Harsh conditions vary from industry to industry. Severely corrosive chemicals might be considered harsh, or incredibly abrasive mediums might be considered harsh. External environments may be harsh to equipment from the outside. The atmosphere may be corrosive or just physically demanding. Facilities using dense phase systems also understand the abrasive nature of something seemingly as simple as baby powder being pneumatically conveyed. Almost any solid material conveyed by air or gas is extremely abrasive. Industries that possess some of the harshest environments are mining, pulp and paper mills, and steel mills. In mining, crushing rock and then moving it in a slurry is definitely abrasive. Pulp and paper mills combine cooking acids, steam and wood chips. The environment is chemically corrosive, and parts of the mill have scaling and abrasion. Steel mills require 35,000 gallons of water to produce one ton of steel. This water picks up steel scale, slag and many impurities, which plays havoc on pumps, valves and all types of equipment. The water within a steel mill is recycled and reused numerous times. There are harsh conditions found in almost every type of processing facility. In many process facilities, there is a goal for standardization to minimize training requirements, reduce material stocking costs and use the best products for the processes. When the majority of the process is not harsh, standard products can be used with effectiveness. The dilemma occurs when standard pumps and valves are used in these harsh environments. In a majority of the cases, these products will not have the survivability and reliability desired by the user. An example would be a chemical manufacturer using ball valves and butterfly valves for shut-off and control of a clean chemical process. If this manufacturer uses lime slurry for pH control, then these standard products would not be ideal and would likely lead to high maintenance costs and frequent repair. Ball valves, for instance, can be adapted to have better survivability in slurries by adding hard coatings, changing Teflon seating to metal scraping seats, adding body cavity fillers and flushing ports. But by the time all of these modifications are made, the valve is no longer a standardized product, and the cost of the valve may be 10 or 20 times the cost of a standard ball valve. A better solution may be to look for valves and pumps that have been specifically manufactured to handle abrasives and are known for their ability to survive in these conditions. By no means does this suggest that ball valves or butterfly valves are poor products. They are fantastic products in the right applications.
Early warnings and easy access provide better maintenance options.
Flowrox
04/04/2018
Image 1. One type of pinch valve is ideal for handling the world’s most abrasive mediums. (Images courtesy of Flowrox)
Image 2. Digital twin imagery can be vivid, and all process inputs can be viewed by users on smartphones, tablets or personal computers. Embedded document management tools can provide all drawings, maintenance manuals and even repair videos into the hands of required personnel in a moment’s notice.
Image 3. A peristaltic pump with IIoT connectivity and digital twin imagery for asset monitoring from any smartphone, tablet or PC with internet connection. For high solids content slurries, peristaltic pumps provide excellent reliability in the world’s most abrasive slurries.
In the digital twin imagery, a comprehensive document management tool can be embedded so that all manuals, drawings, spare parts and repair videos can be accessed by any interested personnel. In a typical plant, maintenance personnel may waste four to eight hours researching documentation prior to any work beginning on a disabled or malfunctioning asset. With embedded document management tools, all necessary documents and information are a few clicks away. This helps to improve response time and, in some cases, rescue an asset in trouble prior to catastrophic failure and improve productivity.
In conclusion, harsh conditions are just another challenge that needs to be addressed. Choosing the correct equipment in these harsh conditions can have a much larger impact than choosing one pump versus another in the more common processes. The operating expense of the harsh conditions can balloon out of control if the wrong equipment is used. Also with the trend toward IIoT and connecting assets, users can capture valuable information to improve their process, reduce operating expense, increase productivity and increase profitability.