Ene 2011

2010 2011 2012
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with emerging nations posting strongest gains
Understand Safety System

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JJanuary 2011
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contents
January 2011 | Volume 74, Issue 1
2011
20 27 39
Columns
Cover Story 7 F
rom the Editor: Gas Buoys U.S.
20 T
he Forecast Gets Sunnier Chemical Industry Outlook
Chemicals output now is on the upswing, especially in de-
veloping countries, and worldwide production is expected 9 C
hemical Processing Online: A Better
to increase moderately in 2011 and 2012. Site Beckons
FEATUREs 11 Field Notes: Do Your Level Best

maintenance and operations
27 Safeguard Your Safety Review 16 E
nergy Saver: Take a Fresh Look at Your
Process Heaters
An assumption gap is particularly dangerous during a pro-
cess hazard analysis (PHA). It could result in inadequate
19 C
ompliance Advisor: 2010 Elections
identification of hazards and major hazards left hidden.
Could Impact EPA Programs
solids and fluids handling
43 P
lant InSites: Control Issues Can Pinch
30 Dust Gets Its Due Energy Savings
The dangers posed by combustible dusts no longer are be-
ing swept under the rug. Tougher regulations and greater 50 E
nd Point: Chemical Engineers Make
corporate resolve make dust hazard management an Explosive Progress
increasingly important topic.
instrumentation and control departments

35 Understand Safety System Tradeoffs 12 In Process: Fabric Destroys Toxic Waste |
Many facilities may be missing an opportunity to improve Seeds May Grow as Feedstock Source
safety via a fieldbus, but each fieldbus approach has ad-
vantages and limitations. 42 P
rocess Puzzler: Vanquish Vexing
Venting
Making it Work
45 Equipment & Services
39 WirelessHART Successfully Handles Control
Use of wireless transmitters provides a new degree of 48 Product Spotlight/Classifieds
f lexibility in reconfiguring pilot plant processes without
installing or relocating transmitter wiring. 49 Ad Index
Chemical Processing (ISSN 0009-2630) is published monthly by Putman Media Inc., 555 West Pierce Road, Suite 301, Itasca, IL 60143. Phone (630) 467-1300. Fax (630) 467-1109. Periodicals postage paid at Itasca,
IL, and additional mailing offices. POSTMASTER: Send address changes to Chemical Processing, P.O. Box 3434, Northbrook, IL 60065-3434. SUBSCRIPTIONS: Qualified reader subscriptions are accepted from
operating management in the chemical processing industries at no charge. To apply for a qualified subscription, fill in the subscription card. To nonqualified subscribers in the United States, subscriptions are $68
per year. Single copies are $14. Canadian and foreign annual subscriptions are accepted at $115 surface per year. Single copies are $16. Canada Post International Publications Mail Product Sales Agreement No.
40028661. Canadian Mail Distributor information: Frontier/BWI, PO Box 1051, Fort Erie, Ontario, Canada, L2A 5N8. Copyright 2011 Putman Media Inc. All rights reserved. The contents of this publication may not
be reproduced in whole or in part without the consent of the copyright owner. REPRINTS: Reprints are available on a custom basis. For price quotation, contact Foster Reprints, (866) 879-9144, www.fostereprints.
com also publishes Control, Control Design, Food Processing, Pharmaceutical Manufacturing and Plant Services. Chemical Processing assumes no responsibility for validity of claims in items reported.
5 chemicalprocessing.com ● January 2011
CP1101_05_TOC.indd 5 12/27/10 11:51 AM

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FROM THE EDITOR
Gas Buoys U.S. Chemical Industry Outlook

Abundant supplies of domestic natural gas may open up more feedstock opportunities
KEVIN SWIFT, chief economist of the American “Two quadrillion cubic feet of America’s natural gas
Chemistry Council, Arlington, Va., paints an upbeat represent more energy than Saudi Arabia’s 200 billion
picture on the prospects for the worldwide chemical barrels of oil reserves — but America’s natural gas is
industry through 2012 in his cover story (p. 20, www. much cleaner and 70% cheaper than Saudi oil,” he adds.
chemicalprocessing.com/articles/2011/chemical-indus- “In 2009, the U.S. passed Russia as the biggest producer
try-bounces-back.html). The global recovery continues of natural gas in the world...”
to advance, he notes, particularly in developing coun- The promise of this abundance of gas certainly
tries such as China and India. hasn’t been lost on major oil companies. Both Exxon- Ample and
The outlook for U.S. chemical makers is positive, if Mobil and Chevron have bought gas producers relatively
inexpensive U.S.
not as heady as elsewhere, believes Swift. He foresees op- recently. “They were late to the table,” says Sheila
erating rates slowly rising this year from the 74% level of McNulty of the Financial Times. “Europeans and Asians natural gas may
late 2010 (p. 12, www.chemicalprocessing.com/Media/ have been eagerly snapping up acreage for several years
alter plant-siting
MediaManager/CP1101_Economic_Snap.jpg). Increas- now.” For instance, in November Chesapeake Energy
ing demand coupled with some capacity reduction and China’s CNOOC International finalized a project decisions.
should boost utilization to 79% in 2012, he expects. cooperation agreement in which the Chinese firm pur-
“The stage is set for improving operating rates and chased a one-third interest in Chesapeake’s Eagle Ford
profit margins. This, in turn, could lead to moderate Shale project in South Texas.
increases in investment in new plant and equipment Natural gas promises to largely displace coal for
in the United States,” Swift says. U.S. electricity generation by 2050, says a study, “The
Longer-term, the prospects may be even brighter: Future of Natural Gas,” released in June by the Mas-
“With improving competitiveness resulting from sachusetts Institute of Technology. Replacing the output
developments in shale gas, the United States may once of America’s dirtiest third of coal-burning power plants
again become a favorable location for investment.” with natural-gas-fired electricity would substantially cut
“Vast new reserves of natural gas in shale reservoirs pollution — eliminating 600 million tons of carbon
deep beneath our country have been discovered in the dioxide, 700,000 tons of nitrogen oxide, 1.5 million tons
past five years. These shale reservoirs are now estimated of sulfur dioxide, 19,000 tons of mercury and millions
to contain more than two quadrillion cubic feet of of tons of particulates each year, says McClendon.
natural gas, more than doubling America’s previously The growing attraction of natural gas also may
estimated natural gas reserves, and giving us close to a threaten the prospects of solar and wind for power
200-year supply...” notes Aubrey McClendon, CEO of generation, warns Dallas Kachan, managing partner
Chesapeake Energy, on the company’s website. of consultants Kachan & Co., San Francisco, in his
December predictions for 2011.
On the feedstock front, natural gas long has served
NEW ENERGY SAVER COLUMNIST DEBUTS to make ammonia, methanol, ethylene, etc. However,
This issue contains the first Energy Saver column by the ample potential supply of the gas is prompting new
Veerasamy Venkatesan. Ven, who already serves as the interest as well as technical developments. For example,
steam and thermal systems authority for our online start-up Siluria Technologies, San Francisco, now is
“Ask The Experts” feature (www.chemicalprocessing. working on a proprietary catalytic process to directly
com/experts/index.html), is general manager of VGA convert natural gas into ethylene.
Engineering Consultants, Inc., Orlando, Fla. He’s a “The prospects of abundant and cheap natural gas
certified energy manager (CEM) and a U.S. Dept. of ultimately may make the United States again a location
Energy-approved specialist in assessing steam and of choice for new capacity,” reiterates Swift.
process-heating systems. He boasts decades of field
experience related to plant operations and process
engineering and has helped sites around the world.
I’m sure you’ll find his column interesting and valuable.
Ven replaces Gary Faagau, who has just taken a new
job in industry. I wish him well and thank him profusely for MARK ROSENZWEIG, Editor in Chief
sharing his practical insights these past couple of years. mrosenzweig@putman.net
7 CHEMICALPROCESSING.COM JANUARY 2011
CP1101_07_Edit.indd 7 12/27/10 11:52 AM

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CHEMICAL PROCESSING ONLINE
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The folks on the editorial side of weig’s Ramblings videos in chrono-
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Regulatory Columnist
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Tim Frank, Dow Chemical article URLs. Previously, these were tpurdum@putman.net.
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field notes
Do Your Level Best

Level control with dP transmitters appears simple but really isn’t
I didn’t think I could solve the problem. I in. and HH were set at 95%, then H would be at
had to specify the level settings for a f langed and (427.5 – 20)/450 = 91%. Change any gap less than
dished tank divided into three compartments 3 in. to 3 in. If you wanted H at 85%, the time
with a bottom head as the third tank. It was a between H and HH would be 4.4 min.
challenge but I met it. What do you know — in- With other shapes such as cones and vessels
tegral calculus is actually good for something! where most of the volume is in the head, the cal-
In a typical level problem, you must set high- culation is more difficult. I’ve found it best to use
high (HH), high (H), low (L) and low-low (LL), the actual volume rather than the column change. Integral calculus
based on percent, for a standard two-element In one vessel only 30% of the volume was in
(wet, dry) differential pressure (dP) transmitter. the cone. I’ve set LL based on liquid holdup and is actually good
Don’t forget about full (100%) and empty (0%). recirculation rate for such tanks. Also, you may for something.
All measurements normally are to centerline un- want to confirm LL against Cameron’s submer-
less otherwise noted. gence recommendation.
For a dP level transmitter, the upper range Calibration introduces new problems. The
value (URV) and lower range value (LRV) are density of ambient water used in testing probably
defined as: won’t match that of your process liquid. There’s
URV = liquid specific gravity (SG) × the dis- a simple correction. If water temperature during
tance between 100% and 0% (h100%) + LRV; and testing is 75°F, SG is 0.997. If process f luid at
LRV = capillary fill SG × distance between process temperature has an SG of 0.880, correct
the elements or pancakes × -1. The LRV distance via a ratio. For example, if an H of 90% were
should comfortably exceed the URV span. desirable, then during calibration, the setting
The HH setting usually is at the lip of the should be: 90% × 0.997/0.880 = 102%. The total
overf low but sometimes is lower if process con- inches of water column is the same but the height
straints dictate. Equating that with 100% full can of the liquid is less for the heavier test water.
cause problems. You may want to measure above While geometry makes life difficult, SG
HH in case the overf low fails. “Cameron Hy- causes real problems in dP level measurement.
draulic Data” recommends a minimum spacing Sometimes a vessel contains more than one
between settings of 3 in. or 2 min. liquid, sometimes it changes during the process.
Establishing LL is simple for a cylindrical Usually, it’s best to set HH and H using the
shape. Cameron suggests 1-ft submergence for ev- lighter liquid but not if the density ratio is more
ery ft/sec velocity for the pump suction. (Suction than about 1.2:1. Otherwise, your HH and LL
is measured from the top of the pump nozzle.) alarms would be separated by only 20–40%,
So, for a 2-ft/sec velocity and a 6-in. nozzle, LL which is unworkable.
should be: 6/2 + 2 × 12 = 27 in. above the pump When this occurs, it’s still possible to use a
suction nozzle centerline. For saturated (boiling) dP — but not alone. Consider a density mea-
liquids, use a safety factor or company standard. surement; a nuclear or dP cell in a still well may
The setting for H depends on the maximum work. Calculate a new URV from the density:
fill rate. The material balance may be helpful. URVnew = SGnew × h100% + LRV. Now, determine
The L setting depends on the maximum with- the true level: % level = (dPnew - LRV)/(URVnew -
drawal rate. It may make sense to set HH and H LRV). In this way, URV and span are variables.
for the light liquid and LL and L for the dense (For more on level measurement options, see
liquid. However, here’s where the calculation gets “Select the Right Liquid Level Sensor,” www.
complicated. ChemicalProcessing.com/articles/2010/208.html.
To calculate a setting for a cylinder, first And for information on effective level control,
calculate the volume per inch. For a 10-ft-dia. watch for the first installment of a four-part series
tank this is 4.9 gal/in. If the fill rate were 50 gal/ on the topic in February’s issue.)
min, then for 2-min. minimum spacing the gap
between HH and H would be 50 × 2/4.9 = 20 in. dirk willard, Contributing Editor
If the total span between 100% and 0% were 450 dwillard@putman.net
11 chemicalprocessing.com January 2011
CP1101_11_FieldNotes.indd 11 12/27/10 11:54 AM

in process
Fabric Destroys Toxic Waste

Adsorbent cloth works with oxidants to decompose pollutants
Activated carbon cloth (ACC), a material Activated Carbon Cloth

composed of fine carbon fibers that have a similar
diameter to powder, may offer significant benefits over
powder alone for cleaning up toxic waste, say research-
ers at the University of Abertay, Dundee, Scotland.
The researchers, led by Professor David Bremner,
Chair of Applied Environmental Science, found that
ACC in conjunction with oxidants creates extremely
reactive hydroxyl radicals. These are so unstable they
instantly react with any pollutants, even at concentra-
tions of just a few parts per million.
“There’s been a lot of research into how activated Figure 1. The fabric’s high level of pore development
carbon in powder or grain form can be used, but what can be tailored for specific applications. Source: Univer-
sity of Abertay
we found is that using it as a fabric has a number of
real advantages, [such as] its efficiency in adsorbing Scotland, (www.carbfilt.co.uk/), which supplied the
everything, its special structure and the fact that it is fabric. CFT produces different versions of the material
electrically conductive,” says Bremner. which already is used for medical clean rooms, air and
ACC is 100% activated carbon (AC). Its high level water filtration and highly advanced wound dressings.
of pore development can be tailored for specific applica- “The fabric has countless tiny pores which adsorb
tions. Typically, ACC is predominantly microporous, the organic molecules onto the surface via weak Van
but materials with levels of mesoporosity can be made, der Waals forces,” explains Ian Johnson, the company’s
notes Carbon Filter Technology Ltd. (CFT), Kirriemiur, director. “The pollutants then react with the oxidant
(ozone) on the surface of the carbon cloth, converting
Economic Snapshot them into smaller molecules or even carbon dioxide
and water. The carbon cloth is really acting as a catalyst,
61,000 82.0
promoting the decomposition of the pollutants.”
81.0
60,000 CFT cites a number of other advantages of ACC,
80.0 including: high capacity and fast adsorption kinetics;
59,000 79.0 suitability for gas or liquid streams; and ease of han-
78.0 dling. The fabric can be cut, shaped and laminated.
58,000
77.0 “At the moment we are adsorbing pollutants onto
57,000 76.0
the ACC and then using hydrogen peroxide and
ozone along with the catalytic effect of the ACC to
75.0
56,000 produce hydroxyl radicals. Fineness and texture of the
$ Million
74.0
%
cloth is not relevant but the size of the pores is impor-

55,000
73.0 tant,” says Bremner.
54,000 72.0 Further research will focus on optimizing the pro-
71.0 cess, using different oxidants and looking at a variety
53,000 of pollutants. Bremner also plans to investigate how to
70.0
52,000 69.0 take advantage of the material’s electrical conductiv-

ity. This work should take about three years, he reck-
68.0
51,000 ons. Pilot-scale trials might begin in around four years
67.0
and it will take at least six years before the technology
50,000 66.0
is ready for industrial-scale demonstration, he adds.
Nov 09 Dec 09 Jan 10 Feb 10 Mar 10 Apr 10 May 10 June 10 July 10 Aug 10 Sep 10 Oct 10
Cost is a disadvantage. “ACC is more expensive than
Shipments (NAICS S325) Capacity utilization AC, but it is much more active and worth the difference
for specialized applications,” he says. Volume production
Shipments sagged slightly but capacity utilization remained might halve ACC cost, he believes.
steady. Source: American Chemistry Council.
For industrial applications, Bremner sees the most
January 2011 chemicalprocessing.com 12
CP1101_12_14_InPro.indd 12 12/27/10 11:55 AM

in process
promising use in the removal and decomposition of

persistent organic pollutants, endocrine disrupters and 11.6%
Yes, at least annually
antibiotics from wastewater prior to reuse. 11.6%
The fabric has not yet been tested to determine Yes, every
few years
how many cycles it would last, but Bremner notes that
it can readily be recycled by ultrasound or heating;
combined with AC, it can act as a mass adsorbent.
“ACC is very effective at adsorbing contaminants
from vapors and from solution but it does get satu-
rated eventually… It’s best considered as a polishing
filter rather than a mass adsorbent. AC can adsorb
0 45 50 55 60
the masses, but always some would leak through…
Actually, the dream team for large scale adsorption 37.2%
is a combination of powdered activated carbon and No 39.5%
Yes, but only only
ACC. Thus, a large bed of AC with an ACC compo- on a sporadic basis
nent would be the perfect solution to ensure that no Responses (%)
substance leaks through,” says Bremner.
More than three-quarters of respondents say audits are
an 6pt done sporadically if at all. To participate in this month’s
vy 7pt
Seeds May Grow As poll, go to ChemicalProcessing.com.
biochemist at Brookhaven who led the research. “…

Feedstock Source
33.3%
Few
0.0%
None Our research shows 21.4%that high levels of the appropriate
Remained
feedstock can be made in plants.”
the same
Many plants contain ω-7 fatty acids that 20.0% could “This proof-of-principle experiment is a successful
serve to make chemical feedstocks. However, theAlllow demonstration of a general strategy for metabolically en- 50%
levels of the fatty acids and those plants’ growth charac- gineering the sustainable production of ω-7 fatty acids Increased
teristics preclude commercial production. Now, though, as an industrial feedstock source from plants,” he adds. significantly
researchers at the U.S. Dept. of Energy’s Brookhaven The researchers now are performing further meta-
National Laboratory, Upton, N.Y., and Dow AgroSci- bolic engineering to boost fatty acid levels even more.
ences, Indianapolis, Ind., have metabolically engineered “We think 85% should be achievable,” says Shanklin.
13.3%
seeds whose oils contain the highest percentage of Most
the Their efforts focus on a common laboratory plant,
fatty acids — more than 70% — thus enhancing the Arabidopsis. Its growth and development reportedly were
28.6%
Increased
prospects of using seeds as a source of raw materials. unaffected by the genetic modifications and accumula-
somewhat
“Our33.3%
new way of providing a feedstock sourced tion of ω-7 fatty acids.
from fattySome
acids in plant seeds would be renewable The seeds hold particular promiseResponses (%)
for plastic pre-
and sustainable indefinitely,”
Responsesnotes
(%) John Shanklin, a cursors. Ethenolytic metathesis of the ω-7 fatty acids
Growing Prospects produces 1-octene and 9-decenoate. The octene already
is consumed at significant volumes to make linear low-
density polyethylene, note the researchers.
Several academic and industrial research groups are
working to improve metathesis catalysts, says Terrence
Walsh, a research fellow at Dow AgroSciences.
“There are still significant technical hurdles to con-
verting the potential feedstocks made in our proof-of-
concept study into plastic precursors. This will require
some significant technical breakthroughs over several
years. One barrier is the development of an effective
and cost-competitive catalytic process for converting
plant-derived fatty-acid feedstocks into plastic precur-
sors. Also, the genetic system for feedstock production
that we demonstrated in a model plant will have to be
Figure 2. John Shanklin holds plant whose seeds transferred into an oilseed crop for large-scale produc-
provide a high level of ω-7 fatty acids. Source:
Brookhaven National Laboratory. tion,” Walsh explains.
CP1101_12_14_InPro.indd 14 12/27/10 11:55 AM

ENERGY SAVER
Take a Fresh Look at Your Process Heaters

A simple four-step program can lead to significant savings
Most of the fuel that plants purchase is con- already is maintained at 2% oxygen in stack gas, it
verted into heat in furnaces and boilers. So, the ef- still may be possible to trim further. For some heat-
ficiency of these units has a big impact on a plant’s ers, you can reduce excess air without significant
energy cost. In this and the next column, we’ll capital investment.
focus on how to improve the efficiency of process Address the quantity of stack gas by setting up
heaters; we’ll look at boilers in future columns. a small team or task force and having it follow a
Furnaces either directly heat the process or simple four-step action plan:
Many plants for- media like heat transfer f luids and air. Unfortu- 1. Organize an on-site meeting about the
nately, minor details often are overlooked at the furnace to discuss and finalize its tuning
get they’re pro- design stage. program. If multiple departments have
viding four times For example, a chemical plant I visited in heaters, conduct meetings at each depart-
Alabama vented considerable amounts of surplus ment because each unit may have different
greater volume steam. Because the designers missed the excess characteristics of operation.
of nitrogen than steam availability, modifying the process heater to 2. Initiate a heater-tuning program. Use a
utilize that steam would be very expensive. Only a portable stack-gas analyzer to validate the
oxygen. few limited options, like selling steam to a neigh- readings of any on-line analyzers.
boring plant, are available now. 3. Give all relevant operators on-site refresher
The biggest loss in any process heater is in heat training on fuel efficiency fundamentals.
conversion, which normally results in higher stack- 4. Start to measure stack condition on a daily
gas losses. The two factors that contribute to the basis and create a monitoring database for
stack losses are the quantity and temperature of the each heater.
gases leaving the heater to the stack or exhaust fan. Have an experienced engineer clearly define
If these factors are higher than required, stack loss- task details in such a way that operators can fol-
es also are higher and heater efficiency is reduced. low them easily.
Controlling the quantity of stack gases is the Field-tune each major heater to meet a target
most-talked-about savings opportunity for process operating level — a combustion efficiency exceed-
heaters. However, at 80% of the process plants I ing 80% with 1%–2.5% oxygen and near 0%
visit no significant efforts have been undertaken. combustibles in the flue gas. This target range is
Plants of course supply air instead of oxygen neither new nor unrealistic. The tough part of the
for combustion. Sadly, many forget they’re pro- task is convincing plant operators to shift from
viding four times greater volume of nitrogen than their comfort zone to the optimum operating zone.
oxygen to the burner. The excess nitrogen gets Seeking the assistance of an external expert may be
into the furnace at ambient temperature, picks worth considering in a few cases.
up heat directly at the f lame and leaves the stack Implementing the above tasks doesn’t require
at an elevated temperature without contributing big capital investment but instead a strong commit-
anything. Hence, the first step in process heater ment from the team and plant management. You’ll
optimization is to control the quantity of excess surely notice positive results after a month. Give
air supplied to the burner. the team and operators credit by duly reporting to
Most burner manufacturers recommend about management and publicizing the results.
10% excess air. Many plants add a further safety The results usually are measurable at the end of
margin, increasing this to 20% or more. At some the first year — and can add up to significant sav-
sites, either operators are unaware of excess air ings if the annual purchased fuel bill exceeds $25
levels or burner control systems are too primitive to million. Typically, the first year payoff is five times
make changes. In any case, it’s worthwhile to evalu- more than the cost of the first year efforts. The
ate the opportunity to trim excess air. program also provides spin-off benefits, particularly
Burners firing natural gas typically require a motivated in-house team.
about 1% excess oxygen (or about 5% excess air)
to achieve complete combustion. So, if the level Ven V. Venkatesan, Energy Columnist
exceeds 2%, the first step is to reduce it. If a heater VVenkatesan@putman.net
CP1101_16_EnergySaver.indd 16 12/27/10 11:56 AM

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compliance advisor
2010 Elections Could Impact EPA Programs

Some new senators may take a hard line against EPA program expansion
The 2010 Congressional elections will likely sig- affected by the 2010 election. The possible changes to
nificantly impact policy and legislative developments TSCA during the past two years are moot. The absence
in the regulation of chemicals and pesticides by the of Mr. Waxman in the Senate will have significant
U.S. Environmental Protection Agency (EPA). The implications for TSCA legislation. Sen. Lautenberg is
decline in the number of elected House Democratic expected to continue to support more extensive changes,
members will make for some significant differences but some of the new Senate members are likely to op-
in EPA’s budget, legislative proposals and general pose any legislation that seeks to “expand government.”
operations. Meanwhile, some newly elected senators The most interesting question lies with the response Changes in the
stridently oppose government expansion and want to of the chemical industry and its allies to the change
rein in federal deficit spending, which could affect in House leadership. Notwithstanding the rhetoric of Senate will affect
the future of EPA and other government agencies. agreeing on many, if not all, of the principles of TSCA any prospects
reform, industry trade groups or any of their members
Committees of Jurisdiction put forth no legislative proposal. Perhaps now with for EPA’s toxics
Changes in House committee leadership will be expected friendlier forums for discussion of TSCA program.
monumental. Most notably, Rep. Fred Upton (R-MI) amendments, industry representatives will hesitate less
replaces Henry Waxman (D-CA) as House Energy and to develop specific amendments they believe will give
Commerce Committee Chairman. This will affect any expression to the stated principles.
prospects for climate legislation, as well as almost every Federal Insecticide, Fungicide, and Rodenticide
element of EPA’s operational programs. The new goal Act (FIFRA) implementation has been quiet over
for many interested parties, who a short time ago hoped the first half of the Obama administration. The new
for expansion of EPA programs, now will be to maintain Republican majority in the House will likely lead to
the current status quo. some level of aggressive oversight of all EPA programs.
EPA’s budget will also face an expected spend- For the pesticide program, immediate candidates for
ing freeze, and is less likely to be allowed exceptions an increased level of scrutiny include the use of “good
or special initiatives directed by the Appropriations science” in decision-making, the use of FIFRA or
Committee. The new chairman of the Oversight and Food Quality Protection Act (FQPA) authority in
Government Reform Committee, Rep. Darrell Issa removing pesticide uses from the market without go-
(R-CA), intends to conduct extensive oversight hear- ing through the FIFRA cancellation process, specific
ings on various programs and agencies. product decisions, and transparency and participation
In the Senate, much less change in committee in developing new program initiatives.
leadership is expected. Sen. Barbara Boxer (D-CA)
was reelected, and is expected to continue as chair of Administration Reaction
the Senate Environment and Public Works Commit- As President Clinton reminded leaders of the Republi-
tee. Senator Boxer renewed interest in focusing on can “takeover” in 1995, the President remains relevant.
climate change. Sen. Lautenberg (D-NJ) was not up Presidents can unilaterally sign Executive Orders or
for reelection, and is expected to continue to champi- determine priorities under current law. One such
on Toxic Substances Control Act (TSCA) reform and example for President Clinton came in 1995 when the
attempt to keep it high on the Committee agenda. President ordered EPA to accelerate the expansion of
Toxics Release Inventory (TRI) and issued an Executive
EPA Appropriations Order mandating greater TRI reporting obligations on
In addition to any expected freeze in domestic pro- federal contractors. The Obama White House likely will
gram spending, EPA could face a variety of restric- consider similar initiatives.
tions or reductions in its operating programs. Some
legislators could also attempt to use appropriations Lynn Bergeson, Regulatory Editor
restrictions to limit any EPA program or policy, which lbergeson@putman.net
is speculated to be a real possibility in 2011.
Lynn is managing director of Bergeson & Campbell, P.C., a Wash-
Chemicals Management ington, D.C.-based law firm that concentrates on chemical industry
The future of EPA’s toxics program is one of the most issues. The views expressed herein are solely those of the author.
CP1101_19_Comp.indd 19 12/27/10 11:57 AM

Positive outlook should last through 2012 with emerging nations posting strongest gains
By Thomas K. Swift, American Chemistry Council
The global economy clearly has emerged chemicals, rebounded robustly during the 1st half
from the deepest recession since the Great De- of 2010 but growth has slowed following the end
pression and a recovery has evolved into expan- of the inventory rebuild. This sector remains well
sion in much of world, especially in developing below its past peak. With consumers still cautious
countries. For the United States, however, a boost and incomes constrained by unemployment,
from inventory restocking has played out and retail sales have softened, though; production of
underlying demand remains weak. The housing durable consumer goods, e.g., appliances and fur-
sector, which precipitated the downturn, contin- niture, has moderated. Light vehicle production,
ues to struggle as foreclosures mount and high which fell sharply during the recession, has come
unemployment persists. The slow U.S. economic back strongly and continues to expand — vehicle
growth to date hasn’t generated jobs for most of sales should rise in 2011 and 2012. Housing mar-
the 8 million put out of work since the begin- kets, however, still need additional time to fully
ning of the recession in December 2007. Gross repair and recovery isn’t expected until 2012.
domestic product (GDP) remains below its past
peak and should increase at a subdued pace com- THE GLOBAL CONTEXT
pared to rates typical at this point in a recovery. The worldwide recovery continues to advance,
Consumer spending, traditionally an engine especially in developing countries. Global trade
of growth, should rise slowly as payroll growth has rebounded sharply from the steep drop in
lingers and consumer behavior remains cautious. 2009 and should expand significantly in 2011
Business investment should be a driver. The and 2012 (Figure 1). In the developed countries
recovery is fragile; multiple risks remain and the consumer and government austerity constrain
wrong trade, tax and other policy initiatives could growth; demographic factors also pose obstacles
derail activity. to long-term economic growth there. Growth in
With the exception of building and construc- emerging markets, however, continues robust and
tion, most major end-use markets for chemicals will underpin economic developments during the
have recovered — some quite strongly. The manu- next 10 years. Fears of sovereign debt crises and
facturing sector, which is the largest consumer of asset bubbles have dampened expectations.
CP1101_20_26_CoverStory.indd 20 12/27/10 11:58 AM

2010 2011 2012
During 2010, trends in the global business of now has experienced recovery. Demand upswings
chemistry paralleled those in broader industry. continued in North America, Europe and Japan
Overall activity in the $3.43-trillion worldwide while emerging markets sustained strong mo-
chemicals sector improved about 9% in 2010 as mentum. At the global level, production volumes
the global economic recovery extended into its exceeded their previous peak in 4th quarter
second year. After a trough was reached in March 2009, and the recovery evolved into an expansion
2009, a sharp V-shaped recovery ensued. This (Figure 2).
was particularly the case in China and elsewhere Most leading indicators of global industrial
in East Asia. Virtually every nation and region production suggest further recovery albeit at a
Global Economic Outlook
16
14
12
Real GDP change (2007-2012)
10
6
Figure 1. GDP con-
4 tinues to rebound,
led particularly by
2
increases in countries
0 such as China and
India.
-2
-4
-6
-8
-10
USA Canada UK Eurozone Japan Mexico Brazil Russia India China

Recent Cycles in Global Chemistry
tion capabilities in emerging markets in addition
110 20%
to anemic growth in domestic demand. Among
100
15% the developed nations, the United States should
90 benefit from low natural gas prices. Ireland also
10%
80
should achieve stronger growth than most other
5% developed nations. Other developed countries
70
face more-muted prospects, although Germany
0%
60 and a number of other large exporting nations
50
-5% currently are experiencing strong gains.
40 -10%
U. S. CHEMICALS OUTLOOK
89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10
For the chemical industry in the United States,
Year-over-Year % Change - three-month moving average (right) the steep and sudden drop in spending caused
Global Chemistry (excluding Pharmaceuticals)
Production Index - three-month moving average, 2007=100 (left) massive inventory imbalances going into 2009.
Demand for many chemistry-intensive items
Figure 2. Production volumes now have surpassed their previous peak in late (light vehicles, construction goods, appliances,
2009.
furniture, carpeting, etc.) plunged. As a result,
Global Chemistry Outlook inventories surged throughout the supply chain.
15 Much of 2009 was spent working these invento-
ries down. As a result, chemical production was
weak as were shipments and most other indicators
% change in production volumes
10
of industry activity.
A recovery emerged in mid-2009, fueled by
5 stronger export demand bolstered by an improved
competitive position with regard to feedstock
costs. The upswing continued into 2010, boosted
0
initially by restocking among downstream cus-
tomers. After the 1st quarter, though, domestic
-5 demand slowed and in some markets even de-
clined, thus increasing the importance of export
-10
markets. Indicators of industry activity all went
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 up during 2010. Production of chemicals exclud-
Developed Nations Emerging Markets
ing pharmaceuticals should rise 5.2% in 2010.
Figure 3. Emerging markets not surprisingly will continue to pace the produc- Basic chemicals — inorganic chemicals,
tion buildup. petrochemicals, plastic resins, synthetic rubber
and man-made fibers — were hardest hit in the
diminished pace. As the worldwide expansion recession, having suffered sharp falls in demand
continues, global output should rise by more than from important customer markets such as light
5% in both 2011 and 2012. During the next two vehicles and housing. This segment, however,
years the most rapid growth should occur in the reached a trough first and has experienced the
developing nations of Asia-Pacific, Africa and the strongest cyclical recovery. Downstream custom-
Middle East, emerging Europe and Latin America ers remain cautious about building inventories
(Figure 3) — most notably China, India and but have largely depleted their stocks; improve-
Brazil. Korea, Singapore and Taiwan also should ments in final demand will necessitate replenish-
present good prospects through 2012. Growth ing once caution is overcome. Many downstream
in the chemical industries of emerging nations customers still face credit and liquidity issues. As
should exceed 12% in 2010, with average gains of is typical in cyclical rebounds, adhesives, coatings
about 8% in 2011 and 2012. and other specialties should lag basic chemicals,
In contrast, after the cyclical rebound of experiencing a more-nominal gain initially but
2010, the chemical industries of developed na- stronger ones in 2011 and 2012 (Figure 4).
tions should average only 3% growth during Leading indicators of manufacturing activity
2011–2012 due to headwinds from rising produc- are pointing to slowing demand. U.S. chemi-

Corrosion_Conferance_ad.pdf 1 12/22/10 1:00 PM
CM
MY
CY
CMY

U.S. Chemicals Production
dampen domestic demand further while a weak
15
world economy would adversely affect exports.
Another downside risk might arise if significant
10
% change in production volumes
output from new capacity in the Middle East

5 and East Asia finds its way into traditional U.S.
export markets and even North America.
0 With a slow recovery of volumes, overall
operating rates rose to an average of 74% in 2010
-5
— see CP ’s Economic Snapshot, p. 12. Further
-10
modest gains in chemical industry production
volumes suggest slowly improving operating rates
-15 in 2011. Further capacity reduction coupled with
strengthening production volumes could boost
-20
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
capacity utilization to 79% by 2012. This implies
Basic Chemicals Specialties the industry is operating far below its optimal
capacity utilization levels.
Figure 4. As is usual, basic chemicals rebounded more strongly initially but
specialties should pick up.
CAPITAL SPENDING PROSPECTS
Narrowing margins, austere market conditions,
U. S. Chemicals Capital Spending
lower operating rates and a high level of uncer-
$35
tainty spurred the stringing out or delaying of a
$30
number of chemical industry projects in recent
years. Furthermore, companies slashed capital
$25 spending budgets to conserve cash f low. As a
Billions of dollars
result, U.S. capital investment in chemistry fell

$20 by more than 9.2% to $25.3 billion in 2009. This
followed a 9.3% drop in 2008 from a peak level
$15 in 2007. Despite a recovery, lingering uncertainty
concerning future demand combined with lower-
$10 than-average operating rates hindered investment
again in 2010, with capital spending falling 1.0%
$5
to $25.1 billion.
Capital spending cycles generally lag cycles of
$0
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 industry activity with profits and operating rates
leading determinants of investment. In general,
Figure 5. A large portion of investments will go for replacing worn-out assets
rather than adding new capacity. improving production and utilization rates, cost
containment from earlier cost-reduction efforts,
cal industry growth should rise 3.0% in 2011, modest increases in raw material costs and higher
buoyed particularly by pharmaceuticals; exclud- gains in selling prices have resulted in a strong
ing pharmaceuticals the chemical industry will recovery of profits during 2010. In addition, uti-
experience a 2.7% gain in 2011. Nonetheless, the lization rates have improved, although they still
gains should be broad-based and more sustainable don’t match the levels of several years ago and are
growth is likely. below the long-term average.
The strong projected 2010 year-on-year Other factors influencing the level of capital
growth rates for most segments must be viewed spending include the business cycle, long-term
in the context of the exceptionally sharp de- business expectations, taxation policies, the cost
clines seen in 2008 and continuing into 2009. It of capital, the burden of debt, the supply of credit
may take years for activity to recover from these and mandated expenditures. The business cycle
steep drops to reach past peaks. The industry is was in a repressed stage in 2009 and a muted
sensitive to a number of risks, most particularly recovery occurred in 2010. Lingering credit tight-
high and volatile energy costs. A double-dip in ness, companies’ debt reduction efforts to repair
the U.S. economy and industrial activity would their balance sheets, and uncertainty over taxation

RELATED CONTENT ON
CHEMICALPROCESSING.COM
and other policies as well as long-term demand are “Economic Snapshot,”www.ChemicalProcessing.com/
hindering capital spending. On the other hand, Media/MediaManager/CP1101_Economic_Snap.jpg
low interest rates make for a low cost of capital. “Better Times Beckon for Contract Engineers,” www.
The stage is set for improving operating rates ChemicalProcessing.com/articles/2010/203.html
and profit margins. This, in turn, could lead to “2010 Salary Survey: Clouds of Concern Begin to
moderate increases in investment in new plant Clear,” www.ChemicalProcessing.com/articles/2010/067.
and equipment in the United States. The need html
to replace existing assets is apparent and will be
a driver. By 2011 the industry investment cycle POSITIVE SIGNS
should re-engage, with U.S. spending rising more Chemicals output now is on the upswing,
than 6% and accelerating to a 9% gain in 2012. especially in developing countries. Worldwide
Capital spending should reach $29.2 billion in production should increase moderately in 2011
2012 (Figure 5), which still falls short of the and 2012. The U.S. chemical industry should
most recent peak. The largest proportion should share in these gains and should boost its capital
continue to go toward replacement of worn out spending, with much of the investment aimed at
assets. The majority of the expansion of produc- replacing aging plant and equipment. However,
tion capacity should target existing product the prospects of abundant and cheap natural gas
ranges and largely be incremental. As the recovery ultimately may make the United States again a
strengthens into an expansion, spending should location of choice for new capacity.
rise in future years. With improving competitive-
ness resulting from developments in shale gas, the THOMAS K. SWIFT is chief economist and managing direc-
United States may once again become a favorable tor of the American Chemistry Council, Arlington, Va. E-mail
location for investment. him at kevin_swift@americanchemistry.com
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Safeguard Your
Safety
Review
Assumption gaps can undermine a process hazard analysis
By G.C. Shah, Mustang Engineers
If listeners misunderstand what a speaker A PHA facilitator should confirm that systems (e.g.,
means, problems can arise. Such an assumption gap material inspection and welding procedures) are in
is particularly dangerous during a process hazard place to verify equipment meets all safety requirements.
analysis (PHA). It could result in inadequate identifi- Multi-plant sites. Plant acquisitions and joint
cation of hazards and major hazards left hidden. ventures can result in sites housing operating units be-
Typically, PHA activities are collaborative efforts longing to different organizations. Often, the organi-
between a facilitator and a team. The facilitator asks zations share some utilities or services. The accounting
a series of questions and the team then works col- and business agreements generally are worked out in
lectively to identify hazards. Because its results form meticulous detail. However, the lower-level procedural
the basis for subsequent safety analyses, the PHA is issues, including safety and risk containment, aren’t
recognized as the foundation upon which the safety of given sufficient thought in some cases. For instance,
the entire project rests. So, here, we’ll look at several many units may share a common flare and a flare
assumption gaps to consider while performing a PHA. header and may have good accounting (flow totalizers)
This list isn’t by any means comprehensive. — but may lack effective coordination on flare design,
Metallurgy. During the design stage, material se- modification or operation among various units.
lection gets considerable attention to ensure hardware Some questions to ponder include:
can handle the corrosion and erosion anticipated dur- 1. Do the flare and its ancillaries (header, knock-
ing normal and abnormal operations. However, there out drum and pumps) have adequate capacity to
may be some assumption gaps. handle anticipated flows resulting from the project
Consider a question by the PHA facilitator: “Is the modifications?
metallurgy of the equipment adequate for all antici- 2. Do release scenarios for the flare system con-
pated operations — normal as well as abnormal?” sider all units at the site?
The PHA team typically would respond “Yes. Met- 3. Are management systems in place to ensure that
allurgy has been considered thoroughly in design.” all companies thoroughly review modifications that
The team may assume that quality assurance and impact the flare system?
quality control (QA/QC) in place at the fabricator and 4. Are management systems or engineering
construction contractor will ensure equipment is free controls in place to prevent unilateral modifications of
from metallurgical defects. However, this may not be shared systems prior to a multi-party safety review?
true in all situations. Indeed, in view of recent cases of 5. Are there proper installation and maintenance
poor quality control at various international fabrication procedures for relief valves and rupture discs?
shops, always re-examine the assumption of QA/QC. 6. Have all companies at the site continually
CP1101_27_28_Operations.indd 27 12/27/10 12:00 PM

management system is robust enough to ensure safe
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operation while the project is being implemented and
after project systems are put in operation.
“Don’t Underestimate Overfilling’s Risks,” www.
Risk management matrix. PHA studies often rely
ChemicalProcessing.com/articles/2010/143.html
on this semi-quantitative method that assigns risk
“Tame Your Transient Operations,” www.Chemical-
based on likelihood and consequence of a hazard. The
Processing.com/articles/2010/123.html
criteria for determining likelihood and consequence
“Watch Out With Piping, Valves and Hoses,” www.
vary widely among companies and among industries.
For instance, offshore oil/gas exploration uses different
“Keep Chemical Operations Safe,” www.Chemical-
criteria than refining in determining consequence
Processing.com/articles/2008/106.html
(severity) of an incident. The PHA facilitator should
“A Haphazard Approach Can Hobble Hazard
review the existing risk matrix to verify that a consis-
Reviews,” www.ChemicalProcessing.com/arti-
tent system of ranking risk is followed.
cles/2008/085.html
CLOSING ASSUMPTION GAPS

reviewed flare operation, emergency response systems Consider the following steps to minimize the risk of
and other utility systems? misunderstanding:
Vents. Some vents may discharge directly to the • Clearly define and communicate to management
atmosphere. On the process and instrumentation the scope of your PHA.
diagrams, they usually are shown as “vented to a safe • Prior to starting the PHA, familiarize yourself with
location.” The term “safe location” may not get scruti- the organization’s safety management systems. Ensure
nized during a PHA. An assumed “safe location” may they can accommodate project modifications safely.
not be sufficiently safe. Some natural-gas vents and • Understand the terminology of the organization
turbine exhausts are routed to the atmosphere. While and technology as far as equipment and procedures of
such vents may be small and generally pose minimal the project are concerned.
fire hazard, it’s appropriate to ensure that: • Make certain the PHA team comprehends your
1. The vent is sufficiently far from any ignition terminology.
source, sparks, or storage of flammable materials. • Pose questions to the PHA team in a clear man-
Industry standards such as NFPA-54 may help in ner. Confirm that the team understands the intention
determining criteria for “safe” locations. of questions. Include examples, where appropriate,
2. During the worst-case conditions of flow to the with your questions. For instance, in terms of double-
vent and atmospheric conditions (stable with no or block-and-bleed, you might clarify what you mean by
mild wind), the ground-level concentration of flam- the term “blocking.” Let the PHA team elaborate on
mable material poses an acceptable hazard. Similarly, their answers.
hot turbine exhausts, under the worst-case scenario, • Before beginning a PHA, review past unsafe
don’t create an ignition or a thermal hazard. incidents at the project site.
3. Venting doesn’t occur in confined spaces or • Consider a system’s approach and lifecycle safety
close to buildings. If it’s absolutely necessary to vent in to ensure safety is maintained throughout the life of
a confined area, verify that effective safeguards (e.g., the project.
gas detectors and alarm and mitigation systems) are in • When preparing the PHA report, avoid arcane
place to manage the hazard to an acceptable level. technical jargon. If you must use jargon, clearly
Isolation valves. Are these valves actually leak-proof? explain the meaning of the terms. A layperson should
For furnace operations, fuel supply is almost always be able to understand the report and implement its
double-block-and-bleed. Not all valves (e.g., plug valves) recommendations in their entirety.
are leak-proof. So, always check the valve leak rating. • As a general rule, to minimize assumption gaps
Safety management systems. Companies differ select PHA facilitators with plant or operational experi-
widely in the structure and implementation of their ence as well as good communication and diplomatic
safety management systems. It’s worth verifying that skills.
management systems suffice to prevent unsafe inci-
dents as a result of the project. Include a brief review G.C. SHAH, PE, is a safety, environmental and industrial hygiene
of the company’s safety management system as part professional at Mustang Engineers, Houston. E-mail him at ghan-
of a PHA. This review should confirm that the safety shyam.shah@mustangeng.com.
JANUARY 2011 CHEMICALPROCESSING.COM 28
CP1101_27_28_Operations.indd 28 12/27/10 12:01 PM

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29 1 11/9/2010
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CP1101_full page ads.indd 11:35 AM
By Seán Ottewell, Editor at Large
Gets Its Due

The dangers posed by combus- Industry is placing One recommendation of the
tible dusts no longer are being swept subsequent CSB studies was that the
under the rug. Tougher regulations greater emphasis on U.S. Occupational Safety & Health
and greater corporate resolve are Administration (OSHA), Washing-
addressing combustion
making dust hazard management ton, D.C., should get more actively
an increasingly important topic for hazards involved in combustible dust hazard
every manufacturing sector includ- management. In late 2007, OSHA
ing the chemical industry. issued its National Emphasis Program
Testifying to the topic’s popularity, a recent CP (NEP) on combustible dust.
webinar on dust control (now available on demand at However, in February 2008, a huge explosion
http://video.webcasts.com/events/putm001/33721/) and fire at Imperial Sugar’s Port Wentworth refinery,
attracted the second largest attendance of any such Savannah, Ga., left 14 dead and 38 others seriously
event. In it, speakers from the National Fire Protection injured. The explosion was fueled by massive accu-
Association (NFPA), Quincy, Mass., Fike Corporation, mulations of combustible sugar dust throughout the
Blue Springs, Mo., Chilworth Technology, Plainsboro, packaging building.
N.J., and Camfil Farr APC, Jonesboro, Ark., outlined Guy Colonna, division manager of the industrial
the key challenges facing the industry today. and chemical engineering department of the NFPA,
says he has attended an increasing number of dust-
THE IMPETUS management events like CP’s webinar over the last two
The importance of dust management really started to years. He attributes their popularity to a much greater
come under regulatory scrutiny in the U.S. in 2003 focus on hazard awareness across all industries and the
when the U.S. Chemical Safety Board (CSB), Wash- public following the explosion at Imperial Sugar.
ington, D.C., determined that lack of attention to dust “Earlier incidents during the decade noted and
had resulted in explosions at three U.S. manufacturing investigated by OSHA and CSB were no less signifi-
plants that year. A January fire and explosion at West cant in terms of their losses to people and property,
Pharmaceutical Services, Kinston, N.C., was caused by but didn’t stir everyone the way the Imperial Sugar
a fine plastic powder that gathered above a suspended incident seems to have established a resolve across all
ceiling over a manufacturing area; six workers died affected interests.”
and many more were injured. Three weeks later, an ac- He cites data reported by CSB in its November
cumulation of resin dust from a phenolic binder used in 2006 dust report and similar incident data published
a production area led to a blast that killed seven workers by the insurance industry that show explosions and
at fiberglass insulation manufacturer CTA Acoustics, fires involving combustible dusts aren’t that rare —
Corbin, Ky. Then, aluminum dust was found to be the about ten incidents per year took place on average
culprit for an October explosion that killed one person from the early 1980s until 2005 in the U.S.
and injured many others at Hayes Lemmerz’s alumi- “Those numbers suggest the various industries
num wheel plant in Huntington, Ind. have ‘coped’ with the hazard and operated around the
CP1101_30_34_Solids.indd 30 12/27/10 12:02 PM

hazard. At this stage, it would appear that industry Flameless Explosion Vent
is no longer looking to cope with the problem and is

resolute in finding common understanding about the
phenomenon that can lead to more effective hazard
assessment and control solutions.”
KEY POINTS
In Colonna’s experience, two issues commonly crop
up in question-and-answer sessions these days — and
both are core to coming to grips with combustible
dust hazards.
The most common relates to the hazard identifica-
tion process for examining a facility and any combusti-
ble particulates that might be involved as process input,
intermediate or final product. This generally requires
testing of a sample and then interpreting the results.
One property commonly determined is the dust’s Figure 1. Layers of stainless steel absorb heat generated
by combustion, allowing venting without flame release.
deflagration index, KSt, which indicates how rapidly a
Source: Fike.
pressure front forms and moves through the combus-
tion zone. the bulk density prorating equation are recognized as
“Often, those interpreting the data are seeking accumulating in a less packed or thicker layer while
guidance on the interpretation for the value reported. still yielding the same amount of accumulated dust
Their question asks whether a ‘low value’ for the KSt mass across a given area. The equation method for
means there is no problem from the dust in terms of establishing the layer thickness doesn’t penalize those
explosibility. The answer to that question is NO. There materials whose bulk density is low relative to other
is no target or threshold value below which no hazard materials by requiring them to comply with the same
is assumed. Lower values of the index just mean the layer thickness as more densely layered dusts,” he says.
rate of rise of the pressure with respect to time will
be ‘slower’ (in a relative sense) than other materials EVOLVING REGULATIONS
that have higher values for the index. The damage Lately, the chemical industry also has become
pattern from a low KSt value dust is different than the concerned about various regulatory standards and
damage experienced when the index is greater, but the consolidations currently afoot. Much of this revolves
overpressure is still present and capable of destroying around OSHA’s notice of its intention to develop a
structures — and the fireball also poses a hazard to federal standard to address workplace safety require-
both personnel and the facility.” ments to protect workers from combustible dust fire
The second issue involves the characterization and explosion hazard conditions.
of the dust hazard condition or area. In many cases One solution could be to adopt the five existing
this currently is based on the thickness of the layer of NFPA dust standards — there are arguments both for
accumulated dust. Colonna explains that NFPA 654 and against this strategy. So the NFPA has challenged
presents an equation that enables adjusting the per- its four combustible dust technical committees to
mitted or target layer thickness based on the specific determine a path that would consolidate the various
material’s bulk density — how packed or non-packed requirements of its dust standards into a single com-
a settled accumulation could be — while still yielding prehensive standard.
an equivalent mass per area. The layer thickness as “Those supporting the concept see that many of
used today serves as a trigger for various protective the steps in the hazard assessment process are the
measures as well as housekeeping. The prorating equa- same regardless of dust type and, once the explosibil-
tion in the standard permits users to adjust their layer ity properties are determined, the protective measures
thickness (ultimately that accumulated mass) based on are the same in general and only become unique in
the specific bulk density. their design due to those properties which become
“So, materials like tissue paper, which have a very part of the design process. A single comprehensive
low bulk density compared to wood and other materi- standard makes enforcement easier and, thus, stron-
als, when evaluated for layer thickness on the basis of ger,” notes Colonna.
CP1101_30_34_Solids.indd 31 12/27/10 12:02 PM

This changing regulatory landscape is driving spected on a regular basis and, if so, how often
increased interest in combustible dust hazards by all and who can do the inspection?
industry groups, says Bob Korn, director of sales for • How do the operating costs of inert atmospheres
explosion protection products for Fike: “OSHA’s NEP compare with capital costs of suppression or
has pushed a new emphasis on OSHA inspections flame-arrest systems?
of U.S. manufacturing facilities. In October, OSHA • W hat type of explosion suppression/relief sys-
chief Dr. David Michaels told a safety group that in tems have you seen installed on direct-contact
the three-year-old combustible dust NEP, nearly 9,100 rotary dryer applications?
violations have been found, although not all of them • W hat methods do you use to determine particle
have been for dust violations, with initial penalties size and shape?
totalling more than $19.5 million. At a symposium, Overall, the best advice he can give to a chemical
also in October, OSHA assistant secretary Jordan maker today is to perform a hazard analysis or risk as-
Barab said OSHA’s inspections of refineries under sessment of its facilities and understand where it needs
the process safety NEP has resulted in an average of to improve housekeeping, add dust collection and
17 violations per inspection with penalties averag- provide protection for processes at risk.
ing $166,000. He said 53 of 58 refineries have been “Organizations that are actively engaged in under-
inspected. At hazardous chemical manufacturing standing the hazard and taking the necessary actions
facilities, inspectors have averaged nine violations dur- to provide a safe work environment will dramati-
ing each of 136 inspections.” cally lessen the effect of an OSHA inspection and
This increase in inspection rates, coupled with any resultant fines. The chemical industry is in the
OSHA’s commitment to the creation of a combustible OSHA spotlight due to other recent serious accidents;
dust standard, has the U.S. chemical industry scram- consequently they are in the top three of industries in-
bling to understand the hazards and develop strategies spected by OSHA under the combustible dust NEP.”
to protect their facilities, Korn believes. For Fike, whose business centers on supply of
This scramble is reflected in the sort of queries he explosion-protection and fire-suppression systems, all
faced in the webinar question-and-answer session. this regulatory activity is spurring product develop-
These typically concerned equipment applications, ment. The company relatively recently introduced
code compliance issues and hazard assessment. For rectangular flameless explosion vents (Figure 1). It’s
example: working on faster-responding suppression devices
• W hat is the anticipated timeline from OSHA because speed is key when dealing with a deflagration.
on the implementation of its widely discussed “Our systems must detect the combustion event and
combustible dust standard? inject a chemical suppressant in a matter of millisec-
• Does your suppression equipment need to be in- onds. From time of detection to full release of the
suppressant happens typically in less than 50 millisec-
Blowout Panels
onds. It takes approximately 250 milliseconds to blink
your eyes, for comparison.”
The company also is looking at impulse valve tech-
nology for opening its chemical suppressant contain-
ers for explosion suppression and chemical isolation of
interconnections between vessels. “The impulse valve
will provide the quick activation we need without the
use of a pyrotechnic GCA [gas charged activation] de-
vice that is currently used. This will be a great benefit
to future systems as we can eliminate the shipping and
handling issues associated with these GCA devices,”
he explains.
EFFECTIVE HOUSEKEEPING
This is a key issue, stresses Dr. Vahid Ebadat, CEO
of Chilworth Technology: “The severity of an explo-
Figure 2. Rebuilt Port Wentworth, Ga., sugar refinery now
contains such wall panels for fire and dust safety. Source:
sion is often directly related to the size/quantity/
Imperial Sugar. spread of the available fuel, in this case, the dust.
CP1101_30_34_Solids.indd 32 12/27/10 12:02 PM

Dust Collection
When one studies the large dust
Figure 3. Sugar-refinery rebuild also in-
explosions that industry has been cluded this dust-collection system. Source:
experiencing, one realizes that Imperial Sugar.
almost always the fatalities and
most of the damage has not been ly in the sugar industry. However,
the result of the initial event but use of this method for conveying
the so-called secondary dust cloud sugar to the top of a 175-foot-high
explosion. Therefore, ensuring silo — as at the Port Wentworth
that the dust is contained within refinery — is unusual. Among
the protected processing equip- the safety features of dense-phase
ment and an effective housekeep- pneumatic conveying in conduc-
ing measure is in place would go tive piping are: complete contain-
a long way towards ensuring the ment of the product; minimized
safety of people and facilities.” generation of static electricity;
The huge accumulations of and no moving parts that could
sugar dust at the Imperial Sugar re- cause frictional heating or impact
finery clearly resulted from a failed sparks,” notes Ebadat.
housekeeping strategy, something The rebuilt refinery also fea-
that Chilworth has been working tures wall blowout panels (Figure
with the company to rectify. 2), dust collection systems (Figure
The last stage in the rebuild at 3) and explosion suppression
the refinery involved the three sugar devices (Figure 4).
silos, each with a storage capacity of
6.5 million pounds of sugar, or 19.5
million pounds total — three million
pounds more than the former silos
held. All sugar begins its curing
journey in a primary condition-
ing silo, where dehumidified air is
percolated through the silo for 24
hours and where a dust-collection
system removes dust. The sugar then
moves to one of the other two silos,
where it sits in storage before moving
to packaging or to a bulk station for
distribution.
Following consultations with
Chilworth, Imperial Sugar opted
for 56 pressure-relief vents on each
of its silos at the Port Wentworth
refinery. More unusual, however, is
the conveying sugar through the si-
los via a dense-phase system instead
of belt or screw conveyors or bucket
elevators. The advanced system uses
high-pressure air to pump sugar
within pipes at a rate of 225 tons/hr.
“Dense-phase conveying is
a form of pneumatic conveying
that is used in the grain, flour and
chemical industries, and for wood
chips and sawdust, and infrequent-
CP1101_30_34_Solids.indd 33 12/27/10 12:03 PM

Explosion Supression
RELATED CONTENT ON
The OSHA NEP has led to “Dust Control,” free on-demand webcast, www.
an increasing degree of aware- ChemicalProcessing.com/articles/2010/204.html
ness in the issue, he believes. “Understand the Shocking Truth,” www.Chemical-
“And rightly so. Many com- Processing.com/articles/2010/192.html
panies still don’t realize that “Expect More Inspections,” www.ChemicalProcess-
combustible dusts can be just ing.com/articles/2009/217.html
as dangerous as flammable “Get Up-to-Date on Explosion Venting Re-
PANEL liquids and gases.” However, in
preparing for an OSHA inspec-
quirements,” www.ChemicalProcessing.com/ar-
ticles/2009/047.html
DISCUSSION tion, companies handling and
processing combustible powders 2. Understand your own powder handling and
WEBCAST and dusts have become increas- processing operations. You should be able to identify
ingly more proactive with their likely ignition sources during both normal and abnor-
combustible dust management mal operating conditions. Also pinpoint location(s)
Figure 4. Multiple units activities, he adds. where combustible dust clouds could exist during
now are installed at
Port Wentworth sugar Ebadat off ers four pointers on how to succeed normal and abnormal operating conditions.
refinery. Source: Impe- in such activities: 3. Take effective measures to avoid or control
rial Sugar.
1. Properly assess your dust’s fire and ignition sources and formation of combustible dust
explosion characteristics so adequate measures clouds. Also consider explosion protection (such as
can be taken for the prevention and mitigation venting and suppression) and isolation to lower the
of hazards in your own facilities and, if you are risk to a tolerable level.
shipping the dust to some other facilities, at those 4. Maintain dust explosion prevention and mitiga-
locations. tion measures.
Register now! 2011 CP PANEL DISCUSSION WEBCAST SERIES!

Join Chemical Processing editors and industry experts as we engage in lively discussions about
strategies, industry challenges and solutions during our CP Panel Discussion Webcasts. Each 60
minute Webcast features experts on the topic being discussed and will also include a Q&A session
with all attendees. Register now for the remaining CP Panel Discussion Webcasts at
www.ChemicalProcessing.com/cpseries
Additional 2011 CP Panel

Next up! Discussion topics include:
Condition Monitoring – February 17, 2011, 2:00 PM ET Asset Management - April
Plants are stepping up their efforts to monitor the condition of key assets to identify potential
problems before they effect operational performance, damage equipment or lead to Emissions - May
costly downtime. This discussion will review key tools and solutions that will enhance your
Alarm Management - June
operations, optimize efficiencies, improve asset life and improve overall reliability. Learn what
you need to do to bring your condition monitoring program up to date. Register now! Dust Control - July
CFATS - August
For more information on each of these Process Safety – Sept.
exciting 60-minute Webcasts and to register, go to: Energy Efficiency – Oct.
www.ChemicalProcessing.com/cpseries Dry Materials Handling – Nov.
CP1101_30_34_Solids.indd 34 12/27/10 12:03 PM

Understand Safety
System Tradeoffs
Each fieldbus approach has advantages and limitations
By Ian Verhappen, Industrial Automation Networks
Chemical plants treat safety as a top prior- nies remain wary of both. Hopefully this article
ity and install a variety of safety equipment and will shed some light on some of the tradeoffs to
systems. However, changes in technology as well help you make an informed decision consistent
as new standards suggest that plants take a fresh with your-risk management practices.
look at their safety systems. Many facilities may
be missing an opportunity to improve safety via SAFETY BUSES
a fieldbus. The majority of fieldbus protocols now Conventional fieldbus networks aren’t suitable for
have an approved safety bus. In addition, many safety-related controls. Additional error detection
automation vendors today favor integrating the and avoidance mechanisms are required for the
safety instrumented system (SIS) with the process communications between devices to detect con-
control system. nection or device failures and to implement neces-
Figuring out what makes sense for your plant sary emergency shutdown action to avoid danger.
requires an understanding of fieldbuses (see “Take The majority of fieldbus systems use a “black
Advantage of Fieldbus,” www.ChemicalProcess- channel” approach to their safety communications
ing.com/articles/2010/149.html) and of the pros bus. This basically means the physical layer is the
and cons of the various fieldbus safety approaches, same as their “regular” bus, but with extra checks
including integration. Using fieldbuses for safety and balances to meet additional protections
and integrating the safety system with process and features required of a safety system. These
control systems are relatively new concepts in the enhancements make the bus a “safety bus” and, in
chemical industry — so, many operating compa- many cases, allow sharing infrastructure between
CP1101_35_38_Intsru.indd 35 12/27/10 12:04 PM

that safety bus and conventional control commu- requirements and criteria upon which a device’s
nications. Despite being able to do so, few if any reliability and, hence, SIL rating are based. IEC
users will mix their control and safety systems at 61511 is the more important standard for end
the physical layer. users as it defi nes how systems are to be designed,
When fieldbus organizations say their fieldbus installed and operated. ANSI/ISA-84.00.01-2004,
safety devices comply with their appropriate safety www.ChemicalProcessing.com/ISA-84, is the
standard, it means the device is compliant and ANSI-approved and OSHA-referenced version of
consistent with IEC 61508 and verified by TÜV this document and the one to which systems in
or some other safety organization. Devices and the United States must comply. The most recent
hosts/logic solvers therefore require two sets of release includes statements permitting use of
safety approvals now — one for the safety fieldbus fieldbus communications as part of safety systems
or communications and a second for the associ- and removes the requirement that SIS and process
ated safety integrity level (SIL) rating. After ob- control systems must be separate. As a result of
taining approval for the communications/fieldbus this change, ISA has issued a technical report,
part of its device, a manufacturer must obtain SIL ISA–TR84.00.06 “Safety Fieldbus Design Consid-
certification from an appropriate organization. erations for Process Industry Sector Applications,”
Most safety fieldbus specifications are designed www.ChemicalProcessing.com/ISA-TR84, that
so devices can achieve a minimum SIL-2 rating, describes the requirements for using fieldbus in
although many buses are certified to SIL 3. safety applications.
Figure 1 shows how a combination of changes The June 2009 release of the ISA18.2 standard,
to both the function blocks (circles in the devices) www.ChemicalProcessing.com/ISA-18.2, has ac-
and communications layer (squares) are needed to celerated the pace of convergence of control and
meet the requirements of IEC 61508 to obtain the safety systems and is leading practitioners to take
SIL rating necessary for a safety bus implementa- steps to treat the two holistically. However, some
tion. The function block changes add the neces- see that approach as counter to the principles of
sary safeguards to the traditional function blocks safety systems. A debate is raging about the wis-
used for control while the communication layer dom of combining these two systems in a single
changes perform additional checks on the mes- environment.
sages themselves. Results of a 2009 online CP poll about SIS
preference (www.ChemicalProcessing.com/arti-
SAFETY STANDARDS cles/2009/134.html) show how polarized positions
The two international standards applicable to are. More respondents (63%) chose “separate from
the process industries are IEC 61508 and IEC the control system” than “integrated with the con-
61511. The IEC 61508 standard is most relevant trol system” (37%). Not a single person selected
to safety device manufacturers as it defi nes the “no preference” or “don’t know.”
Achieving SIL Rating As Figure 2 indicates, safety systems are one
part of the “layers of protection” strategy used to
FF-SIS User Application Extentions
SIS protocol above the Black Channel detects network faults and appropriate action keep a process from entering unsafe conditions.
is taken without human interventions. (circles) The process design itself is where the principles
Function Block diagnostics detect application faults and appropriate action is taken
of safe design must begin. Safety systems serve as
without human intervention (squares) the fi nal automation-based step to control a plant
disruption before mechanical protection must
take over. So, safety systems must have the highest
Design to
IEC 51508 levels of reliability — this involves removing or at
New SIS Function Blocks &
Function Block Diagnostics
least markedly reducing possible single points of
failure of the system and of course minimizing the
Black Channel
impact of any failure that should occur.
Careful design is crucial for a combined sys-
Design to
IEC 51508 tem — with these being new, fi nding people who
know how to do a design correctly can be a chal-
lenge. Otherwise the resulting system could lead
Figure 1. Changes to both function blocks (circles) and communications
layer (squares) are required. to lower overall reliability not only of the safety
CP1101_35_38_Intsru.indd 36 12/27/10 12:05 PM

Layers of Protection
system but the control system as well. Th is often is Process Design
part of the price of compromise. Basic Process Controls, Process
Alarms & Operator Intervention
IMPLEMENTATION OPTIONS
Critical Alarms, Operator
Today, four approaches are available: Intervention & Manual
The fi rst is the traditional route of providing Intervention
two separate and unconnected systems from the
Automatic Response; SIS,
same or diff erent vendors. Th is is the highest cost ESD, etc.
option, both in terms of upfront expenditures and
ongoing outlays for operations and maintenance. Mechanical Protection:
Relief Valves, PSV, etc.
The second option is top-level integration of
the human/machine interface (HMI) function.
Th is relies on a single supplier providing separate
controllers that are both connected to one HMI
via a network. Because the controllers are separate
and diff erent, controller programming requires Figure 2. Safety instrumented systems aren’t enough on their own to
two engineering workstations. Costs are lower keep operations safe.
than with two distinct systems because common

hardware is used at the HMI level. of a control system to implement and maintain
The third uses two HMIs, two controllers and because, in many cases, this requires mapping of
two networks, like the fi rst option, but features parameters across gateways and protocols. In addi-
two controllers from the same vendor. Th is allows tion, typically when something goes wrong at least
programming of both controllers from the same two vendors are involved — it’s always the other
engineering workstation. Because the equipment is supplier’s fault, with you, the customer, being
all confi gured and operated from the same operat- stuck in the middle with the unresolved problem.
ing system and development environment, this One advantage of having separate safety and
approach cuts training and maintenance time. control systems is that changes (addition or re-
The fourth option, which is the most integrat- moval of new hardware, system software updates,
ed one, uses common HMIs and two controllers network changes, etc.) to one system don’t directly
from the same family of a single vendor’s products. affect the other. Therefore, when it’s necessary
Both controllers are connected to the HMIs via a to do this sort of work or even to conduct the
single network and, in some cases, can reside on mandated periodic testing of the full safety loop
the same backplane. Th is is the lowest-cost choice (input, logic solver and output), there’s no risk of
because common HMIs and common engineering inadvertently introducing a disturbance to the
workstations are employed. regulatory control environment.
However, the economics of safety systems involve Regulations increasingly are mandating use
more than just “dollars and cents.” So, let’s look a of safety systems in smaller facilities for such ap-
little further at the economic side of the equation. plications as burner management of furnaces and
boilers. Th is may make a combined system a better
ECONOMIC DRIVERS fit for such sites, which often have limited staff
As noted before, the trend — at least from the — because the people responsible for the plant’s
perspective of distributed control system (DCS) automation systems will only have to work in a
suppliers — is to incorporate the logic solver into single integrated environment instead of having to
the DCS hardware so all components are part of learn how to maintain two different systems.
a single environment. One of the biggest benefits One of the key considerations in obtaining a de-
of this is that the end user now only has a single sirable SIL rating is the time between maintenance
confi guration and maintenance environment and and testing (proof test interval); devices that fail
HMI interface for all data points. more often require increased testing (less time be-
Another significant impact of using the inte- tween intervals) to compensate. Diagnostics enable
grated approach is removal of a third party inter- continuously monitoring the health of all compo-
face (connection to a different system). Integrating nents in the system that can communicate digitally
diff erent systems is always the most difficult part with each other including smart field devices.
CP1101_35_38_Intsru.indd 37 12/27/10 12:05 PM

Four Options
diagnostic information, including device status,
Integrated System Separate System
another link back to the safety system is required
Without Bus With Bus Without Bus With Bus for the instrument status — unless the device
Buses have lim- Integrated diag- Buses have lim- Integrated diag- has been confi gured to fail high (>20 mA) or low
ited support for nostics and field ited support for nostics and field
discrete devices device status discrete devices device status
(typically 3.8 mA).
Being all digital, fieldbuses can communi-
Only maintain a single system Most common
implementation cate field device status every update cycle and
so technical normally not only indicate OOS (out of service
support is widely
available or failed) but also measurement deterioration or
Single integrated environment/ Isolation of safety and control systems
uncertainty. Integrated host systems typically
interface share this type of information more easily than
standalone designs.
Table 1. Integrated and separate safety systems offer different benefits.
Buses, especially Foundation Fieldbus, have
The majority of smart devices today use HART limited support for discrete input/output (sole-
communications. The safety system logic solver noids and contact inputs). Foundation Fieldbus
uses the analog signal while the digital signal, was designed for continuous processes, so discrete
which contains maintenance and diagnostic processes aren’t its core strength. It does support
information, normally goes to a separate system several discrete output (on/off ) process valves,
linked to asset management software. (HART though. The Fieldbus Foundation recently re-
has limited support for discrete devices and thus leased a new transducer block for analog output
only provides sparse information for these types devices (control valves) to enable partial stroke
of instruments and output devices.) Because a testing — in part because such testing is a critical
dedicated asset-management system interprets the component of the testing of safety control loops.
In the end, it’s still a case-by-case decision,
somewhat like deciding whether to use a multi-
purpose tool like a Swiss army knife or a suite of
Material Handling Equipment dedicated tools for each task. Both will get the job
done but there are tradeoff s. Only you can decide
what level of risk is acceptable in your facility and
what approach will work best in your situation.
IAN VERHAPPEN is director and principal consultant of

Industrial Automation Networks Inc., Wainwright, AB. E-mail
him at iverhappen@gmail.com.
Drum Discharger Container Discharger
Lift & Dump

Container Discharger
RELATED CONTENT ON
Reader Poll: “Which Approach Do You Prefer for
Safety Instrumented Systems,” www.ChemicalProcess-
ing.com/articles/2009/134.html
“Integrated System Improves Operations,” www.
“Properly Protect Control Systems,” www.Chemi-
calPocessing.com/articles/2007/104.html
“Get Full Value from Partial Stroking,” www.Chemi-
calProcessing.com/articles/2007/046.html
Bulk Bag Filler
“Meet SIS ‘User Approval’ Mandates,” www.Chemi-
Lift & Dump Bulk Bag
Drum Discharger Discharger calProcessing.com/articles/2006/068.html
“Can You Safely Grandfather Your SIS?,” www.
Call: 800.836.7068
www.materialtransfer.com
CP1101_35_38_Intsru.indd 38 12/27/10 12:05 PM

making it work
WirelessHART Successfully Handles Control

Tests on stripper and absorber show results rival those with wired devices
By Frank Seibert, University of Texas at Austin, and Terry Blevins, Emerson Process Management
In recent years the Separations

Research Program (SRP) at the
University of Texas at Austin has been
involved in testing pilot plant pro-
cesses that require significant equip-
ment modifications and additions.
In these activities, process setup and
decommissioning take about three
times longer than the actual runs. So,
decreasing setup time and pilot plant
downtime are a high priority. Use of
wireless transmitters provides a new
degree of flexibility in reconfigur-
ing the process without installing or
relocating transmitter wiring.
The flexibility of being able to
work on the absorber and stripper
without disconnecting cables offers
ongoing benefit by reducing downtime
and maintenance. However, many
measurements that are candidates
for switching to wireless transmitters
serve for control. Thus, measurement
reliability and control performance
achievable using wireless transmitters
were of primary concern. To allow
direct comparison of the performance
of wireless versus wired installations,
wireless transmitters were installed
in parallel with wired transmitters for a few criti- collector and liquid re-distributor are located in the
cal loops on an absorber and stripper process. This middle of the column. In the SRP CO2-capture
article presents the results of these tests. experiments, ambient air is blended with recycled
stripped CO2 and make-up CO2 and fed to the bot-
PROCESS EQUIPMENT tom of the column. Carbon dioxide is absorbed into
The equipment setup used to evaluate application the downflowing amine solvent as the gas flows up
of wireless transmitters in control currently serves through the packing. The exiting solvent, referred
for testing new energy-efficient stripping processes to as the rich amine, goes to the stripping section to
associated with carbon dioxide capture from coal- remove the absorbed CO2.
fired power plants. From a process standpoint, this The stripper tests packings and determines
involves an absorber to remove CO2 from a simu- the energy efficiency associated with a proprietary
lated stack-gas stream using an amine-based solvent solvent. This column also has two 10-ft beds of
and then a stripper to recover the CO2 and recycle packing. A liquid collector and liquid re-distributor
the regenerated amine solution to the absorber. The are located in the middle of the column. The solvent
photo shows the equipment. leaving the absorber, referred to as the rich amine,
The absorber generally tests proprietary sol- is heated with the stripper bottoms liquid using a
vents and packing or tray internals. The absorption cross-plate exchanger and then is fed to the top of
column provides two 10-ft beds of packing. A liquid the stripper. A kettle-type reboiler generates vapor to
CP1101_39_41_MIW.indd 39 12/27/10 12:06 PM

MAKING IT WORK
Control Performance
Using Wired Using WirelessHART and steam flow control were modi-
Measurements Measurements fied to allow the operator to switch
Loop FIC202 PC215 FIC202 PC215 between wireless and wired inputs.
Column Column Column Column When control with wireless input was
Steam Flow Pressure Steam Flow Pressure
selected, the PID modifications for
Setpoint Average 511.32 24.01 509.66 24.01
wireless control were automatically
IAE on Control 9,134.33 145.46 10,645.15 198.60
used. Also, the new measurements
Number of Measure- 13,655.00 6,649.00 1,184.00 912.00 and a switch to select the source of
ment Updates While
on Control control input were added to the opera-
Time on Control, sec. 6,830.00 6,829.00 5,926.50 5,925.00
tor displays. Thus, using their normal
displays the operators can visually
Table 1. Wired and wireless control provided comparable results. compare wired and wireless measure-
ments at all times and select the measurement
strip off some of the carbon dioxide. The overhead to be used in control.
from the stripper goes to a shell-and-tube condenser Metrics were added to the control module
where the vapor is condensed and lean amine is to calculate the integral of absolute error (IAE)
returned to the absorber feed tank. while on automatic control. Also, the number of
new measurement values used in control and the
WIRELESS INSTALLATION duration of control were automatically captured to
Over the last few years development and design of allow comparison of wired versus wireless control
wireless field devices for the process industries has performance.
rapidly advanced. After a review of available wireless
technology, WirelessHART devices were selected THE TRIALS
for installation at the SRP. (For details about the Preliminary tests of a wireless pressure transmitter
technology, see “Make the Most of WirelessHART,” and a steam-flow differential pressure transmitter
www.ChemicalProcessing.com/articles/2008/071. took place during a recent packing characterization
html.) Pressure and differential pressure transmitters test to determine distillation efficiency and hydraulic
were put in to support testing of control of column performance of Raschig-Jaeger RSP-250 structured
pressure and steam flow. packing. (The stripper also may be used as a distilla-
The WirelessHART gateway was centrally tion column.) The column was operated at total re-
located in the process area and connected to the flux using the cyclohexane/n-heptane binary system.
control system via Ethernet. A DeltaV control system The effect of pressure on distillation performance
installed in the SRP provides standard support for also was studied. The standard test pressures were
the WirelessHART gateway as well as configuration, 2.4, 4.83, 24 and 60 psia. In the wireless testing,
setup and diagnostics of WirelessHART devices. the base pressure was 24 psia. The project sponsor,
Thus, the effort to integrate these devices into the Raschig-Jaeger, had agreed to allow the wireless test-
control system software configuration matched that ing during the runs.
associated with traditional field devices. Because Figure 1 shows pressure control achieved on the
these devices are battery powered, no power wiring column with a wired pressure transmitter and a wire-
was required to install them in the process. less one. For these tests, the proportional-integral-de-
The existing control modules for column pressure rivative (PID) tuning, filtering and control configu-
REFERENCES
1. Broadley, S., Karschnia, R., Nixon, M. and Blevins, T., “Using Wireless Transmitters in Single-Use
Disposable Bioreactor Control,” IFPAC Conf., Baltimore, Md. (Jan. 2009).
2. Nixon, M., Chen, D., Blevins, T. and Mok, A., “Meeting Control Performance over a Wireless Mesh
Network,” 4th Annual IEEE Conf. on Automation Science and Engineering (CASE 2008), Washing-
ton D.C. (Aug. 2008).
3. Johnston, G. and Munns, A., “Make the Most of WirelessHART,” Chemical Processing, May 2008,
www.ChemicalProcessing.com/articles/2008/071.html.
4. Chen, D., Nixon, M., Blevins, T., Wojsznis, W., Song, J. and Mok A., “Improving PID Control under
Wireless Environments,” ISA Expo Houston (Oct. 2006).
CP1101_39_41_MIW.indd 40 12/27/10 12:07 PM

MAKING IT WORK
Performance Comparison
Figure 1. Similar control results were

achieved with wired (top) and wireless
(bottom) measurements.
A POSITIVE STEP
Installation of WirelessHART
transmitters for stripper steam
flow and column pressure has
eliminated the cost to relocate
wiring. Column-pressure and
heater steam-flow control using
WirelessHART transmitters
and PID modified for wireless
communication provide the
same dynamic response and
performance as that achieved
using wired transmitters and
traditional PID.
The application of Wire-
lessHART is being extended to
other areas at SRP. For exam-
ple, three wireless temperature
ration were exactly the same. As this demonstrates, transmitters (4 RTD inputs per device) are being
there are no visible differences in performance. put in to monitor temperature distribution across
Similar results were observed using wired versus the absorber. Also, two wireless pH transmitters
wireless transmitters for steam flow control. Filtering are being installed in the lean liquid input and rich
was 10 sec. for the wired measurement and zero for liquid outlet streams of the absorber to indirectly
the WirelessHART one; the original plant PID tun- monitor CO2 concentration in the amine solution.
ing was used for both wired and wireless control. The Using wireless transmitters should improve the
same dynamic control was seen for set-point changes. accuracy and reliability of the temperature and pH
As the table details, comparable control per- measurements — and hence enhance stripper and
formance versus wired, as measured by IAE, was absorber operation — because the battery-powered
achieved for both pressure control and steam flow transmitters aren’t as susceptible to the ground
control using WirelessHART measurements with the loops that often plague a wired installation.
PID modified for wireless communication. How-
ever, WirelessHART used one-tenth the number of FRANK SEIBERT, P.E. is technical manager of the Separations
measurement samples for flow control and one-sixth Research Program at the University of Texas at Austin. TERRY
the number for pressure control as wired control to BLEVINS is a principal technologist for Emerson Process Manage-
reduce battery drain. ment, Austin, Texas. E-mail them at fseibert@mail.utexas.edu and
These test results indicate the combination of terry.blevins@emersonprocess.com.
WirelessHART transmitters with PID modifica-
tions for wireless communication performed as
reliably as the standard SRP hard-wired transmit- RELATED CONTENT ON
ters using traditional PID. Additional tests were CHEMICALPROCESSING.COM
carried out where compositional and packing “Wireless Proves its Worth,” www.ChemicalProcess-
efficiency HETP (height equivalent to a theo- ing.com/articles/2009/066.html
retical plate) data were obtained using the SRP “Make the Most of WirelessHART,” www.ChemicalPro-
hard-wired transmitters and then the operation cessing.com/articles/2008/071.html
was transitioned to the wireless transmitters and “Wireless Starts to Mesh,” www.ChemicalProcessing.
control. No differences in the relative bottoms com/articles/2008/208.html
and distillate compositions or HETP were ob- “Wireless Proponents Take HART,” www.Chemical-
served in the wireless mode. Processing.com/articles/2007/155.html
CP1101_39_41_MIW.indd 41 12/27/10 12:07 PM

PROCESS puzzler
Vanquish Vexing Venting

Try process-control and equipment changes to eliminate hydrogen losses
This month’s puzzler

improvements can be made, either individually
Our hydrogenation system, consisting of a column filled with cata- or together. One, install a buffer vessel between
lyst, an interchanger and a knockout drum under vacuum, produces the knockout drum and the vacuum pump with
excess hydrogen. The drum is meant to separate the hydrogen a pressure control valve between the knockout
from the product, which is then pumped to the tank farm. The drum and the new buffer vessel. The second is
vacuum pump surges constantly, unable to find a sweet spot. The to reduce the pumpout rate from the knockout
pump vents to atmosphere perhaps as much as 3 std. ft 3/min of drum. It is likely that the rate of change of pres-
hydrogen. Our plant manager wants to know if there’s a way to re- sure and the poor vacuum pump response are
cover the hydrogen and stabilize the level feeding the pump. How caused by the pump curve. A full solution would
can we address this situation? Is there any way to limp along with require a shutdown but the situation might be
this process until it’s convenient to shut it down? improved by altering the control parameters.
Edward Fish, director/consultant
ALTER THE CONTROL SCHEME Pandora Consulting, Manchester, England
There are a number of issues here, so let’s start
with the explicit one — recovery of the hydrogen. RUN BATCH FOR NOW
The vacuum discharge must be connected to the I see several design f laws in this process: the vent
hydrogen input stream, upstream of the existing stack, the configuration of the hydrogenation
H 2 f low meter. The new control loop will need column and the controls.
a buffer vessel, f low controller, f low transmitter My first thought is that the knockout drum
and a compressor. The H 2 f low must be total- is undersized. Horizontal drums are about 150%
ized so that the hydrogen supply makes up the more efficient than vertical drums. The only
difference. Before this can be done a hazard and reason for choosing the latter is to save plant f loor
operability study is needed to comply with man- space. Then, I noticed that the feed is co-current.
agement of change. Counter-current is usually the preferred ar-
The vacuum pump hunting comes down rangement because the weak stream runs into
to poor control design. Two relatively simple Continued on Page 44
March’s PUZZLER
At our batch specialty chemicals plant the production man- process proposed by the production manager appears
ager wants us to use waste isohexane as a cleaning solvent. online at www.ChemicalProcessing.com/articles/2011/
He proposes pumping the isohexane, which is available vanquish-vexing-venting.html.) What do you think of the
from a nearby process, into our columns prior to cleaning commissioning engineer’s objection? Is there a better ap-
for startup. The commissioning engineer opposes using it proach for cleaning the process?
on the grounds that a safer cleaning solvent, such as spent Send us your comments, suggestions or solutions
methanol or acetone, could be available. He suggests using for this question by January 13, 2011. We’ll include as
methanol because it’s cleaner. We’re cleaning two knockout many of them as possible in the January 2011 issue and
pots and two distillation columns that have been used for all on CP.com. Send visuals — a sketch is fine. E-mail
several months in the production of fish oil (eicosapentae- us at ProcessPuzzler@putman.net or mail to Process
noic acid and docosahexaenoic acid). The material safety Puzzler, Chemical Processing, 555 W. Pierce Road, Suite
data sheet for fish oil shows the following: closed-cup flash 301, Itasca, IL 60143. Fax: (630) 467-1120. Please in-
point, 149°C; auto-ignition point, unknown; and conditions clude your name, title, location and company affiliation
to avoid, “oxygen.” The columns each contain one eight-ft. in the response.
bed of structured packing. Normally, the columns oper- And, of course, if you have a process problem you’d
ate at a maximum of 100-torr with electric thermosiphon like to pose to our readers, send it along and we’ll be
reboilers. The condensers use chilled glycol. (The cleaning pleased to consider it for publication.
CP1101_42_Puzzler.indd 42 12/27/10 12:11 PM

PLANT INSITES
Control Issues Can Pinch Energy Savings

Heat integration can make achieving effective control more difficult
OUR INDUSTRY doesn’t use energy as effi- of run.

ciently as it could, contend some critics. They cite The bottoms stream has a minimum tempera-
plants that downgrade heat to a cooling utility ture requirement. This is a problem around 40%
or provide heat from a heating utility even when of the time because of product specifications.
temperature levels may indicate the heat can be Luckily, one steam generator (X451) is already in
recovered. These faultfinders don’t appreciate the service upstream of the proposed exchanger. It
importance of control. supplies steam to dedicated services, so maintain-
The purpose of any control system is to ing its duty at a maximum is also important. Integration
move a disturbance from where it’s undesired to While not ideal, shifting duty from the steam
where it’s unimportant. Utility systems provide generator to the new service is acceptable as long
reduces the
a straightforward and often inexpensive method as the duty shift is always minimized. Placing number of utili-
of absorbing disturbances. As a process becomes the new service after the existing steam generator
more heat-integrated, control becomes more dif- achieves this goal.
ties available to
ficult. Inability to control has real costs. Figure 2 shows the new unit configuration. A absorb control
One part of a recent project involved improving bypass loop prevents the feed from becoming too
unit heat integration. Figure 1 shows a section of hot at start of run. A second bypass loop on the
disturbances.
the unit before modification. The feed goes through tower bottoms shifts duty from the steam genera-
five heating services before heading to trim heating. tor to the new service as required. The exchanger
The trim heating energy ultimately comes from fuel pressure drops set pressure drop available for driv-
firing. The column bottoms’ product goes through ing the bypass f low. Under some conditions the
four cooling services before trim cooling. The trim heat exchangers have insufficient pressure drop
cooling duty varied from 50% to 125% of the trim to force enough f low through the bypasses. Two
heating requirement. Temperature levels were such hand-operated control valves enable adding extra
that the heat could be transferred with a 25°F ap- pressure drop.
proach temperature between the streams. At fi rst The configuration changes reduce the number
glance, this seems an ideal match for heat recovery. of utilities available to absorb control distur-
So, why wasn’t it being done? bances to one from three. A more complex control
One key historical reason is that both streams system is required to shift the disturbance around
are fouling — the feed moderately and the bot- the system. Some extra control f lexibility comes
toms highly. For most fouling services at moder- from allowing the bottoms temperature to rise
ate temperatures economics don’t support ap- above minimum values under some conditions.
proach temperatures less than ~35°F to ~45°F. In Flow bypasses provide a simple way to reduce
this case, though, the permitting and regulatory exchanger duty. They also decrease f luid velocity
benefits of shutting down
a heating service (the trim An Ideal Candidate?
heating) were attractive. Heat

Integration Minimum
Trim Cooling
This still leaves a sec- Stream 1
(Utility)
Temperature
Limit
ond issue, control. The feed Constraint
stream has both minimum Feed

X413 X412
Trim Heating
Minimum and
Maximum
and maximum temperature X401 X441
(Utility)
Temperature
Constraint
constraints. The necessary X442
X433 X432 Heat

surface area for a new heat- Heat Integration
Stream 3
integration exchanger to Integration
Stream 2 bfw
X452
meet the minimum tempera- steam
ture requirement on the feed X451

Tower
when fouled will overheat Bottoms
the feed when clean. Some X446 X447
type of control is needed to

prevent overheating at start Figure 1. Greater heat integration would pose risks of overheating the feed.
CP1101_43_44_InSites.indd 43 12/27/10 12:11 PM

PLANT INSITES
Heat Integration
Heat
Heat
tem will tolerate on both sides — this keeps
Integration Minimum
Stream 1 Integration
Addition
Temperature the velocities higher;
Limit
TC Constraint • using a low-fouling design on the shell-
Feed
X413 X412 X461
HC
Minimum and side — in this case, a helical baff le;
Maximum
X401 X441 TC Temperature • enabling removal of the exchanger from ser-
Constraint
X442 vice during operation for online cleaning; and
X433 X432 Heat
Integration • employing an easy-to-clean design for the
Heat
Integration
Stream 3
X452
tube side — in this case, a TEMA AET shell
Stream 2 bfw
steam to simplify exchanger cleaning.
HC X451 The final package includes process configura-
Tower
Bottoms
tion changes, control upgrades, and special design
X446 X447 criteria for the equipment.
Every plant has different constraints, so ag-
Figure 2. This layout makes handling control disturbances more difficult. gressive energy integration in your facility will
pose its own specific challenges. Nevertheless,
in the exchanger. Low velocity gives higher foul- as you reduce the use of utilities, you will face
ing rates. Using such bypasses can easily create control issues in nearly every unit. It’s essential to
enough fouling to completely negate the benefit track down the consequences of all your changes
of the new exchanger. and address all control challenges.
To reduce the effect of low velocity and faster
fouling, you must adjust the exchanger design by: ANDREW SLOLEY, Contributing Editor
• making the pressure drop as high as the sys- ASloley@putman.net
PROCESS PUZZLER
Continued from Page 42

the strong stream at either end of the equipment, expansion). Also, try reducing the ratio of H2 to
resulting in the greatest driving force. Hydro- oil. Perhaps, by watching the column tempera-
genation is very exothermic. I recall that hydro- tures, the column could be run by batch. Monitor
genation of fatty acids can be as high as 25 kcal the product quality to ensure the reaction is still
per mole. Maybe running counter-current could going on; recycle the oil to the column feed tank
decrease the wasted H2 — if the temperature rise until product quality meets specifications.
permits. To recycle the H2, design a recycle line from
The vent stack is a different matter. I assume the vent back to the hydrogen source. First,
that the process is outside and the stack is well you’ll need to add a second, larger knockout
above any building. Most chemical companies drum, maybe another at the source. The current
and refiners have been forced to get rid of these one continues under vacuum but the first drum
in favor of f lare stacks. Although H2 is lighter should operate with enough pressure to pump the
than air, there is always the risk of unfavorable hydrogen back to the source. The current drum
wind conditions. H2 has a nasty habit of infil- should catch the oil from the new one. Trap-
trating enclosures. Then there is the blue, nearly ping oil vapors may be a problem with recycle;
invisible f lame. take care in designing the drum mesh-pad mist
The most immediate concern, though, is how eliminators.
to keep the process running now. Try reducing Dirk Willard, contract staff engineer
the pressure and temperature of the column (gas Hemlock Semiconductor, Hemlock, Mich.
CP1101_43_44_InSites.indd 44 12/27/10 12:12 PM

Equipment & services
a stand-alone layer of protection

for the coker drum. The system
monitors process variables to detect
unsafe conditions. It then keeps
affected valves from opening at the
wrong time and sounds an alarm.
SIS-TECH Solutions
Screw Compressors Cut 281-922-8324
Downtime www.sis-tech.com
The Nirvana R90-160 kW/125-200 fieldbus commissioning and trou-
hp contact-cooled rotary screw air bleshooting issues for ADM users.
compressors boast V-Shield technol- A built-in expert system automati-
ogy, Progressive Adaptive Controls cally learns the communications
(PAC) protection, and sequential behavior of a segment during com-
cooling systems. These features can missioning, and over time is able to
help maximize reliability, opera- intelligently diagnose any situation
tional efficiency, and productivity, on the basis of past experience. As
preventing unexpected downtime. a result, users are provided with
The R-Series compressor line report- specific warnings as soon as the
edly offers maintenance friendly and Stainless Steel Valve Boasts software detects any condition that
ergonomic features such as single Tamperproof Lock might lead to a critical situation,
side service access with swing out The corrosion-resistant Stainless which can minimize troubleshoot-
separator lid for easy filter replace- Steel L-O-X energy isolation valve ing and plant shutdowns.
ment, cooler cleaning slide rails, less is lockable only in the OFF posi- Pepperl+Fuchs
TPM intervals/long life consum- tion (with a tamperproof locking 330-486-0002
ables and easy access to consumables mechanism) and has a large exhaust www.pepperl-fuchs.us
for service. The new R-Series is also port for rapid pressure relief. The
available with energy recovery op- Stainless Steel L-O-X is available Software Aids Lifecycle
tions to reclaim heat of compression in port sizes of ¼ in. to 2 in. and Costing of Air Filters
to help meet sustainability needs. provides direct manual operation by LCC 2010, the latest version of
Ingersoll Rand a simple push/pull of the handle. Its lifecycle costing software for air
704-655-4554 stainless steel construction and self- filters, uses theoretical averages to
www.ingersollrandproducts.com draining capability are said to make calculate the pressure loss of filters
it ideal for washdown applications. and their actual lifespan using data
The valve comes standard with collected from thousands of instal-
Viton seals that provide protection lations and tests. This information
against contaminant ingression, and helps users choose a filter with the
a pressure sensing port which allows lowest possible energy consump-
the optional installation of a pop-up tion and environmental impact.
indicator or pressure switch. By optimizing air filter choices,
System Prevents Coker Ross Controls the software reportedly can help
Drum Accidents 800-438-7677 identify substantial savings without
The Coker Drum Safety System www.rosscontrols.com compromising indoor air quality. It
(CDSS) automatically inhibits the also recommends energy-saving fan
opening of valves under unsafe Diagnostic Software speeds and generates multi-solution
process conditions. In a crude oil Speeds Up Commissioning calculations and graphical reports.
refinery, this prevents the release of Advanced Diagnostic Module LCC 2010 facilitates the prepara-
hydrocarbons or hydrogen sulfide (ADM) DTM software monitors tion of reports and recommenda-
into the atmosphere, or introduction the quality of fieldbus communications for environmentally friendly
of hydrocarbons to an open drum. tions for Foundation Fieldbus H1 air filter solutions.
The CDSS includes an independent and Profibus PA networks. The Camfil Farr
logic solver coupled with indepen- software includes updates that can 800-479-6801
dent process sensors to provide reportedly speed up addressing www.camfilfarr.com
CP1101_45_46_EandS.indd 45 12/27/10 12:09 PM

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CLASSIFIED
AD-LITS
16 PNEUMATIC CONVEYING CONCEPTS PUMP LOAD CONTROL

Brochure describes Dynamic Air‘s 16 The PMP-25 pump load control guards
different pneumatic conveying con- against dry running, cavitation and
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any conveying velocity desired to suit a given material to (888) 600-3247, www.loadcontrols.com.
be conveyed. Dynamic Air Inc., (651) 484-2900, www.
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By Order of Ercros
CHEMICAL PLANTS AND
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AS S E T S I N C LU D E :
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• CHLOROMETHANE plant designed for the production
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• DICHLOROETHANE plant for the production of 100,000
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• Plates filter
AS S E T S I N C LU D E :
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• Heat exchangers • Transformer: 500 KVA (Qty 6, 2008). 4500 KVA
• Vertical HP pumps (Qty 2, • Storage tanks: 100,000 Litre (Qty 18), Horizontal
Year 2007) (Qty 26)
To view and bid on For further information, please contact:

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CP1101_47_49_CLASS.indd 49 12/27/10 1:13 PM

END POINT
Chemical Engineers Make Explosive Progress

TNT gets a safer replacement and elastomeric material provides blast protection
While it can safely be argued that chemical engi- Anthony DiStasio, ARDEC project officer. “It signifi-
neering and chemical engineers have a substantial in- cantly reduces the logistics burden both here in the
put into most aspects of life today, Time magazine’s U.S. and overseas.”
awards for the top 50 innovations in 2010 highlights The second military innovation in the Time awards
two examples with military flavor. involves blast protection as opposed to blast generation.
The first is a safer, more stable explosive that engi- Created by flexible film and tape specialist Berry
neers tested and qualified at Picatinny Arsenal, N.J., Plastics Corporation, Franklin, Mass., the X-Flex blast
Chemical engi- as a replacement for TNT in U.S. Army projectiles. protection system is an innovative peel-and-stick solu-
Traditional TNT is relatively unstable and can deto- tion that is designed specifically to absorb energy and
neers win awards nate when dropped or when a vehicle carrying it is hit mitigate debris hazards during a significant blast event.
for military by an improvised explosive device (IED) or a bullet. Developed through a co-operative research
Called IMX-101 (Insensitive Munitions Explosive and development agreement between the Engineer
developments in 101), it packs the same punch as TNT, but is more Research and Development Center (ERDC) of the
Time magazine’s thermally stable, according to Philip Samuels, a chemi- U.S. Army Corp of Engineers, Champaign, Ill., and
cal engineer at Picatinny Arsenal’s Armament Research, Engineered Protective Systems of Berry Plastics, this
top innovations Development and Engineering Center (ARDEC). new stretch-and-catch system uses the technology
of 2010. Researchers spent four years working on the of elastomeric material to retrofit walls and greatly
material, which is scheduled for production this year. enhance ability to mitigate secondary debris hazards
IMX-101 is more expensive than TNT, with an initial associated with blast loads.
price of about $8/lb, compared with $6/lb for the “In areas where threat risk is high, X-Flex helps
traditional explosive. provide a measure of safety that was previously un-
Picatinny selected the IMX-101 formula, developed available,” says Elizabeth A. Curran, business develop-
by BAE Systems, from a group of 23 different formulas ment manager.
submitted to the Army by various government groups, Rigorous full-scale testing of X-Flex has resulted
and foreign and domestic companies. Researchers found in proven performance to specific threat levels. The
BAE’s formula to be the most cost-effective option that fiber-reinforced polymer composite is engineered for
exceeded all the system tests designed to represent real adhesion to many surfaces, and performs well across
hazards and threats soldiers face in combat. a wide temperature range and diverse environmental
Because of Picatinny’s efforts to test, qualify and conditions. X-Flex is moisture-, mold- and fungus-
apply the new explosive to existing Army and Marines resistant, and the environmentally-friendly product
field artillery projectiles, soldiers will see IMX-101 in contains no volatile organic compounds (VOCs).
155-mm M795 artillery projectiles in 2011. The new Furthermore, it is easy to transport, store and install.
explosive is also being researched for use in other types “These are factors that are critical to our military
of field artillery, another step towards the Army’s in- personnel,” adds Curran. “Unlike traditional methods
tention to phase out its stockpile of traditional TNT. for increased protection, which required specialized
“If you were involved in an incident near a tra- equipment, toxic materials, difficult transport and
ditional TNT projectile hit with a rocket propelled lengthy implementation through trained labor, X-Flex
grenade (RPG) or an IED, you wouldn’t be stand- can be installed instantly — and performs as soon as it
ing here today to tell about it,” says Charlie Patel, a is installed. Two individuals can retrofit a 10-by-10-ft
program management engineer for Project Manager wall in a matter of minutes.”
Combat Ammunition Systems (PM-CAS) on the N.J. A custom adhesive system allows the patent pend-
site. “But with IMX-101, all that would happen is the ing X-Flex to be applied to the primed interior side
explosive would deflagrate (burn quickly), and the of an exterior wall simply by removing the protective
shell would break into a few pieces. You wouldn’t have film liner and sticking the product to the wall. X-Flex
the big detonation that would wipe out the vehicle is further supported by a simple fastener at the top and
and driver or a whole storage area and crew.” bottom of the wall at the floor and ceiling interface.
“Because it’s less sensitive, the Army can store
more shells in a magazine, and store more in one Seán ottewell, Editor at Large
building at a closer distance to the soldiers,” notes sottewell@putman.net
CP1101_50_EndPoint.indd 50 12/27/10 12:08 PM

WHERE DO THE
KEY PLAYERS IN PHARMA,
BIOTECH AND MANUFACTURING
COME TOGETHER?
MARCH 29 - 31, 2011 | JACOB K. JAVITS CENTER | NEW YORK, NEW YORK
INTERPHEXConnects | www.INTERPHEX.com
Interested in exhibiting at INTERPHEX 2011? Contact Pete Zezima at 203.840.5447 or pzezima@reedexpo.com
IPX11_AD_
CP1101_fullPharmaMan_7.825X10.5.indd
page ads.indd 51 1 12/10/10
12/27/10 11:28
11:36 AM
AM
A Better IEEE 841
Super-E® windings meet or exceed NEMA High strength cast iron frame, endplates,
Premium® efficiency standards conduit box and fan cover are designed
to reduce vibration and assure accurate
mounting dimensions
All internal rotor, stator

and shaft surfaces Oversize bearings on each end
are epoxy coated to for long life
prevent corrosion
Insulation system meets Inpro/Seal™ VBXX Bearing

requirements of NEMA Isolators at both ends assure
MG 1, Part 31.4.4.2 for protection from contamination
VFD use and considered
inverter-ready
Two-part epoxy primer Exclusive PLS® (Positive

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Baldor•Reliance 841XL severe duty motors are • Energy Efficient
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Baldor•Reliance severe duty motors to perform under the • Superior Reliability
most extreme conditions...inside and out.
Now compliant with IEEE Std. 841-2009.
baldor.com 479-646-4711 • Quickest Delivery Available
©2010 Baldor Electric Company

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2010 2011 2012

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