As part of a gas field expansion in Saudi Arabia, an international group approached the specialists at pump manufacturer Lewa Nikkiso Italy in February 2019 to commission the planning and delivery of 16 canned motor pumps. The systems that were ordered will be used in Saudi Arabia in raw oil processing and removing unwanted by-products from the gas flow. In addition to powerful pump technology, it is crucial to remove the medium reliably and safely, since the substances separated with this method often form a toxic, highly corrosive mixture. The Nikkiso Non-Seal pumps being used function without dynamic seals and also feature twin safety shells consisting of an inner stator lining and external pressure-resistant stator housing. As a result, leakage and the associated risks for the environment and employees can be effectively prevented. An integrated E-Monitor also ensures increased process safety at the customer’s onshore installation by monitoring the bearing conditions of the hermetically tight pumps. The project is expected to be completed in 2020, including detailed planning and procurement plus construction and installation work.
In the course of raw material processing, unwanted by-products are continuously removed from the oil or gas flow. “The unusable mixture of substances that is derived from the clean gas flow mostly consists of hydrogen sulfide, carbon dioxide, and amines,” explained Riccardo Marcotti, Senior Product Manager at Lewa Nikkiso Italy. “Hydrogen sulfide is particularly worth mentioning here, since it is a highly toxic chemical compound even in very low percentage and, dissolved in water, it is also highly corrosive to piping and equipment by sulfide stress cracking.” This is why it is only possible to remove unwanted by-products with conventional pump technology to a limited extent – the risk of leakage and thus the release of hydrogen sulfide in the atmosphere is too high.
Second protecting shell and elimination of dynamic seals
In light of these challenges, the global oil and gas company contacted Lewa Nikkiso Italy, a subsidiary of the Leonberg pump manufacturer, in February 2019 and commissioned the production and delivery of a total of 16 Nikkiso Non-Seal canned motor pumps. The pumps are necessary to guarantee that the toxic by-products are transported without complications, while avoiding negative effects on the environment and personnel at the expansion of the onshore gas field. “As you can imagine, the user’s requirements for pump quality and project organization were very detailed,” said Marcotti. “Above all, the customer placed priority on the aspects of pump reliability and safety. Our Nikkiso canned motor pumps were able to meet their standards optimally.”
In total, the delivery to the major customer from Saudi Arabia includes six type HN23F-D2 canned motor pumps, two type HN24E-D3 models, four pumps in the HN23F-D3 basic design – as well as additional four warehouse spare pumps – each model sized for rated performance conditions. All of the variants being used feature a motor that is integrated right into the respective canned motor pump and is protected against leakage by a seal-welded, corrosion-resistant lining. And the entire motor exterior is encapsulated in a second leak-proof protective shell. As a result, we can eliminate the possibility the mixture will escape and contaminate the surrounding area and the environment. “Omitting dynamic seals has also allowed us to significantly boost operating safety during the work process,” added Marcotti.
E-Monitor determines current bearing condition
Absolute process reliability also includes ensuring constant motor cooling to prevent immediate and long-term damage to the pump. Therefore, in the canned motor pumps being used, the medium being conveyed circulates in the area between the rotor and stator lining, affecting the motor temperature while lubricating the slide bushings at the same time. The integrated thermostats attached at the overheating points of the winding monitor the temperature and switch the motor off in case of overheating. This prevents subsequent damage.
In addition to monitoring the temperature, it is possible to check the bearing condition during pump operation. To do this, the sensors integrated into the stator transmit the relevant measurement data to a modern E-Monitor – for example, if the rotor leaves the safe operating position due to bearing wear. The sensors register this type of status change and report it to the monitoring unit. “A green LED lights up on the display to indicate a good bearing condition to the personnel, for example,” explained Marcotti. “A yellow light, on the other hand, indicates that the pump should be checked during the next system downtime. If a red LED lights up, the pump must be shut down immediately.” The device makes it possible for customers to perform preventive maintenance work based on bearing wear and check that the pump’s direction of rotation is correct. As a result, it is not necessary to measure phase rotation during commissioning.
Everything from a single source
In this major project in Saudi Arabia, Lewa Nikkiso Italy has been entrusted with the full spectrum of project implementation. This means the subsidiary of the Leonberg Group has been commissioned with detailed planning and procurement, as well as carrying out the supervision assistance for construction and installation work. “Thanks to our extensive experience with other EPC projects, we will be able to meet all the existing requirements without a problem,” said Marcotti. “In addition to the necessary levels of safety and reliability, this applies to the specifications for compactness and maintenance, in particular.” The modular structure of the pumps to be delivered is helpful here, since they consist of just a few components. All that is required is straightforward assembly and maintenance – without any spacer discs or clearance settings. And no additional motor or pump bearing lubrication is needed, since the medium being transported coats the sliding parts on its own. “This makes the pumps extremely easy to maintain and minimizes expensive downtime at the same time,” Marcotti explained. Delivery of the 16 canned motor pumps is planned for February 2020; he expanded onshore gas field is expected to start up in 2022.
Boosters are needed when, for production-related reasons, compressed air is required at a higher pressure than network pressure. With innovative speed-controlled all-in-one systems, Kaeser Kompressoren is proud to open a brand new chapter in booster compression.
Kaeser’s new boosters provide the ideal solution for compressed air users in the brewery industry who require higher pressure air. As the first all-in-one booster system, the DNC series from Kaeser is now also available with variable speed control and with motor powers from 22 – 45 kW. As a result, the compressor flow rate is matched to actual air demand, which means that only as much energy is consumed as is needed to produce the supply of higher pressure compressed air. The system is therefore also especially efficient in the partial load range since the compressor switches to idle operation when air demand drops below the control range. Compressor operating speed and energy consumption are consequently kept to a minimum.
The DNC SFC system is delivered ready to connect complete with sensors and frequency converter. All systems are CE and EMC certified and thereby minimise planning, construction, certification, documentation and commissioning cost for operators and equipment manufacturers. The efficient compressor unit, the compact enclosure and the entire electrical system are mounted on a space-saving base frame. Moreover, the highly effective sound insulation panelling helps ensure low-noise operation with low compressed air discharge temperatures. Connection of the booster system to an advanced master controller, such as the Sigma Air Manager 4.0, is made possible by the integrated Sigma Control 2 controller. This technology also enables integration of the booster package into Industrie 4.0 production environments.
Kaeser’s new CNC series machines are the ideal choice for breweries with smaller air delivery requirements. With motor capacity from 7 to 22 kW, they will also be available both as standard and frequency-controlled versions in all power ratings.
Efficient solutions in the low pressure range
With a motor capacity of 7.5 to 22 kW and flow rates of 2.3 to 12.2 m³/min, the CBS rotary screw blower provides the perfect solution for users, for example, who require air for wastewater treatment in operational clarification plants with a pressure differential of up to 1100 mbar. The blower also shines through with its many benefits when it comes to liquid aeration, flotation, fluidisation and bioreactor applications. It is up to 35 percent more efficient than comparable conventional rotary lobe blowers and even offers significant energy advantages in the double-digit range compared with many other rotary screw blowers on the market. In fact, a rotary screw blower is so powerful that it can easily and effectively cover the control range of two to three rotary lobe blowers.
Kaeser at the Brau Beviale 2019: Hall 4, Stand 441
One step ahead
Gas odorization for networks up to PN 16
According to the German Energy Agency (dena), biomethane production in Germany may increase as much as ten times over – from currently 9 terawatt hours to about 100 – by 2050. What is more, natural gas is the most important energy source for private households and accounts for 44 percent of the heating market. Before natural gas or biogas is fed into commercial supply networks, it must have an odorant added to it. Odorants serve as a warning in case of leakage. Since the last few years have been marked by a trend toward decentralized production, Lewa has added the MAH 4 size to its micro-metering pump portfolio as a proactive measure for meeting the expected increase in demand. The new unit can be used for odorizing with mercaptans or tetrahydrothiophene at a throughput rate of up to 12,500 Nm³/h. The pump covers the flow range from 200 to 250 ml and can be used as a cost-effective solution in accordance with DIN-EN 1333 for gas networks up to PM 16. At this year’s Gat/Wat trade fair, the company is presenting the new pump model for biogas, natural gas, and liquefied petroleum gas odorizing systems alongside many other products in hall 07 at booth C016.
“Back in early 2018, we started getting more requests for odorizing gas volumes of approximately 12,500 Nm³/h, to the point where it just made sense to design a pump specifically for that amount,” said Walter Richter, Sales Manager for Gas Odorization at Lewa. “The right way for us to respond to this trend was to add an intermediate size, the MAH 4, to our hydraulically actuated and solenoid driven micro-metering pumps from the MAH, MBH, and MLM series. The new size meets the requirements for this range exactly.” The new unit closes the gap between the MAH 3 and the MAH 5 – something that had previously been done using the larger MLM 15 series. However, the stronger stroke solenoid made that design over-dimensioned and less cost-efficient in some cases. Neither the MAH 3 nor the MAH 5 units from the same series were cut out for the job. There was always one of two problems: either they could not manage to pump at the required output of 16 bar, or they could manage a sufficient flow rate at 600 ml but were not designed for the necessary discharge pressure.
The MAH 4 micro-metering pump as a cost-efficient solution
The pump experts at Lewaclosed a gap in the series by developing this unit. The MAH 4 makes it possible to odorize gas volumes of up to 12,500 Nm³/h with precise metering and in a flow range of 200 to 250 ml. Like all solenoid-driven diaphragm metering pumps from Lewa, the MAH 4 also consists of an electromagnetic drive with stroke setting, a pump head with metal diaphragm and a control system contained in a separate housing. “The metering pump is actuated with pulses,” explained Richter. “The discharge stroke is executed by the armature of the magnet. The suction stroke takes place after switching off the electrical pulse using the force of the thrust spring.” The highly reliable, robust pump features a safety switch. An overload – due to a closed valve in the discharge line, for example – automatically leads to magnet standstill, as its force is limited. “In the worst case, a closed valve in the suction line would, cause cavitation,” Richter added. “After the faults are remedied, the pump simply continues pumping.”
Under the same basic conditions, the MAH 4 stands out for its metering accuracy of ± 1 percent and, thanks to the wide control range up to 1:1,000, outstandingly high metering flexibility. Further, its design is absolutely odor-tight and leakage-free, safe from dry runs and features high process reliability. The only difference between the new MAH 4 and the proven MAH 5 is that the new size has a different inner diameter for the plunger and bushing. Both dimensions were reduced from 5 to 4 mm. Thanks to the adjustments and optimizations made to those dimensions, the MAH 4 serves as a cost-efficient solution for the specific range of applications and is perfect for its requirements.
Lewa at Gat/Wat 2019: hall C, Stand C016
Adding value with state-of-the-art separation technologies
Smart solutions for the beer-brewing process
International technology group Andritz is presenting its unrivalled range of separation and filtration technologies for the beer industry at BrauBeviale in Nuremberg, Germany, from November 12 to 14, 2019, hall 7, booth 7-421. Experts from Andritz will be on hand to provide specialist support for a wide range of brewing processes from mash filtration to yeast beer recovery and beer filtration.
The solutions cover a wide range of separation and filtration processes and equipment needed for beer production – from filter presses and dynamic crossflow filters to decanters and separators.
One special product designed exclusively for the brewing industry is the Art Brew beer clariﬁer, the latest version of which will be showcased at BrauBeviale. Combining efficiency and ease of maintenance, Art Brew is a high-quality and simple-to-operate beer clariﬁcation solution, which comes as a plug-and-play unit for the craft beer industry but also in large sizes for industrial beer production.It comprises a unique inert-gas sealing system known as KO2 (knock-out oxygen) that prevents unacceptable levels of oxygen pick-up between the clarifier inlet and outlet connections. Thanks to its small dimensions and custom configuration, the Art Brew is not only highly efficient, but also a very compact solution that is quick to install. The Art Brew range caters to brewers of any size, with a beer clarification capacity ranging from 50 to 700 hectoliters per hour. Visitors will be able to explore the Art Brew’s control options and see the process clearly from close quarters.
Another separation technology that has proven its worth for producers of a wide range of beverages is the Andritz Dynamic Crossflow Filter (DCF). Its rotating membranes allow users to separate highly viscous sludges like surplus yeast up to yeast concentrations containing more than 25% by weight, thereby ensuring optimum yeast beer recovery with the highest filtration quality. Because breweries no longer have to dilute the yeast with water in order to process it, the filtered beer can be blended with the main stream without any impact on the quality or alcohol content. As a result, this method becomes an interesting alternative to traditional concentration technologies.
The membrane filter presses ensure that the effective filtration of mash is kept at a constant, high quality level. As filter press filtration is a sealed process, the risk of oxidation is kept to a minimum. Additional peace of mind comes from the fact that Andritz filter presses are not only easy to clean and come with the option of cleaning-in-place solutions, but the components also conform to FDA standards. In addition, brewery customers in particular benefit from the fact that Andritz filter presses can be adjusted to a variety of processes and recipes.
With the development of Metris addIQ control systems, the company has taken the lead in IIoT (Industrial Internet of Things) solutions for solid/liquid separation processes and offers a wide range of innovative products and services under the Metris technology brand. These technologies allow the evolution of separation processes towards fully automatic operations. In addition to user-free operation, the biggest advantages lie in the fields of predictive maintenance and risk mitigation. The innovative automation solutions add a new dimension to the performance of production facilities by minimizing downtime and maximizing product yield, quality, and consistency – even for operations that are already up and running. Furthermore, they are completely scalable and backed by a specialist network of global automation experts.
One specific smart product that appeals to brewers is the intelligent filter press. Equipped with a Metris addIQ control system, the intelligent filter plate within the filter press is able to measure the residual moisture content in the spent grains while simultaneously monitoring this factor online. This means that the filtration process is always stopped at the ideal moment – gaining valuable filtration time and therefore a higher filtration capacity.
And the expertise doesn’t end with technology – whether customers need spare parts, rentals, local service, repairs, upgrades, or modernization of equipment, Andritz is a full-service provider. From initial consulting through to service agreements, process optimization, and training programs, Andritz specialists are always looking for ways to minimize downtime and increase predictability in operations while raising overall production efficiency. The network of 550 service specialists and global service centers ensures that the firm will always be there to support its customers for many lifecycles to come.
Andritz at the Brau Beviale 2019: Hall 7, Stand 421