PRODUCTS & APPLICATIONS BOILERS, PUMPS & VALVES IMPROVING PUMP EFFICIENCY AN ENERGY EFFICIENT BURNER


According to studies by the Hydraulic Institute and Europump, pumping


systems account for nearly 20% of the world’s electricity energy demand and from 25-50% of energy usage in certain industrial plant operations. But one way to improve the efficiency of an industrial pump is to apply a protective coating. At one UK automotive manufacture,


a 22kW ELPO pump, used for handling process water, was found to be under- performing by a minimum of 30%. Once dismantled, a number of problems were found including the pump being heavily corroded, the seal had seized, etc. So, all components that required coating


were steam cleaned, then LOCTITE 7515 was used to pre-treat the substrates to prevent corrosion and improve adhesion between the metal parts and the polymer composite coating. Next, LOCTITE 7177 was applied as a


‘hold coat’ to smooth the surface imperfections and provide a key for the thicker layers required to return the pump to its original dimensions. A ‘build coat of LOCTITE 7226 was then used to create a tough surface, resistant to future wear, followed by another coat of LOCTITE 7177. The pump was then fitted with new


bearings, and both oil and mechanical seals. The impeller was dynamically balanced, the pump re-assembled and a new 22kW high efficiency motor fitted. Motor and pump were finally installed on the bedplate and laser aligned. The second performance test was


then conducted and found the remedial work had restored the pump to original specification, increasing its efficiency by 30%. The cost of the repair amounted to £5,542. But offsetting this, in the first year alone, was an estimated energy reduction of £3,936. This was calculated at £0.08/kWh at 12 hours per day with an 80% load.


Henkel www.henkel-adhesives.com


New from Babcock Wanson is the Optimo 1 burner. This has all the technological innovations of the Optimo 2 burner (for medium size firetube Steam Boilers), but in a burner designed for smaller output boilers with a capacity of 1-2t/h. Compliant with all applicable regulations, Optimo 1 has been


designed for energy efficiency. It performs with a very high turndown ratio, enabling the burner to adjust its output to meet the needs of the process, avoiding the costly energy losses incurred by continual stop/start cycles. Three interchangeable combustion


air fans, covering the power range 1t/h, 1.5t/h and 2t/h, enable Optimo 1 to perfectly match the boiler requirement and allows greater burner turndown as well as reduced electric consumption when operating at lower power levels. Furthermore, the wider fan range helps reduce noise emission levels. The new casing has all the electronics of the combustion


equipment integrated directly into it, facilitating its interface with a customer’s plant. This, combined with a new Burner Management System, make it easy to install and set up. Optimo 1 is suitable for use on new steam boilers but can


also be retrofitted to upgrade existing boilers. Babcock Wanson


BOILER FEED PUMPS MEET ENERGY MARKET DEMANDS


Argentina’s diverse energy market is one of the most dynamic in Latin America, with significant ongoing investments in both renewable and conventional power generation. Thanks to its expertise in the design and manufacture of pumps, as well the support it provides, Sulzer is often chosen by the country’s energy providers. In fact, over the past 18 months, the company has delivered 70


large-capacity boiler feed pumps to customers in Argentina for both new-build power stations and upgrade projects. Most orders were for groups of three or four pumps, with some customers requiring multiple sets of pumps for different power plants. Boiler feed pumps for power stations are complex, precision-


engineered products, with some modular pump designs incorporating up to 14 stages. Most pumps are manufactured to order, and on-time delivery is a critical requirement for end users and EPCs alike, who are working to tight project timescales. Energy costs are influenced by the running costs of power stations,


which in turn is affected by the efficiency of the equipment used to generate the electricity. As more power stations are commissioned, the choices made at the design stage – such as the pumps to be used – can affect performance and efficiency for many years.


Sulzer www.sulzer.com PLC-BASED BOILER SEQUENCING SYSTEM


Now available from Fulton is SCOPE, a PLC-based boiler sequencing control system that can optimise installations to ensure energy efficient operation and improve boiler longevity. SCOPE is a universal control system


suitable for sequencing up to four steam boilers. It can be retrofitted to existing vertical and horizontal fuel- fired boiler installations, including Fulton’s own range of existing and planned products and those manufactured by other boiler OEMs. This has a high-definition touch


screen used for system programming and displaying boiler status, with values presented including firing rate, fault history, and TDS value


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logging. Additional features include remote access; lead/lag control of up to four boilers; multiple setpoints for lead, assist lag and banked control; steam header pressure monitoring with low/high alarm warning facility; automatic changeover of banked/lag boiler in the event of a fault or increased steam demand; automated slow-opening steam valve control to assist safe operation of boiler priority, emergency steam valve and/or boiler shutdown; hot-well temperature control; and boiler status, steam flow and hot-well tank temperature logging.


Fulton www.fulton.co.uk Swagelok AUTUMN 2020 | ENERGY MANAGEMENT www.swagelok.com / DESIGNSOLUTIONS www.babcock-wanson.com


BALL VALVE OFFERS HIGH FLOW RATES


Swagelok’s full-bore, bidirectional, flow– capable GB series ball valve provides high flow rates at a working pressure of 6000 psig (413 bar) while simplifying installation, minimising rework requirements, and delivering reliable shutoff performance. According to the company, the product


can be widely deployed as a general- purpose ball valve. Examples of ideal applications include hydraulic, injection, and fire suppression systems in the oil and gas industry; isolation for compressed natural gas (CNG) vehicle infrastructure; and isolation in highly corrosive alkylation operations in the chemical and petrochemical industry. When combined with Swagelok’s broad range of tube fittings, tubing and instrument valves, the new ball valve enables customers to build a complete 6000 psig-rated fluid system with tubing diameters up to one inch using all Swagelok components. The valve is designed for quick, easy


setup, with bidirectional flow eliminating concerns about backwards installations. Integral Swagelok end connections that range in size from 3/8in to 1in further simplify system design. Body seal performance is validated through hydrostatic system proof testing up to 1.5 times the maximum rated pressure.


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