vices Efficient - · PDF fileEfficient plant shutdowns 3D printing: The ultimate 9 supply chain 40 years of ... Bringing the NIS Gazprom Neft refinery in Serbia to Euro Level 5

Metso customer magazine for the flow control business » ISSUE 2/2015

A long history in expert services

Good planning is the key to success

Page 4 »

Efficient plant shutdowns

3D printing: The ultimate supply chain9 40 years of

butterfly valve performance24 Increasing

pump wear life at a copper mine28

PUBLISHED BY Metso Flow Control Inc. P.O. Box 304, FIN-01301 Vantaa, Finland tel. +358 20 483 150 [email protected] metso.com/valves

EDITOR-IN-CHIEF Kati Tattari, [email protected]

DESIGN AND LAYOUT Brandkind, brandkind.fi

PRINTING Hämeen kirjapaino Oy, December 2015

ISSN 2343-0540

ADDRESSES Metso customer data

© Copyright 2015 Metso Flow Control Inc.

All rights reserved.

Reproduction permitted quoting “Results flow control” as source.

All product names used are trademarks of their respective owners.

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results flow controlResults flow control customer magazine is published two times a year in English.

ORDERS To receive your personal copy, please contact your nearest Metso office or the e-mail provided.

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“Our flow control service network is very unique and enables good service levels for our customers globally.”

TIMO HÄNNINENVice President, Flow Control Services

28

35

20242 results flow control 2/2015

» Making the big difference

04 PLANT SHUTDOWN Good planning is the key to success

08 3D PRINTING The ultimate supply chain

» R&D

12 READY FOR THE CHALLENGE Valves to enhance fluidized-bed polymerization

16 SIL 4 – AM I SAFE NOW? Evaluating important aspects of safety valves

» Metso experts at your service

20 40 YEARS OF SERVICE EXCELLENCE World-class flow control service & the people behind it

» Technological development

22 FROM IDEA TO ORDER IN SIX MONTHS The cooperative design of the BWX valve from Metso

24 40 YEARS OF BUTTERFLY VALVES The birth and development of Neles butterfly valves

27 CURRENT Latest product & solution news

» The world is our showroom

28 INCREASING PUMP WEAR LIFE IN A COPPER MINE Adding a pumping stage at Kanmantoo copper mine in Australia

31 INCREASING RELIABILITY WITH EMERGENCY SHUT-OFF VALVES Bringing the NIS Gazprom Neft refinery in Serbia to Euro Level 5

32 KEEPING THE HEART OF A COAL MINE PUMPING Major pump delivery to KTK Kaskad 2 plant in Siberia, Russia

34 NEWS Latest Metso News from around the World

Metso is the world’s leading industrial company in the flow control business. Our knowledge, people and solutions help drive sustainable improvements in performance and profitability in our customers’ business.

PROVEN RELIABILITY, increased process efficiency and safety are counted as key targets by many of our customers, which is why they are targets that we simply must meet.

WE HAVE a unique set of assets for serving our customers today and in the future. We have more than 90 years of experience delivering engineered performance and reliability, and more than 40 years of experience in providing flow control services.

BY UTILIZING our strong global operational network and combining our industry-leading solutions and services with our vast knowledge of various industry requirements and our competent valve and pump professionals, we can make the big difference to our customers. To our valued customers, this means that we can offer the best possible valve and pump solutions that truly support their performance. We are at your service.

JOHN QUINLIVANPresident, Flow Control

CUSTOMER CASES FROM AROUND THE WORLD: metso.com/showroom

METSO TECHNOLOGIES IN THE WORDS OF OUR EXPERTS: flowexpertblog.com

EDITORIAL

MORE EXCLUSIVE CONTENT ONLINE:

3results flow control 2/2015



Plant shutdownTurnaround, shutdown, outage or revision – there are many names for the complex event in which an entire process unit in oil or gas production is taken off-stream for renewal. In June of 2015, Neste’s Porvoo refinery in Finland completed the largest turnaround in its history. Metso’s service solution for the turnaround consisted of valve maintenance planning, spare equipment, maintenance and spare parts, as well as real-time project process follow-up.

TEXT: Marjaana LehtinenPHOTOS: Aleksi Koskinen

WATCH VIDEO FOR MORE about successful shutdown planning: https://goo.gl/cjdFWU

COVER STORY NESTE REFINERY, FINLAND

Good planning is the key to success

IMAGE: A well-planned and efficiently executed shutdown ensures a safe and reliable process

until the next planned shutdown.



ROFESSIONAL PLANNING, efficient execution and on-time startup ensure safety as well as high valve availability and reliability until the next

planned shutdown. A major shutdown interval in the oil and gas industry usually ranges from three to six years. Metso was already involved in the previous shutdown in 2010 at the refinery in Porvoo. The maintenance carried out during the latest shutdown, which ran from April to mid-June of 2015, should ensure the reliability of the valves for the next five years. During any shutdown, it is essential to minimize all delays in order to stay on schedule as well as to ensure a smooth transition to normal production and to recover productivity as quickly as possible.

The successful turnaround project at the Neste Porvoo refinery was the biggest ever for Metso’s valve services business in

ABOVE: In terms of valve maintenance and services, the planning procedures for each shutdown are carried out by dedicated experts from Metso.

ON THE RIGHT: Careful planning ensures the availability of all the correct materials and people during a shutdown.

OPPOSITE PAGE: By analyzing equipment condition, we can pinpoint the equipment that needs proactive maintenance by Metso’s dedicated service experts.

Finland. All in all, about 270 Metso valves were maintained during the shutdown, providing the customer with significant improvements to valve availability. The targets set for such huge projects are typically clear: to maintain and improve availability, performance, safety and environmental compliance. Achieving them calls for a partner who not only understands the plant’s needs and targets, but also has expert services and proven methodology.

EXPERIENCE AND CONTINUOUS DEVELOPMENT | “Valve maintenance planning for the turnaround project was preceded by close cooperation between Neste and Metso. Metso’s installed base at the plant is quite large. So by using their valve maintenance know-how, we can be sure that the valves will operate with maximum availability and reliability

until the next turnaround,” says Jarkko Niittymaa, Maintenance Manager, Neste.

The fact that Metso has vast valve maintenance experience and in-depth expertise in shutdowns around the world provides customers with significant benefits. This year alone, the company has been involved in more than 100 shutdowns.

Timo Hänninen, Vice President, Flow Control Services, Metso explains, “To help our customers achieve outstanding, long-term process performance with high reliability and safety, we continuously develop our service knowledge, capability and scope of offering. It is extremely important that customers can rely on a supplier’s know-how during the tightly scheduled shutdown project.”

MINIMIZED RISKS AND IMPROVED SAFETY | Shutdowns are very complex

P

It is the level of planning that determines the success of shutdown execution.

ANNE HASSINEN, MANAGER, SHUTDOWN BUSINESS MANAGEMENT, METSO



and expensive projects. Anything can happen, leading to unexpected situations that interfere with schedules and postpone production startup. An extra day can result in losses of millions of euros or dollars. Being well prepared ensures that the planned downtime will not be exceeded. It significantly improves occupational safety, too.

“Our major concern is the safety of the customer’s and our own personnel. Therefore, our people follow the customer’s and Metso’s safety rules stringently, whether the work is taking place on site or at Metso’s or the customer’s service facilities. Following the rules and planning the work well are key to a safe workplace,” Hänninen emphasizes.

“A shutdown can be considered a strategic project for the plant, a way to manage the plant’s assets,” remarks

Anne Hassinen, Manager, Shutdown Business Management, Metso.

“Having us as a partner for shutdown planning ensures the availability of the correct materials and resources when needed. It minimizes risks and also ensures the safety and reliability of the process until the next planned shutdown.”

ATTENTION TO EQUIPMENT AND PROCESS CRITICALITY | To ensure the plant’s safe operation until the next planned shutdown, it’s important to carefully identify the equipment in need of upgrading, maintenance or replacement. This not only defines the shutdown scope and activities, but also determines the shutdown schedule and the needed resources and materials.

The scope is built based on maintenance needs, maintenance plans and equipment service intervals. “By

analyzing the equipment condition, we can select the equipment that needs proactive maintenance. Equipment should be maintained before it causes any disruption to production or presents any safety risks,” Hassinen explains. “Equipment and process criticality is evaluated together by our service experts and the plant personnel. Through installed base analysis, we make sure that the actions are defined based on actual product types.”

“Through careful planning together with the plant’s personnel, we are able to optimize the shutdown scope and the necessary actions, and thus make certain that the correct materials and resources are available during the shutdown,” Hassinen continues. Equipment maintenance is carried out with manufacturer’s parts, maintenance procedures and recommendations,

It is extremely important that customers can rely on a supplier’s know-how during the tightly scheduled shutdown project.

TIMO HÄNNINEN, VICE PRESIDENT, FLOW CONTROL SERVICES, METSO



so it is possible to guarantee safe operation until the next planned maintenance.

PLANNING DETERMINES EXECUTION SUCCESS | A shutdown is a chain of closely linked events. A well-planned shutdown scope, actions, materials and resources result in efficient shutdown execution and a smooth startup. Hassinen continues: “The actions of our people, on site and at the valve maintenance facilities, ensure that the plant is receiving high-quality valve maintenance and repairs during the shutdown execution. All maintenance activities are performed by our valve service experts and certified

NORTH AMERICA

Biofuels 4 Chemicals 8Natural gas 1Petrochemical 6Refining 34Pulp 20Paper 17Power 5Transportation 1

SOUTH AMERICA

Biofuels 2Refining 8Pulp 10Power 3

AFRICA

Chemicals 1Petrochemical 7Refining 14Pulp 5

EUROPE

Biofuels 5Chemicals 7Natural gas 24Petrochemical 18Refining 33Pulp and Paper 43Power 7Transportation 3

MIDDLE EAST

Chemicals 4Natural gas 3Petrochemical 2Refining 1Power 4Steel/Metal 2

INDIA

Chemicals 1Petrochemical 2Refinery 7Steel 2

CHINA

Petrochemical 1Refinery 1Paper 1

ASIA PACIFIC

Biofuels 1 Chemicals 3Natural gas 2Petrochemical 5Refining 3Pulp 1Paper 3Power 1

Shutdowns & turnarounds with Metso participation

IMAGE: In addition to numerous similar projects around the world, Metso took part in the Porvoo refinery’s largest-ever turnaround in the summer of 2015.

2015 FIGURES

smart product service experts according to Metso’s safety and quality standards.”

Despite careful scope optimization, it’s very likely that something unexpected will come up during the shutdown. For example, it may well be that a piece of equipment needs to be added on the maintenance scope at the very last moment. In such cases, it is crucial to be able to count on a shutdown partner who is capable of adapting and reacting quickly to the changing needs.

“It is the level of planning that determines the success of shutdown execution. Any unexpected event can have an effect on materials, schedules and resources, and thus jeopardize both the

project schedule and budget,” Hassinen says realistically. “During the planning phase, shutdown scope and actions are defined, but we must also be prepared for the unexpected during execution. Detailed planning with the plant’s staff enables us to be prepared and minimize unexpected risks.’’

To ensure a safe and on-time startup as well as a quick return to full production, expert support is available. Metso’s service experts, backed by the company’s whole extensive global network, promptly detect any problems and help to quickly resolve possible issues.

EVALUATION IS IMPORTANT, TOO | Once the plant is up and running, it’s time to evaluate and learn from the project for the next planned shutdown. “Additionally, we provide the plant with tag-specific service reports and test certificates as well as recommendations for future maintenance, upgrades and replacements to improve process reliability and safety,” Hassinen concludes.

MORE INFORMATION: Anne Hassinen Tel.: +358 20 483 5189E-mail: [email protected]



3D printing,additive manufacturing A convergence of technical and social advances is bringing 3D printing to mainstream large-scale manufacturing. The technology has revolutionized manufacturing, but its effects are felt throughout the supply chain. This article explores the potential of 3D printing and its impact on industrial companies.

FROM THE GUEST WRITER’S DESK

The ultimate supply chain 3D printing is predicted to become mainstream over the next decade

TEXT: Juha Turunen, Industrial Internet Lead, Accenture Digital PHOTOS: Tomi Parkkonen and Metso



PRINTING IS the process of making a physical object layer-by-layer based on digital

instructions. The process is also called additive manufacturing. The 3D printing principles were invented 1984. Since then, the use and application of the technology have increased annually.

Products that can be 3D printed come in all sizes and materials. For example, the first 3D printed pill was approved for commercial distribution in the US this

year. In China, a five-storey building was assembled from 3D printed modules. The smallest 3D printed object is the size of an ant’s forehead. Some of the components in F1 race cars are 3D printed, because their shape and performance requirements prevent them from being produced in traditional ways. An industrial equipment company is manufacturing the blades of gas turbines with 3D printing. The manufacturing costs of a space rocket have dropped from USD 50 million to 5 million thanks to 3D printing. And this is just the beginning.

FASTER AND MORE EFFICIENT PROCESSES | Companies and institutions are currently investigating how to improve their operations and processes by using 3D printing. For example, the US Navy is studying the possibility to produce all their spare parts at sea by 2025. EasyJet has revealed a 3D printing plan for speeding up repairs. For industrial company customers, 3D printing enables efficient maintenance operations, as spare parts and tools can be 3D printed on demand and on site, which is especially beneficial for sites that are remote or difficult to access.

3D printers help companies reduce the time and cost associated with prototyping parts and refining their design. For instance, General Electric’s Oil division has been able to shorten the development time from prototype to products from 12 months to 12 weeks. Besides rapid prototyping, 3D printing is also used for rapid manufacturing. It is a new method of manufacturing where companies use 3D printers for short-run custom manufacturing. In rapid manufacturing, the printed objects are not prototypes but the actual end-user product. The method

“3D printing is the process of making a physical object layer-by-layer based on digital instructions. The process is also called additive manufacturing.”

3D

Every company should have a clear understanding of how 3D printing will impact their business as well as a strategy on how it can be used to improve and change the business.

JUHA TURUNEN, INDUSTRIAL INTERNET LEAD, ACCENTURE DIGITAL



3D printing already widely utilized at Metso Flow Control

is used for manufacturing faucets and eyeware frames, among other products.

Over the next decade, 3D printing is predicted to permeate the enterprise as a mainstream digital capability. By taking steps now to understand how to leverage this technology, oil and gas companies will be positioned to disrupt their existing markets and penetrate new ones. By integrating 3D printing into the fabric of their operations, they will be able to transform the efficiency of their upstream supply chains and introduce new markets and new sources of revenue to their downstream businesses.

UNLOCKING THE BUSINESS POTENTIAL OF 3D PRINTING | 3D printing enables industrial equipment companies to generate profit from their long-tail products without big inventory costs and long response times. 3D printing also enables more customizable products. Companies can create one-of-a-kind products cost-efficiently, accommodating specific size and configuration requests as well as rounding out product lines by custom-making hard-to-find variations of a basic high-volume item.

3D printing and additive manufacturing also raise some new questions regarding the commercial use of the technology. For example, how is the quality of the 3D printed products guaranteed? What products are most suitable for additive manufacturing? What is the warranty of the 3D printed products? How can industrial companies protect the IPRs? There are no ready answers; each company needs to solve these issues as they enter the business of 3D printing. The chosen approach to these questions also opens up new collaboration opportunities.

Every company should have a clear understanding of how 3D printing will impact their business as well as a strategy on how it can be used to improve and change the business. The industrial equipment companies that make the first successful moves in this area will have a big head start, because they can help their customers implement an end-to-end digital supply chain, from prototyping to manufacturing to maintenance without warehousing and thus unlock the business potential of 3D printing and IoT.

A T METSO FLOW CONTROL we see 3D printing as a viable emerging technology of the future. We are already exploring the possibilities of utilizing this technology in future production. For example, 3D

printing might unlock new opportunities to supply rarely used spare parts quickly to our customers wherever they are located. Today this technology has already proven to be a valuable tool for the design and testing processes at Metso.

We regularly utilize a fused deposition modeling (FDM) 3D printer in the development of our valves and actuators. During product development we 3D print prototypes in order to verify designs in e.g. eccentric butterfly valves. Studying the mechanism with 3D CAD software is certainly done, but it doesn’t give you a realistic feel of the forces needed to open and shut a valve, for example. When designing new positioners or limit switches, we regularly use 3D printed prototypes to help visualize our designs and even to collect early feedback from customers.

And when plastic product or component prototypes are not sufficient, we use laser sintering for prototype parts. These metallic parts serve for testing purposes. We have also used this method to produce actual components needed in small batches. Our production also utilizes 3D prototypes when designing assembly jigs and fixtures in preparation for mass production. On the marketing side, 3D prints of valve components are often used for demo and training purposes. Even complete models of pumps have been known to get sent out to distributors and sales representatives as training tools or show-stopping giveaways.

MORE INFORMATION:Jukka Borgman Tel.: +358 50 591 3128E-mail: [email protected]

IN FOCUS



Valves to enhance fluidized- bed polymerization

Ready for the challenge

TEXT: Sari AronenPHOTOS: Metso & Adobe Stock


» R&D

The global olefins market is expected to grow by about 4% or more in the next several years. The packaging and automobile industries are examples of important users of polymers. The major source of olefins, the building blocks of polymers, namely ethylene, propylene, butadiene and isobutene, is steam cracking.

SOME VOLUMES OF OLEFINS are produced from catalytic cracking. On-purpose technologies, such as propane dehydrogenation, are also becoming more popular for producing olefins, especially in locations short of olefin supply from naphtha cracking. There are several licensors

offering technologies to produce polymers. Factors associated in selecting an appropriate technology license include, but are not limited to, the capability of the process to produce the desired polymer grades, diversity of the process technology, ability to produce specialty grades, catalyst options and cost.

There are three major types of low-pressure technologies, namely slurry, solution, and gas phase. Each type of process has limitations on the versatility of the resins it can produce. Gas-phase processes are either a stirred-bed type or fluidized-bed type. Gas-phase reactors have the widest operating window, but they encounter difficulties in producing polymers with very low densities due to stickiness and particle agglomeration. Gas-phase processes are very economical at producing commodity-grade polymers, and thus are popular with polymer producers. These polymers, for example, are linear-low-density-polyethylene (LLDPE), high-density-polyethylene (HDPE) and polypropylene (PP). This article focuses on the fluidized-bed type of gas-phase polymer process, and in particular on the challenges valves face in providing solutions for polymer product discharge applications to enhance process reliability and efficiency.

PROCESS OVERVIEW | In a gas-phase fluidized-bed reactor, gaseous monomer, co-monomers and proprietary catalysts combine to produce a dry, co-monomers resin. This resin – along with hydrocarbon vapor, unspent catalyst, and possibly polymer sheets and chunks – flows from the reactor to the product discharge system (PDS) where unreacted gas is separated from the product and returned to the reactor. The PDS consists of one or more product chambers, as well as an assortment of valves and piping for product conveyance, isolation, gas venting recycling and piping connections. Downstream from the PDS, the product is purged with nitrogen to remove

Metal-seated ball valve with

intelligent valve controller


» R&D

Metal-seated ball valves equipped with high-cycle piston actuators, such as Metso’s rugged trunnion-mounted ball valves, have been the choice for many polymer producers for critical applications in the gas-phase product discharge system, such as block valves and discharge line valves.

“Valves play an extremely important role in the successful product discharge system performance of a gas-phase polymerization reactor. ”

any remaining hydrocarbons. Finally, the granular polymer is pelletized with application-appropriate additives.

There are a number of pipes, also called ‘legs’, attached to the reactor to discharge the polymer from the reactor on a frequent basis. The discharge is based on pressure and gravity. The reactor pressure is around 30 bars. There is a continuous switching between the reactor discharge piping. After the polymer flow to the leg is switched to the other leg, the leg is cleaned by flushing it with ethylene or propylene gas to ensure no polymer dust or chunks remain trapped anywhere inside. The largest reactors are capable of processing 400,000 to 600,000 tons of polymer annually.

CHALLENGES FOR VALVES | Valves should be able to withstand a high-cycling rate, with a range from 200,000 to 1 million cycles per year, depending on the type of reactor and discharge piping. Meanwhile, in most applications, a fast cycle time of less than 2 to 3 seconds is required. Therefore, a high-cycle design and construction of both the valve and the actuator are essential. High-pressure differences over the valve, combined with pipe vibration and blending forces, require that the valves are highly rigid and have long-lasting tightness. Some medium may contain hydrocarbon vapor, nitrogen, resin, unreacted polymer and sometimes even sheets and chunks of polymer. The valve seat and bearing must resist the growth of polymer in cavities and grooves due to the continued polymerization of the media. Valve leakage

poses both an environmental and safety issue due to risk of fire, toxicity and the volatility of gaseous hydrocarbons. Graphite packing is usually not allowed due to the tight color specs of the final polymer product; the polymer has to be very clean, bright and clear. The modern catalysts that are used to improve the end-product polymer quality, when combined with the produced polymer, are harder and therefore more abrasive to piping and valves.

The market requires clean and high-quality polymers. It is important that the process is stable, flexible and under control.

Proper valve performance in the piping attached to the reactor, product chambers and the whole polymer discharge system improves the accuracy of throughput control and favorably affects the plant performance. Valves play an extremely important role in successful product discharge system performance. Polymer resin producers are looking for longer plant run-times, since downtime means production losses and represents significant costs that include maintenance costs. This calls for unquestionable equipment reliability.

WITHSTANDING THE HIGH-CYCLE POLYMERIZATION DEMANDS | Metal-seated ball valves equipped with high-cycle piston actuators, such as Metso’s rugged trunnion-mounted ball valves, have been the choice for many polymer producers for critical applications in the gas-phase product discharge system, such as block valves and discharge line valves. This choice has been made due to the polymer-proof metal seat that prevents polymer from penetrating behind the seat and seizing the valve, and due to the anti-abrasive feature that makes it a perfect choice for a hard polymer and more abrasive catalysts, which are nowadays widely used to improve the end-product polymer quality. The valve seating principle is very simple: the seat has continuous contact with the ball, wiping the seat surfaces with every cycle to prevent polymer build-up. This provides a means for reliable, long-lasting tightness and cycle life in these demanding applications.

The use of rotary valve technology provides a way to keep the volatile hydrocarbon emissions low during the whole cycle life. This is based on a certified, emission-proof stem sealing with live-loaded packing that is designed to keep its tightness, even in very high-cycle applications. This kind of high-cycle application calls for an actuator that is tested and field-proven to withstand a high number of cycles without failing.

An intelligent, integrated PDS valve controller, such as a Neles


» R&D

Coolingwater

Compressor

Gas toflare

Resinoutlet

Emergency safety vent

(ESV)

Productchamber

Cooling watervalves

Catalystfeed

Monomer

Hydrogen

Feed control valves

Catalyst feedvalve

Purgegas

Reactor

Block valve

Comonomer

Purge gas valve

This diagram is intended to be a representation and should not be viewed as an actual process flow diagram.

Catalyst

cham

ber

Mai

n d

isch

arg

e lin

e va

lves

Coo

ler

Out

let

valv

eIn

let

valv

e

Product discharge

system (PDS)

SwitchGuard with unique embedded diagnostic features, enables users to guarantee the availability of high-cycling PDS valves. This type of controller gives the possibility to set the on-off valve stroking times and profiles according to the process needs. This means that the valve opening and closing times, as well as the stroking ramp profile, can be defined independently. This feature is especially useful in minimizing the pressure impacts on piping (fluid hammering). Its high pneumatics capacity also gives the possibility to reach fast stroking times without the need for any additional accessories, such as volume boosters or quick exhaust valves. An integrated controller reduces installation costs by eliminating the need for external solenoid valves. In addition, predictive maintenance can be practiced with the help of the diagnostics provided to secure continuous PDS valve operation.

CONCLUSIONS | Global markets are calling for more polymers. Gas-phase polymerization processes are very economical at producing commodity-grade polymers, and therefore, are popular with polymer producers. The market demands clean and high quality polymers. It is important that the process is stable, flexible and under control. Valves play an extremely important role in the successful product discharge system performance of a gas-phase polymerization reactor. High-cycle design and construction of both the valve and the actuator are essential. An intelligent, integrated PDS valve controller, with unique embedded diagnostic features, enables users to guarantee the availability of high-cycling PDS valves.

MORE INFORMATION:Sari AronenTel.: +358 50 317 1518E-mail: [email protected]

Published with permission of Hydrocarbon Engineering magazine. Gas-phase polymerization PDS with valvesFIGURE


» R&D

IMAGE: Neles ESD valve in a real operating environment, colored according to customer specifications.


» R&D

ESD VALVE | An emergency shutdown (ESD) valve is part of a safety instrumented system (SIS). It is a vital part of the safety system and often described as the final element. Normally, the term ESD valve refers to all types of safety system valves, such as shutdown, emergency shutdown, emergency ventilation or blowdown valves. There is much confusion in the functional safety area when it comes to what should be considered with regards to safety valves to make a plant safe. There are different aspects to think about and evaluate in the

case of a safety valve. Excellent probability of failure on demand (PFD) and safety integrity level (SIL) are just two examples.

There is much more than the SIL certification that is needed. For ESD valves, there are three main steps.

VALVE SELECTION | The most important step in the selection of an ESD valve is to use the application-based valve selection process. This step has not been observed often enough in recent years, while the functional safety calculations have attracted excessive attention. FIGURE 1 ESD valve selection

SIL 4 – am I safe now?There are different aspects to think about and evaluate in the case of a safety valve.

TEXT: Ville Kähkönen PHOTOS: Erik Grönlund, Shutterstock & Metso

ESD valves should not be so-called “install and forget” devices. The only way to maintain the safety integrity is to have a test plan and to follow that plan.VILLE KÄHKÖNEN, OIL & GAS BUSINESS MANAGER, METSO FLOW CONTROL INC

Valve selection

Functional safety

Testing and maintenance


» R&D

ESD valves have the same application challenges as normal on-off valves. Correct valve selection includes valve type, pressure class, temperature, materials and other details. If the selection does not fit the application in question, valve failure will be systematic, and we cannot take advantage of the functional safety calculations of the SIL and PFD value. Systematic error in valve selection will make the valve fail every time in the same way, and random error rate will no longer be the main source of failure.

A very good example of systematic error is incorrect seat selection. We can use the example of polymer service to demonstrate systematic error. There are a number of different types of valves and seats in the market, but only some of them can be used in polymer service. After we know the correct pressure class, materials and temperature range, we must consider other details to make the valve work in a real process. A rough categorization could include seat types that have contact between the sealing elements all along the stroke and seat types that lose the contact while operating like plug and rising stem valves. The problem with seat types that lose contact is the polymer accumulation between the surfaces. The valve does not fully work or starts to jam after that.

different seats. The so-called open-seat design (Figure 2) will get jammed when the polymer enters the seat cavity. This problem can be solved by using a closed-seat design in which the functional feature of the seat is protected. This type of seat is an excellent choice for processes that have impurities. For the ESD valve, it would be a disaster if the valve seat is jammed when the valve needs to operate.

FUNCTIONAL SAFETY – TAKE FULL ADVANTAGE | The previous example highlights the importance of application-based valve selection. Even for an incorrect seat type, it would be possible to calculate a high SIL and a good PFD value. If we look at the PFD value alone, it cannot guarantee plant safety.

Following the international standard IEC 61508 and 61511, we typically have a safety integrity level to match based on the hazard and operability analysis (Hazop) and safety integrity level assessment. The final elements are a critical part of the safety loop. If devices, such as valves, are not working properly, the safety instrumented function is not available. In recent years, there have been a number of announcements of manufacturers publishing SIL certification and advertising SIL 3 valves.

This problem can be solved by selecting a rotary ball-type valve with a scraping seat that wipes the sealing surface clean while stroking the valve. This solves one problem, but after selecting the ball-type valve, there are still multiple

Cavity in seat area Valve body Ball

No cavities in seat areaValve body Ball

Polymer-proof seat

FIGURE 2 Closed- and open-seat design

FIGURE 3 Nelprof SIL tool


» R&D

The certification proves that the valve is capable of working in an SIL 3 loop, but it does not guarantee that the function is SIL 3. The final element is part of the safety loop, and, therefore, component certificates are not enough to assure the safety integrity level of the loop. The complete final element as an assembly must be calculated, taking into account all components that are needed for the safety function.

In the final element assembly, typical components are the valve body, actuator and intelligent safety solenoid. All these components have their own component SIL certification and PFD value, which can be calculated according to the testing intervals.

From the example, it is easy to notice the effect of the testing intervals. Even if the SIL 2 capability is achieved in both examples, the PFD value will change. Only by calculating the complete system is it possible to know the final safety system capability.

TESTING & MAINTENANCE | Service and testing make up a large part of the ESD valve’s life cycle. ESD valves should not be so-called “install and forget” devices. The only way to maintain the safety integrity is to have a test plan and to follow that plan. In the example above, the testing interval for full stroke testing was 48 or 36 months; for partial stroke testing, it was 3 months. If the testing according to plan is not done, the safety integrity level is not maintained. Using the Nelprof SIL tool, it is also easy to see what the testing intervals should be as well as what the effect will be on the PFD value if the testing is not possible at that interval. A partial stroke test (PST) interval of one to three months is typically done with an intelligent safety solenoid, such as Neles ValvGuard, to automate the testing routine and documentation.

ESD valve testing is typically categorized into two different types. A partial stroke test (PST) can be done

while the plant is operating, and a proof test happens during shutdowns. The difference between the testing types is that the full stroke of a valve in a proof test will impact the operation of the plant, and the partial stroke test can be done without causing any harm to the process. During the PST, the valve is moved just a few percent of the full stroke to analyze its condition. In proof tests, the full stroke test will complete a 100% stroke. The advantage of carrying out the PST is that the full stroke test then does not have to be done so often and will help to match the turnaround period of the plant.

From the graph above, it is easy to see the advantage of the PST. The gray colored line reached the SIL 2 level much faster than the green colored line with PST. We can also see that it is not possible to completely avoid the proof testing by doing the PST, but the interval for the full stroke testing can be longer.

SUMMARY | ESD valve selection involves more than just calculating the PFD and safety integrity level. The basic work of the application-based valve selection is still a very important part of the ESD valve selection process. After the valve is capable of working in the application, we can take full advantage of functional safety calculations. After these steps are completed to ensure the plant safety during the full life cycle, the testing and maintenance of the valves are important to make sure the ESD valve will work when it needs to work.

MORE INFORMATION:Ville KähkönenTel.: +358 50 354 4735E-mail: [email protected]

Published with permission of Hydrocarbon Engineering magazine.

FIGURE 4 Testing interval

Read more about this and many other interesting topics in our expert blog: flowexpertblog.com

PST testing provides extended plant uptime and enables efficient production in the plant.

Without online testing safety integrity testing must be performed more often

With Neles ValvGuard and PST testing plant uptime is extended

1 2 3 4 5 6

time/year


» R&D

SIL2

SIL3

40 years ofservice excellence

ETSO has been developing its expert valve services know-how and solutions for

40 years. Ever since the opening of the first valve service center in 1975, Metso has invested in the strong knowledge of its valve service experts, which has resulted in continuous development of its services solutions.

“Our flow control service network is very unique and enables good service levels for our customers globally.”

Starting from its maintenance and spare parts business, the company has expanded its services portfolio to include more tailored solutions that meet customers’ ever-increasing process challenges. Today, our extensive flow control services also consist of business solutions and services for ensuring the availability of plants and minimizing risks.

“Our customers’ needs have changed considerably during the past few decades. Nowadays, we often plan maintenance and service activities together with our customers and tailor our offering and solutions to ensure the best possible results for them,” says Timo Hänninen, Vice President, Flow Control Services, Metso.

MORE INFORMATION:Timo Hänninen Tel.: +358 40 585 3042E-mail: [email protected]

World-class flow control services

Full Metso service support

Service support

Flow Control Service Center

The first service centers

outside of Finland were in the UK,

France and Italy

METSO VALVE SERVICE CENTERS

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GIORGIO DE GUIO, ITALY

I WAS WARMLY WELCOMED into the Neles family as a young and inexperienced guy back in 1988. Since then I have been involved with valves in numerous different roles. I have grown up

alongside the company, and today I drive the service business here in Italy with my small but efficient team. My task is to give my guys the same opportunities for personal and professional growth that I was given all those years ago.

With 40 years of experience and expertise, Metso’s flow control services are available through more than 40 service centers worldwide. There are more than 400 dedicated service professionals with in-depth valve application expertise at your service. Let us introduce you to a few of them.

The first valve service center was established in Finland in

1975

Our presence today

400+

20+

40+ Service centers

Service professionals

Countries

CHYE-HUAT NEO, SINGAPORE

FOR 21 YEARS NOW I have dedicated myself to serving people through my work at Metso Singapore. I began my career as a Field Service Engineer at Neles-Jamesbury. In the past,

I have been involved with operational services, technical support and training, and smart product sales. Today I handle Field services & spare parts sales in the South East Asia Region. I believe that a work environment based on trust is the key to success. I look forward to continuing to mentor young technicians and engineers on their professional journey.

JOUNI HYYTIÄINEN, FINLAND

I JOINED THE COMPANY in 1974 as a summer worker. I started in my first permanent position as a service technician the following year. Since then I have worked in several different

positions in service and spare parts. Today I am a member of the service development and support team, offering my support to new service centers that are being established around the world, as well as to existing ones. I am also actively involved in many other service- related responsibilities. What makes my job interesting is that I can truly say that when I come to the office in the morning I never know where I’ll find myself by the end of the day.



From idea to order in six months

BWX VALVE FROM METSO

Successful collaboration with the German Linde Group on the joint development of a new cryogenic metal-seated butterfly valve enabled Metso to win a greenfield project for an air separation unit (ASU) that will be used in a challenging industrial gases application. The main factors that made this project especially valuable for both parties are the remarkably short development time, 100% compliance with the customer’s requirements and strong partnership.TEXT: Martin Dreßen PHOTOS: Linde Group and Metso

The BWX valve was created in

collaboration with Linde Group



HE ABILITY TO QUICKLY ADAPT TO CHANGES has enabled The Linde Group, the world’s largest industrial and medical gases company headquartered in Munich, Germany, to remain steadily profitable, even during the

harsh years of the global financial crisis. Still, the requirements of the industrial gases market in terms of product safety, quality and compliance with all its certification criteria are getting even tougher. This calls for constant development from Linde as well as from its main suppliers.

When the need for a new valve solution arose, the company began to look for a partner who would be able to help Linde step up to the more stringent requirements and succeed in its changing environment. Linde and Metso have a long-term history of cooperation and in 2008 Metso aquired MAPAG Valves GmbH from The Linde Group.

Past experience has proven Metso’s commitment to serve the company with high integrity and a focus on uncompromised quality, even in the most challenging cases. Therefore, Linde selected Metso for the development of an innovative cryogenic valve that was required for a new ASU in a very short time period.

100% REQUIREMENTS COMPLIANT | After completion of intensive research and development, which was jointly conducted by Metso’s development team in Horgau, Germany, and Linde’s engineers, the new BWX valve was approved by the customer in December 2014. The close collaboration of the companies during the design phase ensured that the end product is 100% compliant with all of Linde’s requirements.

Immediately upon approval, the first order for the cutting-edge BWX valve was placed in March 2015, only six months after the initial idea was born.

The cryogenic BWX valve will be installed at Linde’s air separation unit in Eisenhüttenstadt, Germany, on the Polish border. Once on stream, the unit’s main purpose will be to serve oxygen and nitrogen to the local ArcelorMittal steel manufacturing facility. The valves will play a crucial role in securing the plant’s reliable and efficient operations over the long run.

BWX is the latest valve development from Metso. Its metal-seated butterfly design provides high Cv values. The valve is based on a platform design, but can also be customized according to specifications. Thanks to its fully dry assembly and oil-free production option, the valve is ideal for oxygen service, where high cleaniness and an extreme level of tightness are required.

TBEING A PARTNER, NOT JUST A SUPPLIER | “This first BWX cryogenic valve order marks a milestone with one of our key customers. Using our long field-proven experience in the market and decades of process knowledge, we combined the best design features of our existing product series to create this state-of-the-art BWX valve,” says Martin Dreßen, Business Manager, Oil & Gas Business Line, Metso. “There was a clear gap in the industrial gases sector when it comes to products with extremely high tightness that fit the challenging cryogenic and oxygen services. BWX is now capable to successfully fill it.”

BWX not only meets Linde’s requirements, it also offers value for customers in the industrial gases sector as well as pump and turbine businesses by helping them fulfill stricter compliance regulations in the future.

Ingo Leufgen, Sales & Service Director at Metso in Germany and Switzerland, comments on the project: “Time-to-market was a considerable issue for Linde. Thanks to the fast reaction ability and high level of professionalism of the Metso team, we were able to deliver within the short project turnaround time.”

“We are also proud of the value we can now provide for Linde that comes with increased safety and improved process performance. Metso has once again been able to justify that we are not just a supplier, but a long-term partner for Linde for the future, securing technical and commercial competitiveness.”

For Linde, the sustainable value from having BWX valves at its air separation facility is the assurance of the plant’s efficient operations and compliance with the latest safety and quality standards.

MORE INFORMATION:Martin Dreßen Tel.: +49 8294 8695 5406 E-mail: [email protected]

THE LINDE GROUP, the world’s largest gases company, supplies industrial, medical, process and specialty gases, as well as plants, hardware and application solutions to virtually every branch of industry. In 2014, The Linde Group generated revenue of around EUR 17 bn with approximately 65,500 employees working in more than 100 countries worldwide.

IN FOCUS



HE EVOLUTION OF THE NELDISC PRODUCT FAMILY is no different. The story of the 40-year-old Neles butterfly

valve series began back in 1973 when the co-founder of Neles Oy, Antti Nelimarkka, asked his team to finalize a sketch he had drawn in his legendary notebook. The challenge had been to develop a butterfly valve that could withstand temperatures up to 600 °C (1100 °F) and still maintain

The evolution from an idea to a successful product family that can stand the test of time requires both dedication and persistence. It all starts with a challenge and innovative thinking. The most important ingredient, however, is determined people who are willing to invest time and systematic hard work into overcoming all obstacles along the long road to sustainable success. There are no shortcuts. Just hard work.

excellent tightness characteristics with long-lasting tightness and durability. As it was something that had never been successfully done before, it was the perfect challenge for an innovative company such as Neles.

THE FIRST OF ITS KIND | From the very beginning, it was clear that only a metal seated valve could work in such conditions. However, no such designs had

ever been drawn out before. After 2 years of development, the Neles R&D team came out with something that is known today as the Neldisc valve. The U-shaped metal seat and elliptic disc formed a unique triple offset valve design, which we are used to seeing in many butterfly valve products today. At the time, this was a first.

The first deliveries at the end of 1975 exceeded all expectations and the valves were discovered to be bubble-tight even in high temperature conditions. The product contained many construction and manufacturing technology innovations. By the end of the development project IPR protection had been gained for the revolutionary elliptical disc design combined with the metallic seat ring in 13 different countries.

NEW APPLICATIONS DISCOVERED THROUGHOUT THE YEARS | Originally the target industries included the refining, chemical, petrochemical and other process industries. Later on, in order to expand to liquefied natural gas applications,

years of performance

butterfly valve

TEXT: Mikko Vuolanto PHOTOS: Metso

T





a low-temperature cryogenic, high performance butterfly valve was developed in 1982.

Many other prominent possibilities for this highly versatile product were discovered over time. In the early 80’s we realized that butterfly valves are excellent for control applications, as there is no seat friction in the control range at all and the rangeability of the valve is surprisingly high.

To overcome the last true challenge in control applications, the high dynamic torque in big opening angles, S-Disc noise abatement technology was developed and patented in the mid 80’s. The same technology, which is still a top-notch feature today, also enables the elimination of cavitation and reduces the overall noise of the valve. Further doors were opened by the realization that the butterfly valve could be closed much faster than other corresponding quarter-turn valves, such as ball valves, offering excellent performance in ESD and other on-off applications.

TODAY’S FULL PRODUCT PORTFOLIO | Since the early days, the development has continued. Today, the Neldisc product family has many members. The product is now available in all major end designs (L6 double flanged, L1 and LW as wafer, L2 and LG as lug) in the most usual pressure ranges with many options for demanding applications requiring high-cycling resistance, steam jacketing, erosion resistance and so on. Even some weld-end designs have been done over the years.

“In the past 40 years, we have supplied more than 700,000 Neldisc valves all over the world,” comments Mikko Vuolanto, Product Manager, Neldisc butterfly valves. He continues, “It is amazing how flexible the basic design has been in adapting to customer needs over the decades. For example, the Neldisc family conforms to even the newest, global fugitive emission standards, such as ISO 15848, and is fire-safe certified to the latest API 607 6th ed. while offering top-of-the-industry efficiency and performance especially in process industries.”

There have been numerous memorable Neldisc valve deliveries over the 40 years. One of the most memorable was in 2004 when Metso delivered the biggest Neldisc unit manufactured so far, the 80” L6

series Neldisc butterfly valve to a gas plant in the Middle East. In 2013 a heavy 80” double flanged L6 valve was delivered, together with over 280 other butterfly valves, to the Sadara project in Saudi Arabia where this heavy 80” valve is used as a shut-off valve for the cracked gas in a polyethylene plant.

DEVELOPMENT BASED ON CUSTOMER NEEDS | Many success cases have actually been manufactured based on customer need and feedback. Thanks to the flexible basic design concept, the functionality of the valve has been easily extended to new applications. This approach, for example, has given birth to the erosion-resistant butterfly valve design, built specifically for a customer process requiring strong butterfly valve properties (maintenance-free) combined with extreme erosion resistance with metal seating – providing performance where a standard butterfly valve cannot reach.

Today, Metso’s butterfly valve offering is the most comprehensive in the entire valve industry. In addition to Neles Neldisc and Neles B-platform engineered butterfly valves, Jamesbury soft-seated Wafer-Sphere butterfly valves together create a complete offering all the way to pressure class ASME #2500, including the corresponding EN and JIS pressure ratings – a unique product portfolio in the business.

SOLUTIONS FOR THE NEXT 40 YEARS | The development of Neldisc butterfly valves is still in full swing. The next-generation Neldisc design is already in the works, aiming to set the industry benchmark in the field of high performance butterfly valves still during 2016. With this facelift, we at Metso are not only honoring the 40th anniversary of the first-ever metal seated, triple offset butterfly valve design, we are also building continuity to the great story of Antti Nelimarkka’s famous Neldisc butterfly valve family and, perhaps most importantly, ensuring our success for at least the next 40 years.

MORE INFORMATION:Taija Hämäläinen Tel.: +358 50 317 4286E-mail: [email protected]

1973Drawings of first butterfly valve to perform in temperatures up to 600°C

1975First-ever Neldisc deliveries made

1982Low-temperature cryogenic butterfly valve for liquefied natural gas applications was created

1985S-Disc noise abatement technology developed and patented

1990sContinuous development of Neldisc products for numerous new applications

2004The world’s largest Neldisc unit, 80” L6 series butterfly valve delivered

2016Scheduled launch of the newest Neldisc high-performance butterfly valve

“The first deliveries at the end of 1975 exceeded all expectations even in high temperature conditions.”

Neldisc milestones



METSO WILL BE EXPANDING its existing portfolio during 2016 with the new NDX valve controller. It is all about exceptionally simple, reliable and safe functionality. It is a positioner designed from a linear valve perspective, but it also gives excellent support to rotary valves. Its extremely fast and easy installation creates a huge time savings, especially in the case of commissioning a globe valve.

Customers can cut installation costs in half with the simple mounting, magnetic position sensor, intuitive local user interface and quick calibration. The NDX is capable of controlling all valves, from the smallest to the largest sizes, minimizing the investment tied up in inventory. The NDX further strengthens Metso’s position as a leading supplier of control valve positioners.

See the Neles NDX video online: https://goo.gl/GATZcg

MORE INFORMATION: Marko Rissanen Tel.: +358 40 569 8489E-mail: [email protected]

Performance perfectedVALVE CONTROLLERS NELES NDX

ACTUATORS VD SERIES

THE PRODUCTION of the newly upgraded field-reversible version of the Neles VD spring diaphragm actuator is in full swing. Its unique field reversibility allows for the actuator spring to be changed easily in the field without the need for any additional parts. It also features the optional side handwheel (as seen in the picture). The handwheel is mounted on the opposite side of the yoke and positioner and can be fitted without any other changes to the actuator. The new features make the VD series actuator a compact and efficient overall package.

MORE INFORMATION: JongYim (Daisy) Kim Tel.: +82 43 852 7708E-mail: [email protected]

Compact and efficient

EASY TO INSTALL, OPERATE AND MAINTAIN



Increasing pump wear life at a copper mine

TEXT & PHOTOS: Chris Wyper

KANMANTOO COPPER MINE, AUSTRALIA

» The world is our Showroom


IN FOCUS

HE KANMANTOO COPPER MINE in South Australia was constructed in 2011, combining new equipment with refurbished equipment from the Pillara Mine located in Western Australia, which closed in 2008.

Kanmantoo’s tailings storage facility (TSF) is at a higher elevation than the Pillara plant, so a new design was required to include additional tailings disposal pumps. Once commissioned, severe wear issues were discovered, which caused regular downtime for the whole operation. During the first year of operation, the cost of maintenance exceeded one million dollars. The hardness of the garnet was believed to be the major source of abrasive wear together with the high head per stage.

“When the wear life of the pumps is just 120–200 hours, it’s nothing. That’s a total of only ten days. So, every ten days, we had to dismantle and then rebuild the pumps, spending a lot of money each time,” remarked Greg Craddock of Hillgrove Resources.

“In the first year alone, the cost of running such high-wearing pumps was costing a fortune. Performing the maintenance was also a very time-consuming task. Up to 10% of our maintenance effort was spent on this one problem, requiring a day’s work from three to four people,” he continued.

Several unsuccessful approaches to improve the wear life were tried at the Kanmantoo operation. Researching the market for available solutions to their problems, Hillgrove Resources reached out to Metso. After conducting a series of trials, the team determined that the fault was not with the pumps, but the system itself.

Recognizing that a system design problem was causing the pumps at Hillgrove’s Kanmantoo copper mine to wear out much faster than expected, Metso recommended adding an additional pumping stage. This resulted in significant savings in wear life, improved the mean time between failures and reduced operating costs.

MOVING FROM TWO STAGES TO THREE | It is common practice to share the load across several pumps, or stages, when pumping at high heads. The total head is divided among the number of stages. In the initial design at Kanmantoo, there were only two stages. After encountering the numerous operational issues, it was agreed to trial a third pumping stage.

TAKING CHARGE OF THE STOCK | Besides the technical solution, the Metso team took care of the mine’s consignment stock so that Kanmantoo could have stock of wear parts in its inventory permanently.

T

The Kanmantoo copper mineTHE KANMANTOO MINE is a copper mine in South Australia, near the town of Kanmantoo, 55 km southeast of Adelaide. The mine is owned and operated by the Australian-based mining company, Hillgrove Resources Limited.

The current defined mineral resource of 31.3 Mt allows a throughput of over 3.0 Mt per annum, containing about 20,000 tons of copper metal and associated gold and silver, over a proposed 10-year mine life. Associated with this deposit is garnet, an auxiliary mineral, which is a very hard and abrasive crystal. This is not mined as a product, but instead reports to the tailings, or waste stream.

IMAGE: The Kanmantoo mine contacts Metso experts whenever any crushers, screens or other mineral processing equipment require support.



This demonstrated Metso’s commitment to the customer in providing long-lasting support. The mine is now also reaching out for a Metso solution when any crushers, screens or other mineral processing equipment requires support.

Today, because the Kanmantoo mine is lifting the tailings dam, the number of pump stages has increased from three to four, and a fifth stage is to be commissioned in early 2016. For Greg Craddock, the choice was obvious, “We really like using the Metso pumps. The fitters think the hydraulic slidebase is fantastic, and the Metso team has given us the support we need.”

SIGNIFICANT COST SAVINGS IN MANY WAYS | This retrofitting project has provided numerous benefits for Hillgrove Resources, the most significant of which is the lifetime cost saving achieved.

Since multiple pump stages were commissioned, this allowed the mine to reduce the head per stage as well as provided a wider material choice for the pumps. More efficient rubber-lined pumps were installed, bringing the lifetime of the previously failing equipment up to an acceptable level while also reducing energy consumption.

“Once we commissioned the first couple of sets of wear parts and they hit the mark of over 1,000 hours of operation, we knew we were moving in the right direction. This gave us a lot of credibility, and the relationships between the teams became even more cooperative,” says Chris Wyper, Director of Sales, Mining Flow Control for Metso, who expresses how happy Hillgrove has been with the solution.

Wear life has improved dramatically. Currently, the life of

a pump is reaching around 1,700 hours and there are plans to increase it further still. Going from metal to rubber pumps and operating closer to the best efficiency point has raised the pump efficiency from 59% to 69%. The savings in energy reduction is approximately $ 50,000 per annum thanks to a high-efficiency hydraulic design. The savings in of parts alone amounts to hundreds of thousands of dollars, along with the reduced operational costs and the improved mean time between failures.

Due to the hydraulic slide base concept implemented by Metso at the fourth stage, the Kanmantoo mine is able to benefit from reduced maintenance time. Operations are now safer thanks to the fact that less energy is being stored, and there is less risk of trapped liners due to better alignment.

“This is a great example of Metso’s collaboration with the customer to solve a problem,” adds Chris Wyper. “We both knew that it was going to be a long road, with many hours spent testing materials and keeping track of the results. But it was only by going through this process as partners that Metso and Hillgrove were able to best optimize the pumping system. There was also superb cooperation between everyone involved at Metso. I’d especially like to give thanks to Michael Lally for his excellent account management skills and tireless devotion to his customer.”

MORE INFORMATION:Chris WyperTel.: +61 8 9420 5579E-mail: [email protected]

This is a great example of Metso’s collaboration with the customer to solve a problem. There was also superb cooperation between everyone involved at Metso.CHRIS WYPER, DIRECTOR OF SALES, MINING FLOW CONTROL FOR METSO



EETING ALL THE STRICTEST STANDARDS meant that safety and compliance with regulations would be the key criteria

when selecting all systems and applications, including the critical valves selected for the burner management systems on the heaters as well as the truck and jetty loading system.

Unplanned shutdowns cause excessively high costs. For this reason, on-off and safety valves are needed to ensure maximum reliability. Moreover, a valve’s failure to close in an emergency situation can have a major impact on people’s health and the environment.

As the valves handle explosive and toxic hydrocarbons, they must retain their initial gas shut-off tightness and be able to demonstrate a low fugitive emission level that complies with European standards over their entire operational life cycle. To prevent potentially dangerous valve stem leakages, there are regular shutdowns for valve inspection scheduled every four years.

SAFE, RELIABLE AND SIMPLE | For the safety shut-off and venting applications in the newest truck and jetty loading station, including the firefighting system and new hydrocracking unit heater, the NIS refinery selected Metso Jamesbury® high-performance valves.

The selected Jamesbury Series 7000 and 9000 ball valves fully comply with the regulations relevant to the applications in the refinery. With their patented Lip-Seal® design and the unique Xtreme® seat sealing technology, these valves provide superior

long-term bubble tightness and prevent overpressure during sudden temperature rises. This is extremely important when dealing with highly flammable media, such as those used in the burner management systems on the refinery’s heaters.

Another requirement the NIS refinery had for the valves was their official compliance with the most stringent safety regulations. All Jamesbury valves are fire-safe according to API 607 and approved according to IEC 61508 SIL 3. Further safety protection is provided through Neles ValvGuard®, the intelligent safety solenoid with a partial stroke testing feature.

Moreover, on both the Jamesbury ball valves and the high-performance Wafer-Sphere® butterfly valves, which were also included in the delivery package, the shaft sealing is designed to fulfill ISO 15848-1 BH and TA-Luft/VDI 2440. This means that their fugitive emissions level is also in full compliance with regulations.

Increased refinery reliability with emergency shut-off valves

SECURING HIGH-QUALITY PRODUCTION | The total valve package delivered to the NIS refinery included several different valves types, actuators and instrumentation with relevant approvals and certificates for emergency shut-off and venting applications. Now, the new valves with long-term, tight shut-off help keep the plant and truck-loading area emissions levels compliant with the relevant European standards, allowing uninterrupted operations.

This complete solution has enabled NIS Gazprom Neft to reliably, safely and efficiently achieve the desired run-time targets for its hydrocracking process, securing continual high-quality production of gasoline and diesel fuels without any risk to personnel or the environment. After all, every detail is important in potentially hazardous applications. The implemented modernization program at the refinery ensured that everything in the constructed facility is now designed to meet its targeted Euro 5 standards.

MORE INFORMATION:Andreas PischkeTel.: +49 172 833 8994E-mail: [email protected]

The NIS Gazprom Neft refinery in Pančevo, Serbia, made a large investment into its new mild hydrocracking and motor fuel hydrotreatment facility. The aim was to upgrade production quality to Euro Level 5. To do so, all European standards for safety and emissions needed to be met.

TEXT: Andreas Pischke

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NIS GAZPROM NEFT REFINERY, SERBIA



THE KUZNETSK BASIN in Siberia is one of the largest coal mining areas in the world. One of the major companies in the area is

KTK, Kuzbasskaya Toplivnaya Company, the largest producer of thermal coal in western Siberia.

The coal processed in the company’s Kaskad 2 plant is mined from the Vinogradovsky open pit, one of the coal strip mines of KTK. The total installed capacity of its three coal strip mines is 11 million tons of coal per year. Open-cast mining is used because the coal is low in ash and sulfur with a relatively high calorific value, making it well-suited for power plant fuel. The plant is the first one to combine two enrichment methods into an integrated production process. It uses both high-angle separators for scalping and dense medium separation. Together, these two methods help reduce gangue from 50% to 12% as well as adjust the ash content.

To save water and reduce environmental impact, Kaskad 2 employs a closed process water circuit where water is recycled and reused in the process. This allows for lower water costs and prevents harmful discharges that pose risks to the environment. Because of an increased earthquake hazard in the region, the plant has implemented some additional safety

measures. Special sensors deliver real-time data to the EMERCOM duty officer, helping monitor the operating environment and status of the facilities on site.

LONGER OPERATION AND EASE OF USE | It took merely a year and a half to establish this new industrial facility on a previously undeveloped site. The project was strategically important for KTK, because it is able to enrich up to 70% of the coal as a result. This provides the company with high-quality coal that meets global standards and market demand.

To operate, the plant required a number of different pumps for slurry and water transport and for the dense medium separation. The pumps play a key role and have to be able to handle abrasive slurry and dense media. To meet production goals, Metso experts suggested horizontal and vertical pumps designed for heavy and super-heavy duty. In total, Metso delivered 70 units.

For the dense media separation, KTK chose Metso’s НM200 pumps. Made of high-chrome alloy, they provide excellent durability and good resistance to abrasive media. Well-balanced pump hydraulics, together with the advanced application analysis and optimized pump selection through Metso Pumpdim™ for Windows,

greatly increased the operating life of the wet-end parts. All the delivered Metso pumps are characterized by ease of maintenance, repair and scheduling of preventive inspection.

WORKING TOGETHER TO ENSURE PERFORMANCE | The pumps were delivered to the site completely pre-assembled. The critical areas were fitted with pumps mounted on a maintenance slide base, which significantly simplifies maintenance and reduces downtime. Proximity of services to the production site makes it possible to provide technical support promptly, increasing the efficiency of the pumps and minimizing total cost of ownership.

“Our equipment in the coal plant allows the customer to reach its production targets while minimizing operating costs. This project is a good example of cooperation between Metso and Kaskad 2 employees, extending from the design stage to its full commissioning,” explains Pavel Cherepanov, Chief Technical Support Engineer responsible for pumps at Metso.

MORE INFORMATION:Pavel CherepanovTel.: +7 812 333 4000E-mail: [email protected]

Keeping the heart of a coal mine pumping

KTK KASKAD 2 PLANT, RUSSIA

When the Russian coal producer KTK needed pumps for its new Kaskad 2 plant in southwestern Siberia, Metso was the natural choice.

TEXT: Yana MerkulovaPHOTOS: Metso



“We launched a bid and selected Metso as the only supplier of pumping equipment for all of the plant’s operational needs. This includes slurries, circulating water and dense medium. With its equipment, Metso is a world leader in terms of liner durability, particularly in the area of slurry pumps. The equipment was installed in 2012, and the plant was commissioned in 2013. All pumps operate normally and comply with our production objectives.”

VIKTOR GRIBANOV, CHIEF MECHANIC, KASKAD 2 COAL PLANT



Discover the latest Metso Flow Control news stories from around the world

Comprehensive valve solutions for pulp mill expansion project

ETSO has been chosen as the main supplier of valve solutions for Södra Cell’s Värö pulp mill expansion in Sweden. The

valve order was placed by Valmet, which operates as a major supplier of rebuilt and new equipment for the pulp mill expansion. Upon its completion, Värö will be one of the world’s largest softwood sulphate pulp mills. The renewed pulp mill is scheduled to start up in the third quarter of 2016.

The extensive valve delivery includes a total of about 700 ball, segment and butterfly valves for on-off and control applications from the Neles® and Jamesbury® product portfolios. The control valves are equipped with Neles® ND9000 series

intelligent valve controllers. “We are pleased that our reliable valve

solutions will support Södra Cell’s mill expansion by maximizing pulp process availability and increasing efficiency. Based

on the application knowledge of our experts, a well thought out valve component scope means that future valve maintenance will be easier to manage and will bring cost competitiveness for them,” emphasizes Tom Adolfsson, Sales and Services Director, Sweden, Flow Control.

To enable good service levels for Södra Cell’s pulp mill and other flow control customers in Sweden, Metso has just opened a new valve service center in the Gothenburg area.

“The new service center in the Gothenburg area strengthens Metso’s position to stage, test and repair large numbers of valves to meet customers’ high-volume, fast-turnaround repair and service needs during scheduled plant shutdowns,” Adolfsson continues.

M“We are pleased that our reliable valve solutions will support Södra Cell’s mill expansion by maximizing pulp process availability and increasing efficiency.”

PHOTO: Södra Cell, Ola Kjelbye



SÖDRA CELL, VÄRÖ, SWEDEN

Metso’s intelligent solenoid valves selected to ensure safe operations at Orpic’s Sohar refinery in Oman.

AELIM, A SOUTH KOREAN EPC COMPANY, selected Metso’s intelligent solenoid valves to ensure reliable emergency shutdown (ESD) valve operation for over 600 safety-critical

valves being used in the expansion project at Orpic’s Sohar refinery in Oman. The valves ensure that all safety actions can be implemented reliably on demand, if needed.

The valves were chosen because of their ability to perform partial valve stroke tests on a regular basis, to verify performance for the plant’s predictive maintenance purposes as well as to maintain the required safety integrity level (SIL) for the safety loops. The high pneumatic capacity and integrated limit switches of Neles ValvGuard optimize installation costs, allowing refineries to enjoy improved plant safety in a highly cost-efficient way. Neles ValvGuards are also fully compatible with the Foundation Fieldbus communication protocol, and they ensure safe and reliable operations on top of 3rd party and Metso valves.

Ensuring safe ESD at a refinery expansion project in Oman

HE INDIA OIL CORPORATION selected Metso to supply them with Neles® valves for a delayed coker unit in the Barauni refinery’s capacity expansion. Valve reliability and tightness is especially important in the delayed coking process,

one of the most demanding sub-processes in oil refining.“Continuous operation is important for profitable delayed

coking. We are glad that the customer trusts our knowledge in their process needs. With our valve solutions, the customer is able to lower its life-cycle costs and can extend the overhaul intervals,” says Vinay Pradhan, Director, Flow Control, India Metso.

The delivery will include a complete package of valves for the critical specialty valve system, including special Neles valves in Pressure Class 900, ball valves ranging from 2”-20” and a technologically advanced 4-way switching valve. Metso will also provide a programmable logic controller for the continuous control of devices and control panels.

TD

PHOTO: Adobe Stock

PHOTO: Tomi Parkkonen



Advanced valve solutions secure delayed coker unit process

INDIA OIL CORPORATION LTD., INDIA

ORPIC, SOHAR REFINERY, OMAN

Control valves engineered to optimize uptime and lower your costs.

That’s how we make the big difference, the Metso Way.

There is a place where the process always flows. Where efficiency reigns. Where safety is supreme. And where costs are always lower. That place is called uptime. Metso makes it possible with control valve solutions that have been field proven to outperform competitive products. And then we back them with a wide range of expert services.

Discover more at metso.com/valves.

#TheMetsoWay

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