®, which eliminates the need for a double universal joint or gear joints, the Compact C range of PC transfer pumps, the Muncher® range of disintegrators and the latest addition to the family, our revolutionary EZstripTM maintain-in-place PC pump. "These high performance products are used in sectors such as food and beverage, oil and gas, and chemical and pharmaceutical, as well as water and wastewater." Products in Mono's current pump portfolio can handle capacities in excess of 400 tonnes per hour and pressures in excess of 70 bar (1000 psi). These pumps are complemented by additional ranges of grinders, screens, packaged pumping systems and solar pumps. Mono has also developed a comprehensive range of Mono Universal Parts for use in other brands of progressing cavity pumps. These have been designed to be used in seepex®, Netzsch®, PCM, Allweiler, Robbins & Myers, Bornemann and Orbit pumps. Originally formed in 1935, Mono's continual development of product innovations and business practices has seen it thrive into the company it is today. The NOV Mono Group has 700 authorised distributors across the globe and employs over 640 people. Paul Naylon continued, "Through major investment in product design and manufacturing, Mono has made sure that the PC pump is even more relevant today than when it was invented 75 years ago.
Watson Marlow - May 2010
Watson-Marlow Masosine Technology Replaces Gear Pumps at Chocolate Factory
Watson-Marlow Masosine MR and SPS series positive displacement pumps have been installed at the Fakenham, Norfolk plant of chocolate and confectionary specialist, Kinnerton. The first Masosine pump was introduced to replace a gear pump that was damaging product on an Easter egg production line, with a second model acquired recently to support a newly installed caramel production line. The company has now decided to standardise on Masosine pumps moving forward. Established in 1978, Kinnerton today is part of Zetar Plc, and can boast a turnover of £60 million. At its manufacturing plant in Fakenham, the company produces confectionery ranging from Easter eggs and Advent calendars, through to chocolate bars and chocolate miniature figures, as well as chocolate lollipops. Around 600 employees help process over 7,500 tonnes of chocolate to make 1,200 different products every year. In high volume manufacture, production line uptime is vital to profitability and continuity of supply. However, a problem that arose in 2006 threatened to counter this ethos and it soon became apparent that a new solution was required. "We had an inclusion mixer on one particular line that was supported by an ageing gear pump," says the company's engineering supervisor, Phil Barwick. "The line was set up to produce a new white chocolate Easter egg with dried raspberry mixed in. However, when the fruit first went through the mixer, it was squashed by the gear pump - in effect producing ‘pink' chocolate Easter eggs." With Easter one of the company's peak production periods, a quick fire solution was needed. Fortunately a recent trade show attended by Kinnerton demonstrated the merits of Watson-Marlow Masosine positive displacement pumps and the company duly requested the trial of an MR125 model. "It was immediately apparent that it ticked all of our boxes," says Mr Barwick. "Not only did it not damage the product - even subsequently introduced biscuit pieces were damage-free - it was also exceptionally easy to maintain and clean." The MR series is a range of medium duty sanitary pumps offering flow rates up to 91,000 litres per hour and pressures up to 10.3 bar. Typical applications include chocolate, cheese, curd, yogurt, concentrates, yeast, batter and stews. With the MR125 operating trouble-free for the past four years, a more recent project was always likely to see a second Masosine pump introduced at the Fakenham site. "We wanted to establish an in-house caramel production line. The one problem with caramel is that it's very viscous when cool and can cause problems for certain pumps. However, we were confident that a Masosine pump would be up to the task," says Mr Barwick. Watson-Marlow recommended a Masosine SPS 2 sanitary/industrial pump. With a capacity up to 4 m³ per hour and pressures up to 15 bar, the SPS is ideal for viscous applications such as caramel, gelatine and glucose, as well as industrial products such silicones, adhesives and polymers. "We have three SPS 2 pumps on site, and not only do these handle the pumping requirements without a problem, they are incredibly easy to clean," says Mr Barwick. "Even after pumping glucose, a simple flush-through with water is all that is required." The focus on cleanliness is engrained in the manufacturing culture at Kinnerton, which in 1998 decided to create the world's first nut segregated zone in a food factory that handles nuts. The company invested £1 million at Fakenham to introduce a segregated area containing five production lines that can offer chocolate products that are produced on machinery that never runs nut products. In the nine years since Kinnerton first segregated its production facilities, it has produced more than 250 million chocolate products based around its nut segregated facilities and has never had a verified nut incident. Moving forward, Kinnerton has decided to standardise on Masosine SPS series pumps
Mono Pumps - March 2010
NOV® MONO® MAKES PUMP MAINTENANCE A PIECE OF CAKE!
One year on from the launch of its ground-breaking EZstripTM progressing cavity (PC) pump, NOV® Mono®, Europe's leading designer and manufacturer of pumps, parts, Munchers®, screens and packaged systems, has launched another maintain-in-place (MIP) innovation which is set to revolutionise the maintenance of a PC sludge cake pump. Specifically designed to minimise the time and cost involved in maintaining a progressing cavity pump, the new EZstripTM cake pump from Mono can be completely stripped down and rebuilt in just 15 minutes, without the need to disconnect or remove any pipe work. Simon Lambert, Mono's general manager for Europe, commented: "We were overwhelmed with the positive response we received from our customers following the launch of the original EZstripTM and we immediately began looking at other applications for this revolutionary technology.
With over 18 years experience in sludge cake applications, our decision to develop the new EZstripTM cake pump was an obvious one. The new pump features a specifically designed feed chamber that is disconnected by removing only a few screws and allows access to the pin joint area for removal of any blockages or compressed cake. Once the rotor assembly is disconnected from the screw conveyor, the rotor and stator can be removed - all in just six minutes which we think is remarkable by any standards." The EZstripTM cake pump is designed with a large auger inlet and screw conveyor. The screw conveyor extends to the compression area to help push the sludge cake into the cavities of the rotor and stator and provide consistent pumping. A side inlet port also allows the addition of thin sludge for blending applications or for draining the pump. The range is available in cast iron, with a choice of rotor and stator materials as well as a variety of hopper sizes and has a capacity of up to 49 m3/h and 24 bar pressure. Typical applications include thickened sludge cake (up to 40% dry solids content), dewatered sludge, lime powder dosing, sludge blending and barrier layer injection.
For more information visit: http://www.mono-pumps.com/.
Cat Pumps - March 2010
Cat Pumps extends its high-pressure pump range
Cat Pumps (UK) Limited has extended its 60 frame triplex plunger pump range to accommodate the high flow requirements of wash down systems, desalination plants and industrial users. The three model 6775, 6771 and 6777 range uses a new design of valve that enables flow rates of up to 284 L/min to be achieved at pressures ranging between 7 and 85 bar. The three models are available in a choice of Brass, Stainless Steel and Nickel Aluminium Bronze manifolds, giving users a balance between high strength, corrosion resistance and cost benefits. "There are a great many industry sectors where equipment for cleaning and wash down duties require a combination of high water flows and high pressures," says Cat Pumps UK general manager Brian Hubbard. "This uprated triplex plunger pump range employs a special valve design, which provides added durability under high flow operation to suit the most demanding duties." Industry sectors and applications which have been identified by Cat Pumps for this new pump range include food processing, multiple nozzle central cleaning plant, off-shore wash down systems and reverse osmosis water purification. To satisfy the demanding requirements of these types of application and to provide a long, low maintenance working life the valves and seats are made from 316 Stainless Steel and have been hardened and polished for ultimate sealing. Extended seal life is ensured by the use of special concentric, high density polished ceramic plungers and Cat Pumps' own design of high pressure Vee Packing seals.
Flowserve - February 2010
Flowserve Receives $31 Million Pump Order from LUKOIL Neftochim Burgas AD for Largest Bulgarian Oil Refinery
DALLAS-- February 25, 2010 - Flowserve Corporation (NYSE: FLS), a leading provider of flow control products and services for the global infrastructure markets, today announced a pump and solutions order worth more than $31 million, from LUKOIL Neftochim Burgas AD for Flowserve proprietary ebullating pumping systems and heavy-duty high-energy barrel pumps. The contract was signed in the first quarter of 2010. LUKOIL Neftochim Burgas AD, a subsidiary of Russian oil giant LUKOIL, is the largest oil refinery in the Balkans. The pumps will be used in the refinery's new H-Oil & VGO complex in Burgas, Bulgaria, which converts heavy residues to high-valued products. The H-Oil & VGO complex has expected capacity of 47,000 barrels per day. "High crude oil prices and declining supplies of light sweet crude oil are causing refiners to invest heavily in processes that maximize the yield from every barrel of oil," said Tom Ferguson, President, Flow Solutions Group at Flowserve Corporation. "Flowserve has developed proprietary pumping technology and solutions that are well positioned to support the growing residuum upgrading industry." Flowserve ebullating pumps are the only pumps in the world that can withstand the high temperatures and pressures required by the H-Oil RC process used at the Burgas ebullated bed hydrocracker. The pumps will be equipped with Flowserve Technology AdvantageTM Online AssuranceTM, a program available through the newly formed Flowserve Integrated Solutions Group that is designed to provide 24/7 monitoring and life-cycle management to optimize asset availability. Flowserve will support the LUKOIL Neftochim Burgas H-Oil & VGO project through its global network of Quick Response Centers (QRCs). QRCs offer a wide range of service and support activities to help customers maximize the effectiveness of their operations
Armstrong - February 2010
Lancashire Constabulary cuts energy costs and reduces carbon footprint with Armstrong packaged plant rooms
By replacing its old oil-fired boiler house, with four new Armstrong offsite manufactured packaged plant rooms, Lancashire Constabulary has reduced the energy bills for the Hutton Hall site by £245,633 per annum. It has also reduced CO2 emissions by 744 tonnes a year. Offsite manufacture enabled the new system to be installed within an extremely tight timescale (which would have otherwise meant site occupants being without heating and hot water in the winter months). Lancashire Constabulary has responsibility for 220 buildings, including police stations and operational centres with an annual energy bill approaching £500,000 per year. The system for supply of heating and hot water at one of its largest sites, the Hutton Hall Police Training Centre, in Preston, Lancashire , was in urgent need of replacement. The centralised oil-fired boiler, with two calorifiers for hot water supply, had ceased to manage the site's demand effectively some years previously, necessitating the installation of new heating systems for the accommodation blocks. In 2006, it became necessary to install replacement systems for the remaining buildings at the site, including a sports hall, administrative centre, firing range, dining room and teaching block. The existing system was inefficient, with extensive distribution losses, and engineers advised the Constabulary that the boiler could not meet the needs of the site over the coming winter.
Project priorities
Lancashire Constabulary had a number of priorities. As the site is financed from public funds it was important to reduce the energy costs as much as possible. The energy manager, Ed Palmer, who has developed the Constabulary's sustainability policy, also wanted to capitalise on the opportunity to improve the energy efficiency and carbon footprint for the estate, and to position the site to meet increasingly stringent environmental legislation. A key part of this strategy involved a move away from oil towards a gas-fired system with reduced carbon impact. The nature of the operations at Hutton Hall also had an impact on the choice of equipment. The site houses several buildings with 24/7 demand, such as call centres on 24-hour duty, and the National Police Computer Database HQ. The timescale of the project was such that, once the capital investment was approved, there was insufficient time to carry out the installation (using traditional onsite methods) before the onset of the colder weather. An alternative solution was sought that would ensure continuity of supply of hot water and heating for the site's occupants.
Armstrong solution
Ed Palmer carried out a feasibility study comparing three alternative approaches. The solution which proved to be the most effective was the installation of four offsite constructed packaged plant rooms, incorporating highly-efficient variable speed systems based around the Armstrong MBS integrated heating solution, controlling Armstrong IVS pumps and pressurisation equipment. The MBS incorporates fully modulating boilers, variable primary pumps, automatic fill/pressurisation unit and integrated controls, all pre-specified for optimum efficiency, and pre-assembled for rapid installation on site. It enables excellent boiler efficiencies to be achieved and exceeded without time-consuming mixing and matching of system components. Instead of treating the condensing boiler in isolation, the MBS matches pumps, controls and hydraulic system design. This ensures compatibility of components and enables specifiers to meet and exceed the boiler efficiency levels required under the new Part L of the Building Regulations with energy-efficient, low carbon performance designed into the system as standard. Part L2 calls for minimum overall boiler efficiencies of 84% in new build and 80% in existing buildings. The MBS can achieve overall seasonal efficiencies of 94%, providing significant energy savings and carbon reductions throughout the lifetime of the plant. As the system is fully integrated and pre-assembled, additional system design input is not necessary, and installation and commissioning can be achieved much more easily and quickly.
Cost savings and energy reductions
A year after the installation of the plant rooms, Lancashire Constabulary has been able to analyse the resulting energy reductions. The energy requirement of the site was reduced from the equivalent of 4,503,600 kWh per year to 2,550,730 kWh per year. A saving of 1,952,870kWh. The reduction of 1,952,870 kWh in energy consumption, calculated at a cost of 6.5p per kWh (oil) equates to an annual saving of £126,936.55. As the site has moved away from an oil-fired boiler in favour of highly-efficient condensing boilers there are further reductions in energy costs arising from the prices differences between gas and oil. Calculated based on a gas price of 1.8p per kWh and an oil price of 6.5p per kWh, the cost saving as a result of change of fuel is £118,696.45. This means that the total cost-saving amounts to £245,633 per annum. It is estimated that the four packaged plant rooms have paid for themselves in one year.
Environmental improvements
The environmental benefits have also bee considerable.. Calculated at a rate of 0.27 kg of CO2 per kW, the move to the new system has reduced carbon emissions by 525.27 tonnes per year. As the plant rooms use gas for heating instead of oil, there is a further reduction in carbon emissions resulting from the change of fuel of 217 tonnes of CO2 per year. This amounts to an overall reduction in CO2 emissions of 744 tonnes per year.
Streamlining the project
Constructing the packaged plant rooms off site also had project benefits. The packaged plant rooms were assembled concurrently with the excavations for the gas pipes rather than commencing once this work was completed. This significantly shortened the timescales for the project making it possible to complete it by the target date of the start of October. The installation time was also reduced from several weeks to just a few days. The plant rooms were delivered to site, fully assembled, requiring only final connections.
By completing the project by the target date, it was possible to guarantee continuity of supply of hot water and heating for site occupants. Traditional onsite methods of plant room construction could not have met the target date and would have continued into the winter months. Finally, manufacturing the plant rooms in a purpose-designed factory instead of at the Hutton Hall site reduced the health and safety risks associated with the project. Contractor presence and traffic at the Hutton Hall site was also reduced. Ed Palmer, Energy Manager for Lancashire Constabulary said, "It was only when we analysed the energy consumption the end of the first year, that we realised just how much money the packaged plant rooms had saved the taxpayer. The equipment has paid for itself in just a year, and will continue to deliver cost savings throughout its life. "In addition, with the timescale we were working to, there simply wasn't any other way that we could have completed the installation before the onset of cold weather. And being without heating and hot water was not an option."
Grundfos - February 2010
Grundfos put in great performance in Vancouver.....
The 2010 Winter Games in Vancouver have been much anticipated. The stunning backdrop of British Columbia is a spectacular setting for the athletes who gathered in the hope of being crowned Olympic champions. Also gathered to give their best performance were a total of 2077 Grundfos pumps and packaged sets who provided support for both the athletes and the media who gathered, from all the corners of the globe, to be part of this momentous event. Supplying a wide range of pumps, all of whom were specifically selected for their sustainability, many different applications have benefited from Grundfos solutions, including: water supply, heating, cooling and hot water applications as well as providing a wide range of bespoke pressure boosting sets that included sets for use in rainwater harvesting applications that will reduce potable water requirements by over 30%, where fitted. We all have our favourite sports - whether it's the speed and agility of alpine skiing or speed skating; or perhaps the grace and control of the figure skating or snowboarding; or perhaps the excitement and danger of the luge or ski jumping. Whatever your sporting preference the games will deliver many performances that will live long after the games are over as will the many pumps supplied by Grundfos
