Energy Intelligence for Pumps and Compressors

Related Vendors

Lutz Pumpen GmbH

Italvacuum, Srl

ProMinent GmbH

DECHEMA e.V.

Automation Reduces Operating Costs

It is important to distinguish between two different requirements profiles for valve automation. One is open/close control only, where the valve merely needs to be moved to the end stop. The other scenario is control mode, where a valve is adjusted to control the flow based on a set value. Valve automation costs depend not only on the actual valves that you select, but also on the mode of activation (manual, electrical, pneumatic or hydraulic). Different combinations result in different capital investment, operating and energy costs.

There is also another aspect to consider. Lower activation force is needed for 90°-valves (flap, stopcock) compared to linear valves (butterfly, gate). The drives are smaller and less expensive. A number of partners offer the standardised OPOS Interface, which supports reliable, efficient solutions that combine intelligent positioners with pneumatic thrust or swivel drives. The attractive features of this interface include low-cost installation, lower spare part inventory costs, increased reliability and stability and safe positioner replacement during ongoing operation due to built-in shutoff. The advantages are particularly evident in safety-related applications. The nonproprietary interface gives users a wider choice of products.

The dramatic changes of the global economy during the past decade are also mirrored in the development of process component manufacturers: China has become the number 2 in process automation and measurement systems.

Keeping Valves and Positioners Under Surveillance

Inadequate maintenance on control valves can have a very negative impact on process reliability. Complex analysis and the manufacturer’s expertise are required to assess the actual condition of a control valve in the production process. FDT/DTM can be used to provide connectivity to a monitoring console or plant asset management system.

The production team can keep valves and positioners under constant surveillance. The goal of suppliers is to provide predictive, preventive diagnostics rather than drawing attention to symptoms. The emphasis is on the condition of the valve and not on alarm messages. The root cause of the problem is identified and recommendations are issued concerning what action to take to extend the functionality of the valve and the entire production process.

Automated Valves – On the Way to Energy Efficiency

Can automated valves contribute to improved energy efficiency? ZVEI has determined that this is indeed the case. Valves with electro-pneumatic positioners can be used to optimise flow control. Control systems can react much more quickly in high-speed process applications in the chemical and petrochemical industries. Less primary energy is needed to produce larger volumes of product.Product yields increased three per cent simply by installing an intelligent electropneumatic positioner and a suitable pneumatic circuit in an OLEX process to separate butane and butene.

Acoustic sensors can be used to detect leaking valves and prevent creeping product loss. If wear on a flare valve with a DN 150 nominal diameter and an upstream pressure of 20 bar results in three per cent leakage (which equates to a leakage loss of 800 kg/h), product losses can be as high as €10,000/day.

Compared to conventional equipment, stateof-the-art positioners consume only a tenth as much instrument air, significantly reducing consumption of auxiliary energy. Conventional positioners consume around €200 to €250 of instrument air per year and device. At a medium- size plant with say 100 positioners, the savings can be as high as €20,000. Compressed air consumption in the system can be managed more efficiently.

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* This trend report was compiled by international specialised journalists on behalf of the chemical industry association DECHEMA.

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