Are Things

Looking Up?
Annual salary survey
points to some positive
developments

Industry Gets Cyber-Security

Reality Check
APRIL 2011

Make the Most of Condensate

Seal Off Centrifugal Pump Problems

Online Analytics Improves Batch

Operations

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 contents
April 2011 | Volume 74, Issue 4

18 26 30

Cover Story Columns

18 A
 re Things Looking Up? 7 F
 rom the Editor: Biofuels Development
Our 2011 Salary Survey indicates that raises are reappearing — Gets a Boost.
but not necessarily making up for previous pay freezes or cuts
and increasing costs of benefits. Satisfaction and job security 9 C
 hemical Processing Online: Blog
results are similar to last year’s poll. Broadens Subject Scope.

11 Field Notes: Know Your Rights.

FEATUREs
Design and Optimization 16 E
 nergy Saver: Optimize Your Steam
22 Make the Most of Condensate System, Part II.
Making simple changes in system designs and following prac-
tical management steps for condensate recovery can return 17 C
 ompliance Advisor: OSHA Updates
significant savings and boost heat exchanger performance. PPE Standards.

40 P
 lant InSites: Properly Assess Energy
Maintenance and operations
Recovery Projects.
26 Industry Gets Cyber-Security Reality Check
The emergence of the Stuxnet worm, which targets control 50 E
 nd Point: U.K. Wants More Chemical
systems, exposed serious knowledge gaps in how cyber secu- Engineers.
rity is implemented and maintained by process companies.
departments
Solids and Fluids Handling
13 In Process: Renewable Route Beckons for
Acrylic Acid | Nanocatalysts Boast Better
30 Seal Off Centrifugal Pump Problems
Performance
Seals play a crucial role in retaining lubricant, excluding contami-
nants, separating fluids and confining pressure. Paying proper 38 Process Puzzler: Foil Future Fires.
attention to seals can improve pump performance and life.
42 P
 roduct Exclusive: Process Gas
Making it Work Chromatograph Eases Maintenance.
34 Online Analytics Improves Batch Operations
43 Equipment & Services
The methodology promises to increase the consistency of
quality products and provide greater throughput due to better 46 Product Spotlight/Classifieds
yields, decreased cycle times and fewer outages.
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 ● April 2011

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Biofuels Development Gets a Boost
Facility promises to ease scale-up efforts
Forecasters predict double-digit annual
increases in demand for biofuels (www.ChemicalPro-
cessing.com/industrynews/2010/057.html). Meanwhile,
researchers are developing a host of technologies to make
fuels from biomass (see, e.g., www.ChemicalProcessing.
com/articles/2010/161.html, www.ChemicalProcessing.
com/articles/2010/138.html, www.ChemicalProcessing.
com/articles/2010/049.html, www.ChemicalProcessing.
com/articles/2009/131.html, and www.ChemicalPro-
cessing.com/articles/2009/071.html). However, moving
promising biofuels technology from the lab to demon-
stration scale often poses a significant financial as well as
technical hurdle.
Now, though, developers can take advantage of an
expanded government research facility. Indeed, the U.S.
Department of Energy’s National Renewable Energy
Laboratory (NREL), Golden, Colo., is eager for firms to
use its Integrated Biorefinery Research Facility (IBRF).
“The IBRF is designed specifically to help industry
scale up their technology,” notes John Ashworth, NREL
team leader for partnership development. The first
industrial user, Amyris, Inc., is expected to start trials
shortly, he adds.
The IBRF represents a $33.5-million two-stage
investment by NREL to add a new high-bay building
that houses feed-handling systems, two new pilot-
scale pretreatment reactors and four large high-solids
enzymatic hydrolysis reactors. Stage 1 was completed
last August and since then has been undergoing testing
and bringing equipment online. It includes a complete
process train — feedstock milling and handling, pneu-
matic conveying to conversion operations, pretreatment
and high-solids enzymatic hydrolysis. Its pretreatment
system is designed to handle a wide range of catalysts
and operating conditions in one or more interconnected
horizontal screw reactor tubes.
“The new [pretreatment] system can operate at resi-
dence times as low as several minutes up to two hours.
This gives us the ability to support a wide range of
pretreatment catalyst options, including dilute acid and
alkali-based treatments,” explains Dan Schell, manager
for bioprocess integration R&D.
“In the IBRF, we have two large batch mixers that
perform high-solid enzymatic hydrolysis,” notes Schell.
“Once we liquefy the biomass in the high-solids reac-
tors, we can pump it into a conventional stirred-tank
reactor and finish converting biomass to sugars. This
gives us the capability to perform enzymatic hydrolysis
at commercially relevant solids levels.”
CP1104_07_Edit.indd 7
FROM THE EDITOR
Stage 2, presently under construction, will add a
second process train with a less-complex two-reactor
vertical pretreatment system.
The IBRF provides 27,000 ft2 of high-bay space
and can process up to 1 ton/day of dry biomass. For full
details on its capabilities, check www.nrel.gov/biomass/
pdfs/49323.pdf.
“We have created an empty bay in the facility so “The facility can
someone can bring in their own pretreatment reactor
handle virtually
or other equipment required for biochemical biomass
conversion. Companies can use part of our system or any type of bio-
they can use their own technology and we can run it in
mass feedstock.”
parallel with ours.” says Ashworth.
“Industry partners can come in and try whatever
they might have in mind from a very mild pretreatment
to a very strong pretreatment and the system is set up
for that,” he adds. “The high-solid enzymatic hydrolysis
reactors sit directly beneath the pretreatment reactors.
All of this allows us to really push the limits of how you
can use the system and still get to sugars.”
The facility can handle virtually any type of biomass
feedstock, from corn stover and wheat straw, to hard-
woods and even industrial waste streams. Moreover,
notes Ashworth: “The IBRF is not restricted to one end
fuel. The technology here will work just fine if someone
wants to make butanol or take lignocellulose and go
to jet fuel or diesel. All of these technologies on the
biochemical side use pretty much the same front-end
treatment and enzymatic hydrolysis equipment.”
“There is no set fee or minimum cost. The building
and equipment are owned by the government, so there is
no charge for their use. We ask firms to reimburse us for
supplies and for the time of the engineers, scientists and
research technicians working on their project,” says Ash-
worth. Small-scale pretreatment screening experiments
or compositional analysis of key samples could cost
as little as $5,000 to $10,000 while a large multi-year
cooperative research-and-development agreement could
run into the millions of dollars.
Developers of biofuels technology ranging from
small startups to large established companies should
welcome the IBRF.
Mark Rosenzweig, Editor in Chief
mrosenzweig@putman.net
7  chemicalprocessing.com April 2011
3/25/11 11:27 AM
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Senior Digital Editor, x428
tpurdum@putman.net
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Editor at Large
Ireland
sottewell@putman.net
CONTRIBUTING EDITORS
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CP1104_09_Web.indd 9
Blog Broadens Subject Scope
The Chemical Reaction blog covers diverse topics that matter
WITH SO many stories, news items,
and articles of interest, what is a
journalist to do? If you’re a blogger,
you can turn any item into a post
geared toward the chemical industry.
And if you’ve read my blogs with any
regularity, you know the topics I cover
are varied. See for yourself by going to
community.chemicalprocessing.com/
chemical_reaction.
One recent post stemmed from a
conversation I had with Catherine T.
“Katie” Hunt, director, Innovation
Sourcing & Sustainable Technologies
at The Dow Chemical Co., regarding
her involvement in a groundbreaking
global affair entitled “Women Sharing a
Chemical Moment in Time.” This event
brought women in chemistry together
worldwide (via Skype and other elec-
tronic means) for a breakfast meeting
that was held Jan. 18, 2011.
“It was awesome, exciting and a
whole lot of fun,” says Hunt, who called
in via Skype at noon to connect with
women at Dow AgroScience in Hawaii.
“This was a global handshake around
the world that really brought people
together.” (To read “Global Handshake
Brings Chemists Together,” see the
sidebar for the URL.)
Another post focused on the issue of
worker safety. This entry drew upon the
study “Workers’ Perception of Chemical
Risks: A Focus Group Study.” Essen-
tially, it reported that chemical work-
ers feel they are at risk and don’t trust
management to keep them safe. Instead,
they rely on each other. To illustrate,
one study participant stated: “By passing
on information to our colleagues we
feel like we’re contributing to our own
safety, but that feeling soon wears off.”
(See sidebar for URL.)
Ideas for blog posts come from all
over. I was reading the New York Times
when I saw an article about how the pro-
totype kilogram has lost weight over the
last century, thus making it an unreli-
9 CHEMICALPROCESSING.COM
CHEMICAL PROCESSING ONLINE
able source of measurement. (See sidebar
for URL to “When A Kilogram Doesn’t
Weigh A Kilogram.”)
While searching for a gift for my
nephew, I came across blog fodder in
the form of an interesting book, “The
Cartoon Guide to Chemistry,” (2005,
Collins Reference). What struck my If you’ve read my
fancy was the Amazon.com review: “If
blogs with any
you have ever suspected that “heavy
water” is the title of a bootleg Pink Floyd regularity, you
album, believed that surface tension is
know the topics I
an anxiety disorder, or imagined that a
noble gas is the result of a heavy meal at cover are varied.
Buckingham Palace, then you need The
Cartoon Guide to Chemistry to set you
on the road to chemical literacy.”
I take it as a personal challenge to
work odds and ends into entertaining
and informative blog posts that serve
engineers in the chemical industry. If
you spot an idea you’d like to see as a
blog, send it my way. You never know
what I’ll write about next.
TRACI PURDUM, Senior Digital Editor
tpurdum@putman.net.
RELATED READING
Global Handshake Brings
Chemists Together
http://community.chemicalprocess-
ing.com/content/global-hand-
shake-brings-chemists-together
Chemical Workers Feel At Risk
On The Job
http://community.chemicalprocess-
ing.com/content/chemical-workers-
feel-risk-job
When A Kilogram Doesn’t Weigh
A Kilogram
http://community.chemicalprocess-
ing.com/content/when-kilogram-
doesnt-weigh-kilogram
Let Cartoons Be Your Guide To
Chemistry
http://community.chemicalprocess-
ing.com/content/let-cartoons-be-
your-guide-chemistry
APRIL 2011
3/25/11 11:27 AM
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Know Your Rights
Intellectual property agreements can pose significant concerns
You’ve got to admire lawyers for turning a
subject like intellectual property into fodder for
Ph.D candidates, I thought as I reviewed a ten-page
confidentiality agreement required of contractors.
The project looked interesting but I didn’t want to
sign away my life if things didn’t work out.
The agreement seemed to indicate that the com-
pany owned every idea I’d ever had that it deemed
pertinent to its manufacturing. The text had a
threatening tone, suggesting I alone bore the burden
of proof. I had a vision of confronting the law firm
of Payne and Fear in court. So, I put off signing this
form until I reviewed the current state of intellectual
property rights. I eventually did sign after getting
some clarifications.
In my research, I found you might face two
documents when starting with a new company:
a confidentiality agreement and a non-compete
agreement.
A confidentiality agreement defines information
you can exchange with a third party and who owns
what if you invent something for an employer. De-
fending a confidentiality agreement in court is easier
for companies; it’s more binding than a non-compete
agreement. Usually, the confidentiality agreement
has no time limit.
A non-compete agreement is more sinister. It
says you can’t work for a competitor. Courts usually
decide that a non-compete agreement bars employ-
ment for no more than a year, as in the 1999 case of
Earthweb versus Schlack; after all, the skills of the
defendant, a software engineer, might be considered
outdated or even obsolete after a period longer than
that. Rulings in Texas, California and Michigan
generally concur. Obviously, you may want to
decline such an agreement unless it’s amended to
loosen the noose around your neck.
I’ve known a victim of a non-compete agree-
ment. Shelly worked for a newspaper in Boston in
the advertising department. She signed an agree-
ment that virtually chased her out of the East
Coast. When I met her she was living in poverty
in Chicago.
Now, let’s move on to the question of what are
intellectual property rights. This has real world
consequences. I remember working with the owner
of a company on this very question. As a subcon-
tractor for a large U.S. engineering firm he was
concerned by the agreement he was asked to sign.
CP1104_11_FieldNotes.indd 11
field notes
This story was repeated at a different company on a
later contract with the same engineering firm.
There basically are two camps: those following
Massachusetts law and those following Minnesota
law. Massachusetts law says that if you have an
idea, even if completely unrelated to what your
employer manufactures, the company owns it; some
states restrict the period of time this draconian
restriction applies. Minnesota law, in my opinion,
is more lenient: a company only owns an invention
if it pertains to its production operations. Given the
complicated nature of modern manufacturing and
the intricacies of the chemical process industries, it
seems unlikely that an idea would be of much use
outside of a particular area. But, then again, a revo-
lutionary concept appeals specifically to a competi-
tor. And it’s often easy to reverse-engineer a process
— hence fewer and fewer are patented. It’s tempt-
ing, I suppose, to find an easy solution in the patent
office. Industrial espionage is a dirty business.
On numerous occasions, companies have used
recruiters to line up engineers for the sole purpose
of fishing for trade secrets. In one interview I was
brought in for, the firm seemed more interested
in what my current employer was doing than in
my accomplishments. When I mentioned this, the
interview was over. While I was with a cereal maker,
a process engineer was secretly recruited and hired
away from a competitor, in part because of the de-
tailed knowledge he’d acquired.
Another technique is to initiate bidding on a
project that will never be built. The Chinese have
used this technique against American engineering
companies. Actually, the Chinese have gone much
farther. I’ve seen them bring in a competitor to
complete a chemical plant after the constructor quit
because the Chinese were building an identical plant
next door!
In the end, intellectual property agreements
are only as good as our word. Of course, en-
gineers will feel a stronger bond to companies
that treat us with decency and respect. Perhaps
creating an honest rewards system for successful
new ideas would be more of an incentive than
the elusive suggestion of a 2% raise or a mythical
10% bonus after a productive year.
dirk willard, Contributing Editor
dwillard@putman.net
11  chemicalprocessing.com April 2011
3/25/11 11:28 AM
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 in process

Renewable Route Beckons for Acrylic Acid

New catalysts promise efficient production from lactic acid
How much does your site typically spend annually on
Alkali phosphates-modified NaY recapitalization of existing assets (as a percentage of
zeolites may spur use of a sustainable feedstock for replacement value)?

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25%
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82 Source: American Chemistry Council.
have contacted us concerning possible coopera-
81
80
13  chemicalprocessing.com April 2011
79
78
77 CP1104_13_15_InPro.indd 13 3/25/11 11:29 AM
 IN PROCESS
tion on the development.” The researchers foresee
industrial application in the near future, perhaps
in five to eight years.
“Commercial production of such a catalyst is
not a problem, [from] both [a] technical and eco-
nomical point of view,” Au and Ji say. “There are
no particular obstacles for producing the alkali
phosphates-modified zeolites on an industrial
scale. Actually, the related preparation procedures
are quite simple and straightforward.”
More details on the catalysts appear in a
recent article in ACS Catalysis.
Nanocatalysts Boast
Better Performance
A team of researchers from Northwestern Univer-
sity, Evanston, Ill., have discovered a method for
controlling the faces exposed by metal nanoparti-
cle catalysts that could improve their performance
for a wide range of structure-sensitive catalytic
reactions. Th is could have great impact for chemi-
cal companies and catalyst makers because the
selectivity and yield of these nanoparticles as
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catalysts depends on which of their crystal faces
are exposed.
Previous attempts to change the shape of the
nanoparticles were unsuccessful as the structures
reverted back to their original shape.
The team, led by Laurence D. Marks, profes-
sor of materials science and engineering at the
McCormick School of Engineering and Applied
Science, discovered that epitaxy — the relation-
ship between the position of the atoms in the
nanoparticle and atoms on the substrate — plays
a bigger role than expected in determining which
faces of a nanoparticle are exposed.
“Instead of trying to engineer the nanopar-
ticles, we’ve engineered the substrate that the
nanoparticle sits on,” explains Marks. “Th at
changes what faces are exposed.”
Marks notes that current testing shows the
nanoparticles appear to be stable enough to
survive long-term use as catalysts. More details
appear in an article by Marks and his team in a
recent issue of Nano Letters.
“The trick is to fi nd the appropriate reaction
(which is structure-sensitive), then tune the ap-
propriate metal/substrate combination to improve
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 in process

Nanoparticle Researcher nanocubes substrate could be alternative method of depositing

fairly easy to scale up. “There are
discussions in the ALD [atomic
layer deposition] community
on scaling up the method of
depositing the platinum for
catalysts and similar systems, or
with some developmental work
one could probably work out an
the Pt nanoparticles based upon
existing methods which are
already known to be industrially
scalable,” he adds.
The team would welcome
chemical companies or catalyst
makers cooperating on further
development of such catalysts.

#1 in Bearing Isolators
Figure 1. Laurence D. Marks, and his team, www.inpro-seal.com
have found a new method for positioning
nanoparticle catalysts. Source: Northwestern
University.

the performance. I would not

be surprised if we find that the
effect we talk about is already
there in some current metal/sub-
strate catalyst combinations used
industrially — and perhaps by
using our concepts this could be
designed to work better. YOUR SAME-DAY SHIPMENT SPECIALISTS
“We believe the concept as a When your equipment is down, you need a partner
method of designing better cata- that ships a solution to you same-day…not some day.
At Inpro/Seal, we recognize the high cost of downtime
lysts is most promising,” Marks facing our customers; that’s why we’ve designed our
says. “This method could be operations to support quick–turnaround of our
custom–engineered bearing protection products.
used with a variety of different
metal nanoparticles. It’s a new With manufacturing locations in North America and
the United Kingdom, we’re able to offer industry–
strategy, and it could have a very leading products with unparalleled response time
big impact.” For instance, Marks and service to customers around the globe.
The right technology…right when you need it.
has seen a “noticeable improve-
ment in propane oxidation due
to the epitaxy for platinum on
strontium titanate samples pre-
pared by the same approach.” He
adds: “I think it fair to say that
for some classes of reaction such
as combustion (e.g., automo-
tive catalysts) the improvements
could be dramatic, and there
may well be others.”
For industrial production,
Marks notes strontium titanate

CP1104_13_15_InPro.indd 15 3/28/11 11:16 AM

 ENERGY SAVER
Optimize your Steam System, Part II
A simple four-step process can improve steam efficiency
In the final part of this series, we’ll cover steps
three and four of steam system optimization.
(To review Part I, go to www.ChemicalProcess-
ing.com/articles/2011/optimize-steam-system-1.
html.)
Step 3: Review steam utilization by various
steam users. The most useful part of steam’s heat
For optimized content is its latent heat, rather than its sensible
heat. (Super-heated steam is preferred only to
steam use supply steam turbines.) To fully utilize the latent
consider other heat in steam, two critical factors apply:
1. c ontinuous removal of condensate from the
options to do the heat exchanger and
same job. 2. m aintenance of the lowest possible back-
pressure.
If the condensate removal is reduced, conden-
sate could f lood heat exchanger surface, limiting
the area available for heat transfer. If the back-
pressure at the outlet of an exchanger increases,
the latent heat available from steam would be
reduced gradually. When the backpressure equals
the supply steam pressure, the heat exchanger
potentially could stall. Hence, it is better to check
the existing heating control systems to ensure the
steam-heated exchanger is neither f looded nor
stalled. [For more on such issues, see “Make the
Most of Condensate,” p. 22.]
For optimized steam use consider other op-
tions to do the same job. Switching to motor
drives, instead of steam turbines, is a common
alternative when excessive low-pressure steam is
vented. However, when high-pressure steam is
continuously dropped through a valve to lower
pressure level, installing a steam turbine is a bet-
ter option.
Another option is to use mechanical vacuum
pumps in place of steam jet ejectors. At low
ranges of vacuum creation, steam jet ejectors need
at least ten times more input energy than me-
chanical vacuum pumps. Also, whenever steam jet
ejectors are used the condensate must be drained
to the sewer, adding to the wastewater treatment
plant load.
Many process plants use steam strippers,
where steam directly contacts the process streams
to raise the temperature of the incoming stream
and then strip out the intended component. It
would be more efficient to indirectly heat the
incoming stream in a separate (external) exchang-
April 2011 chemicalprocessing.com  16
CP1104_16_EnergySaver.indd 16
er, then supply steam only for the purpose of
stripping. This would recover part of the supplied
steam as condensate and reduce the amount of
wastewater generation.
It is very common to see many air-cooled
and cooling-water exchangers. Thus, one option
to optimize steam use is to preheat the incom-
ing stream with a process stream that goes to
cooling. It may be possible to identify a suitable
heat source nearby. In some plants, the wasted
heat from boiler or furnace exhausts also could
be utilized to preheat the incoming stream. Keep
in mind the concept of “pinch” technology —
matching suitable heat sinks and heat sources.
Step 4: Recover and reuse the condensate to
the maximum possible extent. Steam systems are
designed to work on 100% make-up boiler feed
water. In the most efficient steam systems, the
make-up water addition is only about 20%.
At present, most process plants must treat and
dispose wastewater they generate. The steam con-
densate, if not collected and reused, would end up
in the wastewater stream. So first, have your en-
ergy or utility engineer calculate the value of the
steam condensate. It could be surprisingly high,
justifying many condensate recovery actions.
Reasons for not recovering and reusing the
condensate include:
1. c ollection pipes and pumps weren’t pro-
vided in the initial design,
2. fear of contamination in the condensate, or
3. c oncerns about backpressure/water hammer
in the return system.
Modern online analytical instruments can
obviate fear of contamination, eliminating that
excuse for draining the condensate. Specialists
can easily address backpressure and water ham-
mer in the return system. In addition, reengineer-
ing the existing system with necessary piping
changes and additions could eliminate the water
hammer problem. Cases exist where prolonged
water hammer caused catastrophic damages to the
integrity of steam systems — with a few ending
in fatal accidents. Eliminating water hammer not
only optimizes the steam system, but improves
the system’s integrity.
Ven V. Venkatesan, Energy Columnist
VVenkatesan@putman.net
3/25/11 11:31 AM
 compliance advisor

OSHA Updates PPE Standards

Several key changes help clarify the use of personal protective equipment

On February 15, 2011, the Occupational Safety that reflect court and Review Commission decisions
and Health Administration (OSHA) issued a revised concerning PPE. Appendix A has a chart that lists, by
directive that provides enforcement guidance on deter- standard number and date, a summary description of all
mining whether employers have complied with OSHA’s interpretation letters that address Sections 1910.132-.138
personal protective equipment (PPE) standards. The of 29 CFR.
Enforcement Guidance for Personal Protective Equip- Fourth, the guidance provides information that
ment in General Industry, CPL 02-01-050, is the latest allows employers to use PPE selected in accordance
word from OSHA on PPE, and an important document with the most recent national consensus standards. A thorough
for employers and employees alike. This information is especially useful for employers as it
can be difficult to select the most appropriate PPE for a review is the
Background workplace hazard. best protection
PPE standards have evolved greatly to keep pace with Fifth, OSHA amended the provision that re-
scientific advances in detecting and eliminating work- quires safety shoes to comply with a specific American against
place hazards, developments in materials and fabrics National Standards Institute (ANSI) standard. Now allegations of
that can be used to abate hazards, and the range of respi- employers may select footwear that is at least as effective
ratory protection and personal protection tools. PPE has as footwear that is constructed in accordance with ANSI non-compliance.
become more sophisticated as a result of these advances standards.
and the standards’ reach has expanded over time. According to OSHA, the new guidance also sup-
OSHA revised the general industry standards for ports the U.S. Department of Labor’s National Strategic
PPE in 1994 when it added provisions that required Plan Outcome Goal 3A for increased emphasis on
employers to select appropriate PPE based on the nature reducing workplace injuries, illness and fatalities. The
of the hazard present or likely to be present in the guidance provides OSHA compliance officers and
workplace, prohibited use of damaged or defective PPE others in government and private sectors with informa-
and mandated training of employees so that they use tion about PPE selection and guidance useful to prevent
appropriate PPE properly. injury to workers. The guidance also supports the Site-
In 2007, OSHA required employers in certain Specific Targeting (SST) program for general industry
industries to pay for most types of required PPE. OSHA employment and provides available general industry
again revised the PPE standards in 2009 for eye- and PPE safety and health information in a web-based for-
face-protective devices, head protection and foot protec- mat with electronic links to related information.
tion. The new enforcement guidance, which became The new directive is well-written and useful in that
effective on February 10, 2011, replaces Inspection the document instructs OSHA enforcement personnel
Guidelines for 29 CFR 1910 Subpart I, the revised on both OSHA’s interpretations of those standards and
Personal Protective Equipment Standards for General procedures for enforcing them. A thorough review of the
Industry, issued in June 1995, and reflects the changes guidance is the best protection for employers against al-
set forth in 2007 and 2009. legations of non-compliance. It is equally important that
employees read the directive to ensure they know their
Important Changes rights, duties and obligations.
There are several key changes. First, the guidance clari- OSHA does not release new enforcement guidance
fies what type of PPE employers must provide at no all that often. Take some time to review this new direc-
cost to workers and when employers are required to pay tive to be well-situated to be in compliance with the law
for PPE, including respirators, personal fall protection, and comforted that employees are properly protected
hearing protection, hard hats, firefighting equipment from workplace hazards.
and protective footwear. The guidance also spells out
when employers are not required to pay for PPE. Lynn Bergeson, Regulatory Editor
Second, the directive clarifies the payment require- lbergeson@putman.net
ments for PPE worn off the job, what PPE must remain
at the job site and provides guidance for employee- Lynn is managing director of Bergeson & Campbell, P.C., a Wash-
owned PPE. ington, D.C.-based law firm that concentrates on chemical industry
Third, the guidance contains enforcement policies issues. The views expressed herein are solely those of the author.

17  chemicalprocessing.com April 2011

CP1104_17_Comp.indd 17 3/29/11 11:15 AM

 Are Things
Looking Up?
Annual salary survey
points to some positive
developments
By Amanda Joshi,
Managing Editor

PAY RAISES and bonuses are on the rise, according HOW LONG HAS IT BEEN SINCE YOUR LAST
to the results of Chemical Processing’s 2011 Salary and SALARY INCREASE?
Job Satisfaction Survey, although much else remains the
same compared to last year’s poll. An increasing number More than
of chemical processing professionals say they received a 3 years (7%) Less than
one year (56%)
salary increase this year. Last year, only 37% garnered a
pay raise within the past 12 months. That number has
now jumped to 56% (957), indicating the economy and
the industry are on the mend (Figure 1).
But many respondents were quick to point out that the
salary boost wasn’t enough to make up for past pay cuts or
wage freezes.
“We had a salary freeze in 2009, and for 2010, no effort
was put into making up for that lost salary increase ...we got 1-3 years (37%)
a paltry 2.5% this past year,” grumbled one reader.
“Although raises were re-established at the beginning
of 2011, this followed a year [with a] 7.5% pay cut, 401K Figure 1.
match suspension, and [another] year of a salary freeze. The

No, not at all (12

APRIL 2011 CHEMICALPROCESSING.COM 18

CP1104_18_21_CoverStory.indd 18 3/28/11 11:10 AM

ss than
raises did not compensate for those past 2–3 years of
lost compensation. The cost of benefits, meanwhile
ARE YOU CONCERNED ABOUT JOB SECURITY?
CP
2011 SALARY SURVEY

e year (56%)
s than increased during that time,” noted another respondent.
e year (56%) While salary increases provide a positive outlook, Yes (51%)
No (49%)
concerns about job security are split — 51% said they
No (49%) Yes (51%)
aren’t worried, while 49% voiced concern (Figure 2).
These results are similar to last year’s, although the
Figure 2.
concern was slightly higher then (52%). In addition,
49% report a slight chance they could be fired or laid
off in the next two years and 23% indicate a moderate
chance (Figure 3).

HOW MUCH DO CHEMICAL ENGINEERS MAKE?

In 2009, the average salary was $107,804, which de-
clined for the first time last year to $97,554. For 2011,
WHAT ARE THE CHANCES THAT YOU WILL BE LAID
the average salary of full-time respondents climbed to
No, not at all (12%) Yes, very much (12%) OFF OR FIRED WITHIN THE NEXT TWO YEARS?
$101,553 (Table 1). (Responses from those appearing
Very likely (2%)
No,to beatunemployed,
not all (12%) retired or working part-time
Yes, very were
much (12%) None (20%)
Likely (4%)
excluded from the salary calculation.) Very likely (2%) None (20%)
In addition, the average pay raise was 4.34%, Likely (4%)
rising for the first time since 2009. In fact, 7.44% of
respondents received pay increases exceeding 10%.
In comparison, only 3.64% had pay raises of 10% or
higher in 2010.
Average bonuses also edged up to $6,102 com- Figure 3.
pared with an average $5,835 in 2010.
No, not really
(37%) While most readers (59%) believeYes, they’re ad-
Somewhat Moderate (23%)
equately compensated, many expressed
No, not really (38%)
frustration
(37%) that benefits are declining. Yes, Somewhat Moderate (23%)
(38%) Very slight (49%)
“Compensation is adequate, but I could do better
Very slight (49%)
by going to another company. [My current] company
used the excuse of ObamaCare to more than double my
health insurance premium,” complained one reader.
Yes, somewhat “Benefits are very good, unfortunately the expec- HOW THE DATA WERE(2%)
Unsatisfied GATHERED
(38%) tation is everything will be cut, particularly retire- A total of 1,722 respondents participated in this
Very satisfied Unsatisfied (2%)
year’s survey.
Satisfied (44%)
Yes, somewhat From January through March, respondents accessed the
ment benefits,” noted another. (13%) Satisfied (44%)
(38%) survey questionnaire via a link listed on the www.Chemical-
“I currently feel fairly compensated, blessed and Very satisfied
Processing.com website, and in e-newsletters and e-mail
(13%)
fortunate in this struggling economy. However, the blasts sent to readers. Additionally, those who follow Chemi-
upcoming inflation and my not-terribly-distant retire- cal Processing on Twitter at Chem_Processing and Face-
ment make me focus on maximizing my compensa- book at Chemical Processing Magazine were encouraged to
participate.
tion as the economy struggles to recover,” commented
a respondent.

THE JOBS PICTURE

CONGRATULATIONS!
Approximately 26% (450) of respondents report staff- IPOD TOUCH WINNER
Somewhat
More than
Dennis Glascock,
3 yearssatisfied process design
(41%) Less than and heat transfer
ing levels have increased in the past 12 months, com- lead at
(7%)
one year (56%)
ConocoPhillips, Houston,
Somewhat TX., was random-
pared to just 16% last year. However, 46% (794) note satisfied
ly selected (41%)
as the winner of an 8-GB iPod Touch No (49%)
staff levels have not changed from 12 months ago. offered by Chemical Processing as an incentive for
Most respondents (91% or 1,545) say they work participating in the survey.
“Thanks! I am very surprised to win. My Dad
directly for an employer versus 9% (148) that work was always the lucky person in my family, so God
as contractors. In “Better Times Beckon for Con- bless my genetics!” he said.
tract Engineers,” (www.ChemicalProcessing.com/ 1-3 years We
(37%) appreciate the answers and comments we

articles/2010/203.html), Chemical Processing reported received from all of this year’s survey participants.

19 CHEMICALPROCESSING.COM
No, not at all (12%) Yes,APRIL
very much
2011(12%)

Likely

CP1104_18_21_CoverStory.indd 19 3/28/11 11:11 AM

Yes, Somewhat Moderate (23%)
(38%)

Very slight (49%)

HOW SATISFIED ARE YOU WITH YOUR JOB?

Unsatisfied (2%)
Satisfied (44%)
Very satisfied contract engineering positions are on the rise. Of those
(13%)
working as contractors, 58% (90) report their positions
had no fixed term. More than 22% (35) indicate their
Figure 4. work would last over one year and 13% (21) said their
contracts ran between six months and a year.
“[My position] is a contractual job and hourly salary
rates are normally high. It also depends on the project
and the type of industry and company. Oil and Gas
right now are really paying you good money especially in
Somewhat
the offshore area,” said one respondent.
satisfied (41%) On the other hand, “Being a contractor means no
benefits. The economic woes of the world have given
2011 2010 2009 2008 2007 2006 2005 an excuse to corporations to hire people at lower rates,”
Very satisfied 13% 10% 13% 8.3% 7.9% 7.3% 26.8% complained one reader.
Satisfied 44% 38% 45% 40.5% 38% 35.8% 46%
Somewhat satisfied 41% 38% 34% 41.2% 41% 42.5% 20.4% JOB SATISFACTION REMAINS POSITIVE

Unsatisfied 2% 14% 9% 10.2% 12.8% 14.4% 7%

Similar to last year’s results, the majority of respon-
dents (44% or 700) are satisfied with their jobs (Figure
1500
800
WHAT LEADS TO SATISFACTION? WHAT DO YOU DISLIKE ABOUT YOUR JOB?
700
1200 1200
600
Figure 5. Figure 6.
Number of respondents

Number of respondents

900 500900

400

600 600
300

200
300 300
100

0 0 0

Factors Responses Percent Factors Responses Percent

Challenge and stimulation 1,232 72% Lack of recognition 655 42%
Salary and benefits 959 56% Hours and workload 445 28%
My colleagues 787 46% Salary and benefits 416 26%
My company's work environment 715 41% My company's work environment 395 25%
Making products that help people 569 33% The commute and traveling 343 21%
The prestige 219 12% Lack of challenge 185 11%

SALARIES EDGE UP
YEAR SALARY RAISE BONUS AGE RESPONSES
2011 $101,553 4.34% $6,102 47.3 1,722
2010 $97,554 3.68% $5,835 47.8 1,827
2009 $107,804 4.23% $6,407 47.3 1,528
2008 $95,231 5.06% $6,561 45.7 1,078
2007 $90,038 4.28% $6,069 46.3 1,830
2006 $89,690 3.84% $4,795 47 1,258
2005 $85,234 3% $4,534 47 1,205

Table 1. Salaries, raises and bonuses all rose slightly compared to last year.

APRIL 2011 CHEMICALPROCESSING.COM 20

CP1104_18_21_CoverStory.indd 20 3/28/11 11:11 AM

 More than
3 years (7%) Less than
one year (56%)

CP
No (49%)

2011 SALARY SURVEY

4). About 13% (203) said they are extremely satis- and environmental performance. Be the employer of
fied. Nearly 41% (644) rated their job satisfaction as choice and the neighbor of choice, and your commu-
1-3 years (37%)
just “okay.” Slightly less than 2% said they’re not at nity will choose to support you and your continued
all content. ‘social license to operate.’”
As in the previous year, the challenge and stimula-
tion of the work lead to a high degree of satisfaction, DOES NEGATIVE PUBLIC OPINION ABOUT THE
according to 72% (1,232) of respondents (Figure 5). Sal- INDUSTRY BOTHER YOU?
ary and benefits follows at 56% (959) as the next leading No, not at all (12%) Yes, very much (12%)
factor in satisfaction. Other factors readers say contrib- V
ute to a highly satisfying job include: colleagues, 46% Likely (4%)
(787); the work environment, 41% (715); and making
products that help people, 33% (569).

JOB WOES Figure 7.

Lack of recognition remains the top frustration for
most respondents 42% (655) (Figure 6).
“The recognition is typically not very good for
the amount of effort you give, but the field is chal- No, not really
(37%) Yes, Somewhat Moderate (23%)
lenging and rewarding in other ways,” remarked one (38%)
survey participant.
Other leading gripes include the hours and
workload, cited by 28% (445), as well as salary and
benefits, noted by 26% (416). Several readers report
having to do more — and for much less.
“Compensation is flatat,alland
No, not not increasing as
(12%) U
Yes, somewhat
promised, but I’m still asked to do more. My posi-
(38%)
Yes, very Very satisfied
tion has advanced as far as responsibilities, but
much (12%) (13%)
the title and compensation have not,” groused one
survey participant.

INDUSTRY PERCEPTIONS
Respondents are split on the public’s negative opinion
of the industry (Figure 7). Nearly 38% are somewhat
concerned about public opinion and 37% remain un-
concerned. Only 12% are very concerned about public
opinion and another 12% aren’t at all concerned.
No, not really (37%)
Despite the split view, many respondents agree
the public’s perception could change with more
positive media reports on the industry and improved
corporate responsibility.
“Companies certainly have to do their job and go
beyond the minimum regulatory requirements. If you
do, and put safety and company image as a priority, you
will be doing your part in improving the image of our
industry,” suggested one reader.
Another respondent proposed: “Engage, engage,
engage. Host visits. Sponsor educational meetings in
the schools and community. Sponsor emergency re-
sponse training for local fire, police, EMT and other
related departments. Volunteer the services of plant
emergency responders into these functions for off-
site emergencies. Maintain best-in-class safety, health
WORLDWIDE RESPONSE
The above map shows that the bulk of survey respondents are in the U.S.,
with additional responses coming in from Europe, South America, Asia,
the Mideast, and the former Soviet Union.
Somewhat
satisfied (41%)
REVIEW PAST SURVEYS
Chemical Processing’s Job Satisfaction and Salary Survey is now in its
seventh year. If you’d like a more detailed look at our past surveys, go
to www.ChemicalProcessing.com or use one of these links:
2010 — www.ChemicalProcessing.com/articles/2010/067.html
2009 — www.ChemicalProcessing.com/articles/2009/072.html
2008 — www.ChemicalProcessing.com/articles/2008/048.html
2007 — www.ChemicalProcessing.com/articles/2007/055.html
2006 — www.ChemicalProcessing.com/articles/2006/049.html
2005 — www.ChemicalProcessing.com/articles/2005/431.html

21 CHEMICALPROCESSING.COM APRIL 2011

CP1104_18_21_CoverStory.indd 21 3/28/11 11:11 AM

 Make the
Condensate
Most of
A few steps can yield sizable savings and improve exchanger performance
By Steve Ashby, Armstrong International
CONDENSATE OFTEN gets overlooked and
ignored. Often thought of as an inexpensive
byproduct, condensate can allow you to conserve
make-up water and save on expensive treatment
chemicals.
Condensate is a ready-made supply of recover-
able energy for a boiler system (Figure 1). Chemi-
cal plants typically should be able to recover more
than 60% of the generated condensate. How-
ever, traditional system designs and installation
practices often can’t ensure positive condensate
drainage. As a result, the condensate frequently is
drained to waste when the heat exchanger stalls,
diminishing performance.
Making simple changes in system designs
and following practical management steps can
return significant savings as well as increase heat
exchanger performance and integrity.
DRAINAGE DESIGNS
Return of condensate to the boiler plant requires
APRIL 2011 CHEMICALPROCESSING.COM 22
CP1104_22_25_Optimization.indd 22
some means of motive pressure. This comes from
the supply steam pressure or via a mechanical
pump. Either way, the motive pressure always
must exceed the condensate return backpressure
to guarantee continuous drainage.
Two common piping designs for heat-exchang-
er condensate drainage are to incorporate a level-
actuated collection pot or use steam traps. Both
types of devices are direct piped to the condensate
return system and can be affected by varying
return line backpressure.
A level-actuated collection pot often is chosen
for large, high-capacity high-pressure reboilers
as well as vacuum columns and f lash tanks. The
heat-exchanger control scheme can be a constant-
level design incorporating a modulating steam
valve for temperature control, or a variable system
employing a constant-pressure steam supply while
changing the exposed heat-exchanger surface
area. Both approaches use an actuated drain valve
to maintain condensate levels.
3/28/11 11:21 AM
 Both designs provide process temperature
control but pose potential performance and
equipment-integrity problems.
The constant-level control system relies on
varying steam pressure and volume to maintain
desired process temperature. As the thermal
requirement decreases, the modulating supply-
steam control valve closes, reducing steam pres-
sure and volume. This results in low condensate
return motive pressure. If the steam pressure in
the heat exchanger becomes less than the con-
densate backpressure, a f looded condition will
arise — decreasing thermal performance, creating
a corrosive condition (carbonic acid from cooled
condensate), spurring surface pitting (accelerated
by trapped noncondensable gases) and potentially
compromising the structural integrity of the
tubes, tube sheets and other components through
stress cracking and water hammer (Figure 2).
The variable-level control system relies on
constant steam pressure — the condensate drain
valve is modulated to expose or f lood the heat
exchanger surface area. As thermal requirements
decrease, the condensate drain valve closes to
back up condensate into the vessel, effectively re-
ducing the surface area exposed for heat transfer.
The constant steam pressure provides a positive
motive pressure for condensate return. Again,
though, the downside is corrosion and decreased
vessel life and structural integrity.
A steam trap is designed to drain condensate
and vent noncondensable gases without allowing
live steam to escape. Because its internal mecha-
nism performs as a discharge control valve, the
steam trap inherently operates comparably to a
constant-level condensate system.
Similarly, with adequate steam pressure to
Steam Distribution System
100 psig
337.9𝚼F
Trap
Trap
Vent
CP1104_22_25_Optimization.indd 23
overcome the condensate return backpressure,
the heat exchanger will perform with optimum
efficiency — and if the supply-steam control valve
closes due to reduced thermal requirements, the
available condensate motive pressure decreases and
potentially backs up and floods the vessel. Again,
the heat exchanger loses performance and becomes
subject to corrosion and structural damage.
The recurring theme is that positive pressure is
required to ensure condensate drainage and non-con-
densable gas venting from heat exchangers. Unfor-
tunately, the quick remedy to drain a flooded vessel
is to open valves to the atmosphere, wasting valuable
energy and creating a potential safety hazard.
Incorporating a pumping device will prevent
heat exchanger f looding and ensure positive mo-
tive pressure to overcome any backpressure in the
condensate return, keeping the heat exchanger
operating at optimal efficiency and assuring
structural integrity.
EQUIPMENT STALL
Stall is a condition in which heat transfer equip-
ment can’t drain condensate and becomes f looded
due to insufficient system pressure.
Stall occurs primarily where the steam pres-
sure is modulated to obtain a desired output (i.e.,
product temperature). The control requirements
for heat exchangers (coils, shell-and-tube, etc.)
can be segmented into two distinct modes: opti-
mal performance and stall.
During optimal performance, the exchanger’s
operating steam pressure exceeds the backpressure
present at the discharge of the steam trap. There-
fore, a positive pressure differential exists across
the trap, allowing for condensate to f low from the
heat exchanger to the condensate return line.
50.3 psig
297.97𝚼F
PRV
Trap
Trap
Trap
Trap
Figure 1. Typical set-
up provides heat to a
variety of equipment
and returns conden-
sate to boiler.
23 CHEMICALPROCESSING.COM APRIL 2011
3/28/11 11:21 AM
 Water Hammer Damage
In the stall mode, the exchanger’s operating
pressure is less than or equal to the backpressure
present at the discharge of the steam trap. As a
result, no pressure differential exists to force the
condensate through the steam trap. Condensate
begins to collect and f lood the heat exchanger.
When exchangers become f looded due to stall,
a variety of problems — including water hammer,
frozen coils, corrosion, poor temperature con-
trol, short equipment life, control valve hunting
(system cycling) and reduced heat transfer — can
occur. Hammer and corrosion can lead to dam-
age to the tube bundles/coils, causing product to
contaminate the condensate; this also can create
serious problems at the boiler. Figure 2. Flooding can cause water hammer, which col-
Installing a mechanical pump in a closed-loop lapsed this float.
arrangement allows maintaining a dry heat ex-
changer regardless of the steam-system pressure, treme heights to allow for proper drainage. Because
condensate rate or efficiency of the tube bundle. they are immune to the cavitation issues that cause
This eliminates tube bundle corrosion and failures in electric pumps, mechanical pumps can
potential tube failure; both could cause an upset reduce the skirt height required for columns or re-
condition and interrupt production. By ensuring boilers, which often can lead to thousands of dollars
condensate removal, you can take advantage of in construction savings.
all the surface area available in the tube bundle.
The heat exchanger can operate at the optimal CONSIDER THE BIG PICTURE
performance level while utilizing the lowest, Condensate management requires a holistic
most-efficient steam pressure required. approach to realize significant energy savings.
In new construction putting a mechanical pump Here’re a few practical points to remember:
on process heat exchangers can lead to savings on From a design perspective, gravity and dis-
installation costs. For vacuum systems, net positive tance play key roles in efficient recovery and re-
suction head is critical for typical electric pumps. turn of condensate to the boiler. A typical system
Therefore, heat exchangers often are elevated to ex- design involves overhead condensate return lines
Impact on Elevation
as well as long piping runs. Vacuum systems may
require extensive elevations to drain a conven-
tional level-control condensate pot.
30” Full
Adding a device such as a pumping trap can
Vacuum
Reboiler
minimize the height necessary — sometimes to as
little as four feet — which can lead to savings of
30” Full
Vacuum thousands of dollars in construction costs alone
Reboiler
(Figure 3). A pumping trap also enables the heat
exchanger to run at its lowest, most-efficient
Motive

Equalizing Line Equalizing

Steam steam pressure, minimizing energy consumption.
40 ft.
Vent Line
The sizing of condensate return piping is anoth-
Condensate Pot
with Level Controller
er critical design factor. Lines must be large enough
4 ft.
to accommodate the movement of liquid con-
Typical densate as well as the presence of steam and flash
Condensate
Pump TVS 4000
Steam
vapor. In addition, receivers (flash tanks in open/
Trap
vented system) must be sized to provide adequate
separation of flash steam and condensate; failure to
Pump Trap Discharge
Steam Trap properly size receivers may cause upset conditions
within the drainage system. Vent lines also must
Figure 3. Vacuum reboiler may require only one-tenth the elevation when a pump
trap is used. be sized adequately to decrease flash steam velocity,

April 2011 chemicalprocessing.com  24

CP1104_22_25_Optimization.indd 24 3/28/11 11:22 AM

 RELATED CONTENT ON CHEMICALPROCESSING.COM
“Optimize Your Steam System, Part 1,” www.ChemicalProcessing.com/articles/2011/optimize-steam-system-1.html
“Optimize Your Steam System, Part 2,” www.ChemicalProcessing.com/articles/2011/optimize-steam-system-part2.html
“Consider Dynamic Simulation for Steam System Design,” www.ChemicalProcessing.com/articles/2010/186.html
“Refinery Pumps Up Energy Savings,” www.ChemicalProcessing.com/articles/2008/107.html
“Succeed With Condensate Control,” www.ChemicalProcessing.com/articles/2008/107.html

which likely will reduce the risk

of condensate carryover.
A properly sized steam trap
also is essential for efficient Capture the Power: Buhler Aeroglide.
system operation. A number Product uniformity, efficiency, durability. Aeroglide® conveyor
of variables dictate which type and fluid bed driers and coolers provide these critical elements
of trap to use but, in general,
to chemical processors around the world.
mechanical inverted-bucket
traps usually prove to be the
best solution because they allow
continuous drainage of conden- Buhler Aeroglide
100 Aeroglide Drive, Cary NC 27511 USA
sate. A rule of thumb is to locate
Tel +1 919 851 2000, Fax +1 919 851 6029
traps at 100–300-ft intervals. aeroglide.sales@buhlergroup.com, www.aeroglide.com/chemicals
Condensate collection as-
semblies, which bring multiple
valves together in one central
location, may offer advantages
by reducing the number of in-
dividual condensate collection
points along a line — cutting
installation costs and space
requirements and increasing ac-
cessibility to equipment for rou-
tine maintenance and repairs.
Simple management practices
such as insulating distribution
and condensate return lines can
pay big dividends. Insulation can
reduce energy losses by 90%;
insulate any surface over 120°F.
Establishing a routine steam-trap
inspection and maintenance pro-
gram also is essential for maxi-
mizing condensate recovery and
return. An effective trap manage-
ment program alone can achieve
fuel savings of up to 10%.

STEVE ASHBY is sales manager,

Condensate Management Group, for
Armstrong International, Three Rivers,
Mich. E-mail him at sha@armstrongin-
Innovations for a better world.
ternational.com.

CP1104_22_25_Optimization.indd 25 3/29/11 11:18 AM


In early March the Security Incidents Organiza-
tion (SIO), Sellersville, PA, released its annual report
on industrial control system (ICS) malware inci-
dents. “This report shows the details of the continu-
ing threats to manufacturing and infrastructure
security around the world. As the Stuxnet malware
showed in 2010, the threat continues and has be-
come even more complicated and mature,” says SIO
executive director John Cusimano.
The emergence of the Stuxnet worm, which appar-
ently targeted Siemens control systems at an Iranian
nuclear-enrichment facility, certainly exposed serious
knowledge gaps in how cyber security is implemented
and maintained by process companies.
A new white paper, “How Stuxnet Spreads — A
Study of Infection Paths in Best Practice Systems,”
(www.tofinosecurity.com/how-stuxnet-spreads), aims
to help bridge those gaps. Published in late Feburary,
it’s co-authored by a trio of cyber-security experts:
Eric Byres, chief technology officer, Byers Security,
Lantzville, BC; Andrew Ginter, chief technology
April 2011 chemicalprocessing.com  26
CP1104_26_29_Maint.indd 26
Stuxnet attack points up
vulnerabilities of control systems
By Seán Ottewell, Editor at Large
officer, Abterra Technologies, Calgary, AB; and Joel
Langill, chief security officer, SCADAhacker.com,
Lantana, TX.
The authors describe a hypothetical industrial
site that follows the high security architecture and
best practices defined in vendor documents. They
then show the ways the Stuxnet worm could make its
way through the site’s defenses to take control of the
process and cause physical damage.
While speculation continues as to the creators of
Stuxnet, the worm underscores that ICSs now are the
target of sophisticated attacks, note the authors, who
add that owners and operators must adjust their secu-
rity programs accordingly. In particular, stress Byers,
Ginter and Langill, security programs must:
• Consider all possible infection pathways and
have strategies for mitigating those pathways rather
than focusing on a single pathway such as USB keys;
• Recognize that no protective security posture is
perfect and take steps to aggressively segment control
networks to limit the consequences of an incursion;
3/25/11 11:33 AM
 • Install ICS-appropriate intrusion detection
technologies to spot attacks and raise an alarm when
equipment is compromised or at risk of compromise;
• Deploy, operate and maintain at maximum ef-
fectiveness ICS-appropriate security technologies and
practices. These include firewalls, antivirus technol-
ogy, patching systems and whitelisting designed for
supervisory control and data acquisition (SCADA)
and ICS, to make attacks by sophisticated malware
much more difficult;
• Look beyond traditional network-layer firewalls
to firewalls capable of deep packet inspection of key
SCADA and ICS protocols;
• Focus on securing last-line-of-defense critical
systems, particularly safety integrated systems (SISs);
• Include security assessments and testing as part
of the system-development and periodic maintenance
processes followed by correction of identified potential
vulnerabilities, thereby decreasing the likelihood of a
successful attack, and;
• Work to improve the culture of industrial secu-
rity among management and technical teams.
“These changes to improve defense-in-depth
postures for industrial control systems are needed
urgently. Waiting for the next worm may be too late,”
they say.
CHANGES NEEDED
Byers highlights two requirements in particular as
being essential. The first is culture: “On the macro
level you need upper management to really develop
a security culture: enthusiastic engineers are not
enough.”
He points to the safety culture that has emerged in
the chemical industry over the last 20 years as a model
for how this could happen. “Security needs to follow
along the same lines now: it must become a top-to-
bottom culture with programs that are both technical
and procedural. Nothing works unless this is in place
first.”
BP, Exxon and Shell in the oil and gas sectors and
Dow and DuPont in chemicals exemplify how a safety
culture can become a security culture, he says. “The
management of these companies really understands
the security challenge because they already have
sophisticated risk-management cultures. So they have
concepts in place that allow them to measure and
predict risks far better than other companies.”
Byers also cites the findings of a major oil compa-
ny that recently evaluated the risks and consequences
on an offshore oil platform associated with a serious
fire versus those of a cyber attack. It determined they
CP1104_26_29_Maint.indd 27
were almost identical in terms of cost and loss of life.
Yet, the company was spending $50 million/yr on
platform fire suppression but only $1million/yr on
cyber security. “This spend was instantly increased.
This is a level of risk sophistication that is lacking in
many other companies.”
Such a lack of sophistication was evident at a
distributed control system (DCS) vendor’s users’
conference he attended shortly after Stuxnet appeared
last June. While delighted to see operating company
managers there treating malware as a serious problem,
he was shocked that one proposed solution involved
filling USB ports with silicone. “I realized how badly
these people were missing the point. Use as much
silicone as you like, it won’t make any difference. The
next attack will come via a pdf or some other source.”
Byers’ second priority is to firewall-off mission
critical systems such as safety ones. “Remember that
Stuxnet only had to attack one system because both
control and safety were bundled together in the
system it infected — all the eggs were in one basket,”
he cautions.
Once the low-hanging fruit such as safety systems
have been tackled, you must start to work back. “You
need what I call multiple prongs: the people and their
culture; then mission critical systems; then standards.
The new ANSI/ISA-99 and IEC 62443 standards are
concerned with dividing plants into different security
zones, so that no worm gets a free rein.”
STEPS TOWARD SOLUTIONS
Byers emphasizes that the white paper really focuses
on problems rather than solutions. However, a
number of papers on solutions currently are being
developed.
The first concerns OPC and related protocols for
open connectivity. With input from Matrikon (now
part of Honeywell), Edmonton, AB, the paper will
propose solutions to ensure that OPC gets through
but a worm cannot, says Byers. It is due to be pub-
lished this month.
The second paper involves work with an as-yet-
unnamed software company to help operating com-
panies better understand network traffic on the plant
floor. “Most companies suffer from a lack of visibility
about what is going on in their networks. If people
had been watching the network that Stuxnet infected
they would have seen all sorts of new traffic: pieces of
equipment talking to each other that had never done
so in the past, for example.” This paper is due to ap-
pear in the spring.
Also due out then is a third paper, on managing
27  chemicalprocessing.com April 2011
3/25/11 11:33 AM
 A Sticky Issue
in the sector have focused almost 100% on physical
security and have done little or nothing yet with cyber
security.”
Matrikon’s cyber-security philosophy has three
aspects: people, process and technology. “You must
address all three to be secure — and people is the
toughest one to nail down,” says Kaun.
To show how challenging this can be, he cites the
example of a security firm that went back to check
on how a client was implementing a new and very
rigorous cyber-security program. The security firm
left a selection of USB sticks containing hidden data
mining tools around the client’s parking lot, reception
area and cafeteria. “Within a day the tools were on
the network. It’s human nature to pick a USB up and
plug it in. So if a customer doesn’t really get what it’s
trying to do — and enforce it — then it is dead in the
water,” he warns.
Figure 1. Web-
based security up- Modbus traffic. By creating deep-packet-inspection He also points out that if the authors of Stuxnet
dates recommend capabilities for firewalls that look inside Modbus hadn’t used a USB stick as a key method of distribu-
a range of actions
including not using
messages, Byers says users will get very fine-grained tion, the attack would likely have taken much longer
USB sticks. Source: control over exactly what they want a human/machine to detect. Siemens’ web-based Simatic security update
Siemens. interface or workstation to be able to do over the net- still is advising against use of any USB sticks or other
work to a DCS, programmable logic controller (PLC) mobile data carriers (Figure 1).
or safety integrated system (SIS). He cites the new Cyber threats are impacting how Matrikon does
Honeywell Modbus read-only firewall for SIS (see business. For example, the internal risk-assessment
www.tofinosecurity.com/article/honeywell-selects- group at one major industrial client has called in the
tofino%E2%84%A2-modbus-read-only-firewall- company to assess the cyber security of specific control
secure-critical-safety-systems) as an example of this. systems and networks. Matrikon is doing this through
Meanwhile, Rick Kaun, Matrikon’s manager, a combination of interviews, document reviews, physi-
industrial security and compliance, warns of a future cal login/inspections and control penetration testing.
fraught with risk. “Stuxnet proves the concepts of: (1) Using a system of likelihood and impact findings,
targeted attacks, on (2) control systems using (3) zero Matrikon then will be able to provide a priority list for
day exploits [those in which there’s no time between remediation.
when the vulnerability is discovered and the attack]. This sort of assessment also appears as a new trend
Add to this the recent revelation of Chinese hackers within Matrikon’s own cyber-security projects. The
infiltrating oil and gas companies and the release of last three customers all have requested that Matrikon
Stuxnet code to the public and you have a whole heap return to assess whether their new security measures
of potential risk. A perfect storm is coming.” have been implemented properly and are being run
Like Byers, he believes cyber security must be effectively. “People are much more concerned now to
treated as an everyday plant issue — just like safety. know that everything is working properly. And this
“Security isn’t about being bulletproof. It’s about op- is important because, for example, a customer might
erating facilities in a safe and secure way. So security have left the firewall ports open to conduct a vibration
needs to have the same philosophy or culture as safety. analysis and forgotten how to lock them down again,”
Security is about how quickly you can detect, contain, he says.
recover and learn lessons from an incident.” For chemical operators overall, Kaun emphasizes
The U.S. chemical industry is giving increased two basic vulnerabilities that must be tackled to im-
attention to security because of the Chemical Facility prove cyber security: awareness and enforcement.
Anti-Terrorism Standards (CFATS). However, Kaun
feels a lack of emphasis on cyber security in CFATS BETTER STANDARDS
has led to an overly strong focus on managing physical In early March, the International Society of Automa-
security. “There are notable exceptions, but still many tion (ISA), Reseach Triangle Park, NC, announced

April 2011 chemicalprocessing.com  28

CP1104_26_29_Maint.indd 28 3/25/11 11:34 AM

 that its ISA99 standards com- RELATED CONTENT ON CHEMICALPROCESSING.COM
mittee on industrial automation “Leadership Podcast: Cyber Security,” www.ChemicalProcessing.com/
and control systems security has multimedia/2010/cyber_security.html
formed a group to conduct a gap “Strengthen Your Cyber Security,” www.ChemicalProcessing.com/ar-
analysis of the current ANSI/ ticles/2010/088.html
ISA99 standards with respect “Protect Your Plant,” www.ChemicalProcessing.com/articles/2008/127.html
to the rapidly evolving threat “Become a Cyber Security Pacesetter,” www.ChemicalProcessing.com/
landscape. articles/2007/186.html
The purpose is to determine “Plug Cyber-Security Gaps,” www.ChemicalProcessing.com/arti-
if companies following the ISA99 cles/2007/152.html
standards would have been
protected from such sophisticated erations Management, Dollard- tion systems at Shell Projects &
attacks and to identify needed des-Ormeaux, QC. Technology, The Hague, The
changes, if any, to the standards “This document provides the Netherlands.
being developed by the committee. common language we need to “We’ve now come to a truly
A technical report summarizing communicate our expectations functional cyber-security standard
the results of the group’s analysis around security to our suppliers based on the needs of end-users
may come out by mid-2011. and the framework to work to- and it is now up to us, the end-
Last November, the Interna- gether to help improve the overall user, to take advantage of this
tional Instrument Users’ Associa- security posture for our critical effort and insist that our vendors
tion, The Hague, The Netherlands, systems,” adds Peter Kwaspen, are certified,” stresses Jos Menting,
launched Version 2 of its “Process strategy and development man- cyber-security advisor with GDF
Control Domain Security Require- ager, EMEA control and automa- Suez Group, Paris.
ments for Vendors,” which it calls
the first international standard that
outlines a set of specific stipula-
tions focusing on cyber-security
best practices for suppliers of
industrial automation and control
systems.
Led by major companies
such as BP, Dow, DuPont, Saudi
Aramco and Shell, dozens of other
end-users, as well as leading ven-
dors such as Invensys and multiple
government agencies, the group
spent two years developing and
piloting the program that culmi-
nated in Version 2.
“Not only do the requirements
provide current-state measures,
they allow us to continue to
improve and adapt to the ever-
changing security landscape.
From our perspective, this
program is a major shift, not only
focusing on tactics, but one that
puts into place strategic elements
that address operational change,”
says Ernie Rakaczky, portfolio
program manager control systems
— cyber security for Invensys Op-

CP1104_26_29_Maint.indd 29 3/25/11 11:34 AM


Seal Off
Centrifugal Pump
Problems
Paying proper attention to seals can
improve pump performance and life
By Rick D. Farris, SKF USA Inc.
Seals play a crucial role in centrifugal pumps.
They serve at both the “dry” and “wet” ends of
the pumps, primarily to retain lubricant, exclude
contaminants, separate fluids and confine pres-
sure. Without effective seals, contaminants (solid
or liquid) can find openings to infiltrate both the
lubricant and bearings — leading to potentially dire
consequences impacting both the cleanliness and
integrity of the lubricant and the life of the bear-
ing. And, in cases where seal failure causes lubricant
April 2011 chemicalprocessing.com  30
CP1104_30_33_Fluids.indd 30
loss, dry-running operation can prompt premature
and rapid deterioration of bearings and, in turn, the
pump.
The correct specification of seals consistent with
operating conditions ultimately can help maximize
component service life and keep pumps up-and-
running as intended.
THE BASICS
Bearings in centrifugal pumps support hydraulic
loads imposed on the impeller, the mass of the
impeller and shaft, and loads due to couplings and
drive systems. They also keep shaft axial and radial
deflections within acceptable limits for the impeller
and shaft seal.
Dynamic radial shaft seals, which come in a vari-
ety of designs and materials, commonly protect the
power frames of API heavy-duty process pumps and
ANSI light- and medium-duty class pumps; bearing
isolators or labyrinth-type seals usually are located at
the pump’s wet end. Many API pumps are migrating
gradually to bearing isolators at both the thrust and
line ends.
In general, dynamic radial seals create a barrier
between surfaces in relative motion (one usually
is stationary while the other rotates). These seals
— more often than not made from nitrile rubber
— may feature a plain, wave or helix lip design. In
many cases, a garter spring holds the primary seal-
ing lip in position and also promotes oil retention.
Standard seals usually incorporate a simple L-shaped
shell with the sealing material bonded to it; others
also may include an inner shell to help protect the lip
from damage or distortion during installation.
Bearing isolators or labyrinth-type seals (Figure
1) provide highly effective exclusion capabilities.
Instead of a contacting radial lip element, these seals
rely on a labyrinth or maze-like internal structure
to collect and eject contaminants before they can
intrude. Designs typically integrate a stator pressed
into the housing and a rotor fixed to and turning
with the shaft. The two components are locked
together for easier assembly and to prevent dam-
age during handling. Standard versions usually will
incorporate polytetrafluoroethylene (PTFE) for
the structural body material and fluoroelastomer
O-rings to promote high chemical and temperature
resistance.
MAKING A CHOICE
Seal specification for centrifugal pumps begins with
identifying the correct general design for the ap-
plication, followed by proper sizing of the hardware
3/25/11 11:55 AM
 Bearing Isolator
Figure 1. Maze-like internal structure collects and ejects
contaminants before they can intrude.
(never mix inch and metric dimensions and toleranc-
es). Then, for optimized seal performance, evaluate
all relevant operating conditions to narrow the field.
Important operating parameters to consider
include:
Surface speed. Radial shaft seals are designed to per-
form within designated surface speed limits. Generally,
surface speed capability is inversely related to param-
eters such as seal torque, power consumption, under-lip
temperature and the effect of dynamic run-out. All
these speed-related influences can affect seal life.
The majority of standard small-bore (under 8 in.
shaft diameter) radial seals are rated up to 3,600 ft/
min, while larger diameter seals are rated to approxi-
mately 5,000 ft/min. PTFE bearing isolators usually
can work at up to 5,000 ft/min, while metallic
versions can handle 10,000 ft/min. An application
calling for higher speeds requires specialized design
considerations.
Options to help mitigate the negative effects of
higher shaft speeds include reducing the radial load
on the seal lip, switching to a sealing material that
can handle higher temperatures, changing lubricant
type or viscosity, optimizing the shaft sealing surface
or using a non-contacting labyrinth seal design.
Pressure. Standard radial seals are designed for
only about 7 psi. System conditions or a fault such as
a plugged vent can mechanically load and distort a
seal’s lip profile, resulting in rapid wear and failure.
Solutions to compensate for the effects of pressure
include pressurizing the seal cavity to allow the
seal to serve as a main pressure retention seal, and
redesigning lip profiles to resist deformation under
pressure loading and moderate surface speeds.
CP1104_30_33_Fluids.indd 31
In situations where higher shaft speeds will be
encountered, the permissible pressure differential
across the seal becomes smaller. As pressure is ap-
plied to the seal, more lip surface is forced against
the shaft, which produces greater friction (as does
increased shaft speed). Too much friction leads to
faster wear and shorter life of seal and shaft — so,
pressure and surface speed must be balanced against
each other for maximized seal performance.
Temperature. Operating a seal material beyond its
recommended temperature range can cause thermal
stress that will harden the compound; the hardening
often appears as a series of radial cracks on the seal.
(Historically, such heat aging of nitrile rubber seals has
represented a more common cause of failure than wear.)
Changing the seal material from rubber to PTFE or
fluoropolymer can raise a seal’s thermal limit.
Surface finish. Shaft surface roughness and direc-
tionality rank second only to heat damage as culprits
for leakage. Under a microscope, a shaft’s surface
can be mapped as a series of peaks and valleys. Too
smooth a surface may not support an oil film, which
can result in a higher-than-desired under-lip tem-
perature. If a surface is too rough, peaks can project
through the lubricating film and abrade the lip. The
best practice is to consult the roughness and texture
specifications developed by manufacturers and based
on industry standards. Additionally, consider us-
ing electronic tracing instruments to assess surface
finishes accurately.
A shaft also may exhibit directional lead (a spiral
or screw pattern) from the initial turning or grinding
method. While an inward lead might prove benefi-
cial in some respects, an outward pattern can result
in more oil under the lip than its pumping action
can handle. Keep the potential consequences in
mind and inspect shafts accordingly.
Damaged Seal
Figure 2. Arrows show where seal has suffered intru-
sions from foreign matter.
31  chemicalprocessing.com April 2011
3/25/11 11:55 AM

Media. Nitrile rubber performs well with a wide
range of mineral-based oils as lubricants. However,
polar solvents such as acetone can lead to catastrophic
swell (observed as a softening) and physical destruc-
tion of the seal. Similarly, compounds such as ethylene
propylene will swell rapidly from contact with aromat-
ic hydrocarbons and mineral oils. And some lubricants
based on synthetics, while resisting oxidation, can
attack rubber compounds. The appropriate marriage
of seal and lubricant can help avoid seal degradation
and contribute to improved performance.
TROUBLESHOOTING SEAL FAILURES
Despite all the advances in sealing system designs,
materials and performance over the years, seals
aren’t immune to potential failure — many times for
reasons other than the seals themselves. Picking an
inappropriate replacement, improper installation or
switching or mixing lubricant can cause problems
over time. When good seals go bad, the best trouble-
shooting practice is to ask the right questions and
then follow a logical sequence of steps to analyze the
failures and take remedial action.
Questions that will help to pinpoint failure
causes include:
• How well has the seal performed in the past and is
it the correct seal for the application? If there’s a history
of failures with a particular seal, the culprit may
not be the seal itself — unless the seal isn’t the right
design or the material is inappropriate for the appli-
cation. At the first signs of failure, such as intrusion
of foreign matter (Figure 2), check the seal’s part
number and review recommended applications to
exclude the seal itself as suspect. Then, via a process
of elimination, focus on the many influences that
can impact seal performance and service life.
Always check whether operating conditions
conform to the optimum range specified for the seal.
Lip Wear
Figure 3. Inner diameter of seal exhibits uneven lip wear, as
indicated by arrow.
APRIL 2011 CHEMICALPROCESSING.COM 32
CP1104_30_33_Fluids.indd 32
FOLLOW A FEW GUIDELINES
These pointers, which apply to all types of seals, will
help ensure effective protection of your pump:
• Never re-use worn seals.
• Properly store seals in a cool area (not work area)
at 40–70% humidity.
• Ensure packaging is intact and inspect the
seal’s lip for possible distortion from improper
handling.
• Use the correct installation tools.
• Make sure to keep the area clean as well as free of
contamination.
• Select the correct seal for the speed.
• Pick the proper seal for the pumped medium.
• Check the operating temperature against lip
material specifi cations.
• Verify the lubricant (including additives) is com-
patible with the seal lip material.
• Confi rm that the leading edge of the shaft is
chamfered.
• Make sure shafts are hardened to Rockwell C 30
or harder.
• Validate tolerances for the shaft diameter are
within range.
• Wherever possible vent equipment to help pre-
vent pressure buildup.
Subjecting a seal to operating conditions outside that
range surely will result in its failure. For example,
when operating temperature or pressure exceeds the
lip material’s maximum, the seal may exhibit heat
cracking, which is indicated by a hardened seal lip
or fine cracks visible in the seal lip surface. Excessive
surface speeds or insufficient lubrication at the seal
lip can eventually lead to heat cracking and damage.
Shaft-to-bore misalignment or dynamic run-out
can cause early lip leakage, excessive and uneven lip
wear on one side of the seal (Figure 3) or excessive
but consistent lip wear all around. (Shaft-to-bore
misalignment results from inaccurate machining,
shaft bending, lack of shaft balance or worn bear-
ings; dynamic run-out is a similar condition where
the shaft doesn’t rotate around its true center.) The
seal’s lip area with the greatest wear will indicate the
direction of the misalignment.
A breakdown in lubrication or improper lubri-
cant also can lead to problems. Sometimes heat may
be high enough to break down the lubricant but not
enough to harden the seal’s lip. In such cases, sludge
or varnish-like deposits will accumulate on the seal
lip and damage will occur. Using the proper lubri-
cant and regularly changing it are among the best
practices to help avoid lube-related seal failures.
Improperly installed seals likely will fail quickly.
Symptoms of damage caused by a hammer blow dur-
ing installation include visible dents on the seal back,
3/25/11 11:56 AM
 RELATED CONTENT ON CHEMICALPROCESSING.COM
“Seal In Long-Term Savings,” www.ChemicalProcessing.com/ar-
a distorted sealing element or a garter spring that ticles/2007/103.html
pops out. All are causes for concern and necessitate “Find the Best Value Seal,” www.ChemicalProcessing.com/ar-
seal replacement. ticles/2005/567.html
“Properly Seal That Pump,” www.ChemicalProcessing.com/ar-
Other factors ranging from possible media
ticles/2005/465.html
intrusion to undue pressure within a seal cavity can
compromise seal performance. Also, it pays to review
maintenance and operating practices to see whether Your observations will help pinpoint the failure’s
they could adversely impact sealing systems. root cause and appropriate remedial actions to pre-
The central message here is to confirm the seal vent repetition.
has been installed properly, runs within specified
operating condition ranges and benefits from the SUCCEED WITH SEALS
proper lubricant. Optimizing a sealing system truly is a balancing act.
• What is the source of the leak? It’s helpful as a Carefully identifying the application’s requirements,
reference point to determine whether the leak is in evaluating all conditions and adopting a holistic
the inner or outer diameter of the seal. If you can’t approach to seal specification with a system-wide
locate the leak, add ultraviolet dye to the sump or perspective will contribute significantly to how a
spray white powder on the area. After operating for seal performs and for how long. Partnering with
15 minutes, use ultraviolet light to show the leakage an experienced manufacturer of bearings, seals and
source. In addition, documenting when the leak first lubricants can help maximize system potential and
occurred may relate it to a change in maintenance or minimize problems.
operating procedures.
• What are the initial best practices when analyzing RICK D. FARRIS is director of platforms and brands for SKF
failures? When a seal fails, follow these five basic steps: USA Inc., Kulpsville, Pa. E-mail him at Rick.D.Farris@skf.com.
1. Inspect the seal before removal. Check the con-
dition of the area, note the amount of leakage that has
occurred and determine the source of the leakage.
2. Wipe the area clean and inspect for:
• nicks on the bore chamfer;
• seal cocked in the bore;
• proper seal installation;
• shaft-to-bore misalignment;
• seal looseness in the bore;
• seal case deformation; and
• paint on the seal.
3. Rotate the shaft to ascertain whether there’s
excessive end-play or run-out, which can indicate
THINK
misalignment issues.
BIGGER!...

BOILERS
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• coked lube on the shaft; ▪▪▪ Heavy Industrial-Duty Fired and Waste Heat Boilers
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5. Identify the seal style and materials and ▪▪▪ Large Inventory of Parts
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inspect for:
• primary lip wear;
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Contact: Charles Swallow, 918.382.4840, cswallow@victoryenergy.com
Title: Think Bigger
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Publication: Chemical Processing
CP1104_30_33_Fluids.indd 33 3/28/11 11:24 AM
 Making it work
Online Analytics
Improves Batch
Operations
Field trial shows value for fault detection
and quality prediction
By Robert Wojewodka, Lubrizol, and Dawn Marruchella,
Emerson Process Management
The goal of batch manufacturing is to safely
produce a maximum yield batch within product
quality specifications in the shortest amount of time
and with a minimum amount of waste. However,
achieving that goal presents many challenges. Op-
erators often work in a highly complex, interlinked
and dynamic environment and must manage a large
amount of data and information on a running unit.
This makes it easy for batches to end up with unde-
sirable processing events or inadequate end-of-batch
quality. It also makes it easy for operators and engi-
neers to miss atypical process variation relationships.
The proliferation of data being collected today as
well as the expansion of instrumentation and number of
measurements are increasing the complexity of the situ-
ation. Coupling this with the drive by many companies
to do more despite a smaller work force creates a situa-
tion where even more things may go unnoticed.
The traditional univariate (one variable at a time)
approach to problem solving may provide some
insight. However, it can’t adequately deal with this
complexity because interactions often occur among
variables. Unfortunately, the shortcomings of applying
univariate approaches are not always realized.
Some companies also determine the quality of a
batch by comparing it to a “golden batch,” i.e., one
that has met quality standards and is considered ideal
for a particular process. However, this approach of
relating results to a single batch doesn’t take into ac-
count interactions among inputs and process variables
and output quality characteristics. It does not incor-
porate the concepts of acceptable and unacceptable
variation. And, it does not provide any process insight
into what is and is not important regarding inputs to
the process, the processing conditions, and the effect
that this variation has on product quality character-
April 2011 chemicalprocessing.com  34
CP1104_34_37_MIW.indd 34
istics. It’s a univariate approach to what in reality is a
multivariate problem. Trying to replicate the golden
batch often just leads to chasing after “fool’s gold.”
It’s better to compare a batch to a multivariate-
based model, or a “golden profile,” that compiles
many acceptable batches and accounts for process re-
lationships and process variability. This allows a much
more accurate analysis of that batch and, depending
on the techniques used, fault detection and end-of-
batch quality prediction. In addition, it affords process
insight unobtainable from a golden batch analysis.
However, online analytics that takes into account re-
lationships among variables and also characterizes typi-
cal and atypical process and product-quality variation
has proven challenging in batch operations for many
reasons, including process holdups, access to lab data,
feedstock variations, unsteady operations, data organiza-
tion and concurrent batches. When done however, the
benefits achieved usually are immediate and substantial.
To advance these concepts, we have partnered to
develop and incorporate online multivariate batch
process analytics into the manufacturing process
to aid operators and engineers in dealing with this
complexity. A six-month field trial started in late
2009 at Lubrizol’s plant in Rouen, France; the plant is
continuing to use the online batch analytics.
FIELD TRIAL
In preparation for the field trial, Lubrizol formed a
multi-discipline team, which included plant opera-
tions, to provide inputs.
It was critical that lab as well as truck-shipment
data be integrated and available to the analytics
package. Feed tank properties needed to be calcu-
lated automatically with each new addition of raw
materials from truck shipments.
3/28/11 11:30 AM
 Making it work

Batch Processes
To apply advanced control to a process, its basic
Batch Process 1 Batch Process 2
equipment must be functioning properly — otherwise,
you risk wasting time and effort in the long run. So, PROCESS PROCESS
staff surveyed all process instrumentation and loops INPUTS
Major Processing Steps Major Processing Steps
to ensure that all instruments were problem-free, and Initiation OUTPUTS Initiation OUTPUTS

loops were tuned to achieve optimum performance.

Before going online with the trial, we ran training Step 2 Step 2
INPUTS
sessions so operations personnel were comfortable
Step 3 Step 3
enough with the new application to use it in the field.
The field trial was run on two batch processes —
Step 4 Filtration
each made different products. The output of Process 1
was an input into Process 2 (Figure 1). We used 18 input Filtration
variables, 38 process variables and 4 output variables for
the modeling and online analytics. (Many more process
Figure 1. Output
variables could have been included but we kept the Figure 2 shows the main screen monitored by opera- from Process 1
scope small for the trial.) Data were collected at 1-min. tors. It displays active batches for each process, along serves as an input
intervals. We relied upon historical batches for analysis with an indication of any process faults detected. To to Process 2.

and model development across these two processes.
We created a separate model for each process
stage — defined uniquely by product, equipment and
operation performed. This allowed inputs and outputs
used in analysis to differ for each stage.
The tools used for offline development of the
models required selection of historical batches as well
as appropriate variables from historical data. The tools
enabled comparing the results of the model against
historical data to determine the model’s accuracy or if
a particular batch was an outlier and, so, shouldn’t be
used in developing the model.
Once suitable models were in place, online analyt-
ics tools were put to use via a web-based interface.
Such an interface was important because some process
specialists who would be working with the analytics
were located throughout the world.
investigate a detected fault, the operator simply selects
the batch and is taken to another display (Figure 3),
which provides the statistical charts for the selected
batch. Whenever statistical values for the batch exceeded
the upper limit (a value of one), the trend for the indica-
tors appears outside of the green zone. The operator can
select anywhere on the line to see on the left side of the
display the list of contributing variables for this point
in time, in order of greatest contribution. To further
analyze the situation, the operator can select any one
variable to get its individual trend for the selected batch,
which is overlaid against the model developed for the
particular process, along with the upper and lower limits
for the variable (Figure 4). In the example shown, it is
clear the variable is trending well above the output from
the model and the acceptable variation, so the operator
can address the situation as needed.

Main Display

Figure 2. Operators
see active batches and
get indication of any
faults detected.

35  chemicalprocessing.com April 2011

CP1104_34_37_MIW.indd 35 3/28/11 11:31 AM

 Making it work
Fault Detection

Figure 3. Screen shows

statistical data for
relevant variables for
selected batch.

Variables’ Impact

Figure 4. Operators
can view the contribu-
tion of all variables
related to a fault.

Actual Versus Predicted Results

Figure 5. Graph com-

pares process variable
trend to modeled
value and limits.

April 2011 chemicalprocessing.com  36

CP1104_34_37_MIW.indd 36 3/28/11 11:31 AM


Finally, the operator can view on a separate trend
the predicted end-of-batch quality with confidence
limits (Figure 5).
IMPORTANT IMPROVEMENTS
The Rouen facility has realized numerous and ongo-
ing benefits that started immediately. Some include:
• During a “train the trainer” class, the online
analytics uncovered a fault in the actual process — a
previously undetected problem with the mass flow
meter for a key component charged into the batch.
This fault was going unnoticed with “traditional”
monitoring systems. This revelation helped highlight
the benefits of the technology and certainly got the
attention of operations management!
• Once up and running, the field trial showed an
increasing deviation on the key-component density
measurement through several batches. This phenom-
enon was linked to the start of plugging. It was quickly
solved by applying steam without time cycle impact.
• The online tool indicated a problem with the
cooling system of the reactor. It detected that a key
component was being introduced too slowly and the
reactor temperature was running a little bit higher.
The problem was solved on the cooler. Using a univari-
ate approach would not have shown this.
• A process fault detection led to identification of a
regular issue on the unit’s reactor-heating control loop.
This prompted actions to revisit the loop tuning on key
process control parameters.
• Another problem was detected on the hot-oil
heating system — an upstream boiler was negatively
impacting operations. Discovering the problem in the
traditional manner would have taken a number of
days. The plant avoided losing five hours for the batch in
process and following batches.
NEXT STEPS
The field trial was successfully completed in mid-2010.
The teams are in the process of updating and redeploy-
ing the batch analysis models following several signifi-
cant process redesign changes. This is necessary because
these changes modified the batch operations and phases.
An additional and successful field trial was com-
pleted in a bioscience application area. This further
cemented the benefits of these approaches to batch
process modeling.
If the results of these field trials hold true for
others, online analytics will provide manufacturers
with additional insight and benefits through greater
understanding of batch processes. This should lead to
an increase in the consistency of quality products as
well as greater throughput through better yields and
CAS-193E.indd 1
CP1104_34_37_MIW.indd 37
MAKING IT WORK
RELATED CONTENT ON CHEMICALPROCESSING.COM
“Improve Batch Processing,” www.ChemicalProcessing.com/ar-
ticles/2009/227.html
“Improve Batch Reactor Temperature Control,” www.ChemicalPro-
cessing.com/articles/2008/088.html
“Rethink Batch-Manufacturing Alarm Systems,” www.ChemicalPro-
cessing.com/articles/2008/019.html
decreased cycle time and outages — in short, more
good batches at a lower cost to manufacturers.
ROBERT WOJEWODKA is technology manager, process
improvement team leader, for The Lubrizol Corp., Wickliffe, Ohio.
DAWN MARRUCHELLA is a marketing manager for Emerson
Process Management, Austin, Texas. E-mail them at Robert.Wojew-
odka@Lubrizol.com and Dawn.Marruchella@Emerson.com.
FURTHER READING
Wojewodka, R., and Marruchella, D., “Benefits Achieved Using On-
line Analytics in a Batch Manufacturing Facility,” WBF Make2Profit
Conference, Austin, Texas (May 2010).
Wojewodka, R., and Blevins, T., “Data Analytics in Batch Opera-
tions,” Control, p. 53, May 2008, www.controlglobal.com/ar-
ticles/2008/164.html.
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3/28/11 11:32 AM
 PROCESS puzzler

Foil Future Fires

Readers point to possible causes of a blaze

This month’s puzzler

We had to do a hot-tap on the top of an atmospheric tank containing
crude triethylamine (boiling point: 50°C). As an extra safeguard, the
approved job plan required diverting the tank’s nitrogen blanket to
an upper nozzle because our safety department deemed the area on
top of the tank partially enclosed. Nitrogen was bubbled through a
4-ft-dia. polyethylene tank containing an aqueous 10% HCl solution;
waste product overflowed the tank into a long grated drain in an
area with a 6-in. dike. One side of the diked area is partially open to
allow vehicle access. Plans called for scaffold erection on the first day,
welding on the second day (weather-permitting) and scaffold removal
on the third day. Ambient temperatures were in the mid-80°Fs. Sniff
tests were performed on a periodic schedule around the work area
at the top of the scaffold. A few hours into the welding, a small fire
erupted several yards outside of the diked area. The safety depart-
ment is investigating the accident. What do you think caused it? Is
there a better way to do this welding?
LIMESTONE MAY BE THE CULPRIT
I suggest limestone contacted the overflow of the
polyethylene tank, neutralizing the triethylamine
hydrochloride to calcium chloride and triethyl-
amine. Triethylamine, now free to be a vapor,
then caused the fire. I suggest the diversion of
the nitrogen blanket was an unneeded compli-
cation. Triethylamine has an upper flammable
limit (UFL) of 8%. Eight percent of 760 mm
Hg = 61 mm Hg. Using Antoine’s equation and
constants listed in Lange’s, at 79°F the vapors
in the tank would be above the UFL. This is a
second safeguard since the tank is inert padded
with nitrogen. A proper hot-tap device could also
Distillation Feed Drop Tank
RP
Recycle Feed
FO
RP
Feed
(furnace) FC Feed
PI
Column A Column B
FO
LT SG
RP
RP
FC Column feed A
FC
RP: rack and pinion Tank farm (de-inventory)
actuator.
Figure 1. Level increased after pressure-relief valve blew.
be equipped with inerting nipples, eliminating air
intrusion into the tank.
Mike Gentilcore, principal research engineer
Covidien Imaging Solutions, Hazelwood, Mo.
IT WASN’T NECESSARILY THE TORCH
I would guess that some triethylamine escaped
from the tank and found its way into the dike.
According to the MSDS I found, triethylamine is
highly flammable, 3.48 times heavier than air, has a
flash point of about 20°F, and an auto ignition tem-
perature of 419°F. It’s possible a spark from welding
ignited the vapors if they were allowed to reach
the mixture, but it could easily have ignited from
any other ignition source or hot spot. With the
information given, it doesn’t seem that the welding
itself had anything to do with the fire if it ignited
several yards from the dike (assuming the ignition
point was also several yards from the welding). I
suspect the problem lies with improper control of
the flammable material rather than the generation
of an ignition source.
Pete Bisila, system reliability engineer - utilities
Flint Hills Resources, Hastings, Minn.
WHAT TESTING WAS DONE?
Sniff tests should have picked up an ignitable mix-
ture but not if the liquid drained out of the work
area. A number of questions come to mind. How
was the acid concentration being maintained in
the bubble column? Has this method been tested,
preferably in the safety of a laboratory before risking
operators? Did anyone calculate the amount of TEA
potentially present in the vapor? Will a plastic tank
hold up from the heat of solution with HCl-H2O
Product
and heat of reaction with TEA? Making a 10%
solution of HCl by weight will produce enough heat
Recycle
to evaporate almost 10% of the water. Did anyone
consider doing a new electrical area classification for
Waste
the job plan?
Counting on operators to add acid every few
hours is not a safe practice. A better approach
would be to add a small acid tank and metering
pump with a rheostat to adjust the f low. Inex-
pensive metering pumps can control to a few
percent accuracy, which is more than adequate.
It’s crucial that the bubble column have a pH well

April 2011 chemicalprocessing.com  38

CP1104_38_39_Puzzler.indd 38 3/25/11 11:53 AM

 PROCESS PUZZLER

below the pKa of the amine. Also, a cheap local
pH alarm could suffice to avoid troubles. It might
also be useful to establish a control link with the
control room.
As for the bubble column design, consider
a simple hillbilly solution: use a brick tied to
a mesh pad or bunch of plastic grating with
polytetraf luoroethylene rope; anchor the hose
connecting the tank nozzle to the bottom. This
cheap improvement will raise bubble residence time.
The trouble with small dikes that are easy to step
over is that they won’t prevent flammable vapors
from exiting a slit drain and becoming a fire hazard
away from watchful eyes. Sniffing could easily miss
fumes. They were probably focused on the welding
and not the column.
Dirk Willard, senior process engineer
Middough Consultants, Holland, Ohio

JUNE’S PUZZLER
One of our board operators saw a spike in the level of a
feed tank for a distillation process during a winter startup
(Figure 1). She killed the fired heater feeding the tank.
The fired-heater pressure relief valve blew ten minutes
later. An hour after that, after the heater relief was iso-
lated, a field operator looked at the tank pressure gauge
and sight gauge. The level transmitter read 70% (com-
pared to 65% before the incident). Later in the day when
the board operator tried to de-inventory the tank, the
pump cavitated. The field operator then noticed the po-
sition indicator on the pump suction valve showed it was
closed; the other valves don’t have position indicators.
Can you explain what caused this series of problems?
Send us your comments, suggestions or solutions for
this question by May 13, 2011. We’ll include as many of
them as possible in the June 2011 issue and all on CP.com.
Send visuals — a sketch is fine. E-mail us at ProcessPuz-
zler@putman.net or mail to Process Puzzler, Chemical
Processing, 555 W. Pierce Road, Suite 301, Itasca, IL
60143. Fax: (630) 467-1120. Please include your name, title,
location and company affiliation in the response.
And, of course, if you have a process problem you’d
like to pose to our readers, send it along and we’ll be
pleased to consider it for publication.

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 plant insites

Properly Assess Energy Recovery Projects

Impact on other operations and transfer prices may alter the economics

Energy recovery projects often focus atten- The heater also included a steam generator
tion on fired heater duties. Burning less fuel presents system that provided medium-pressure steam for a
an obvious benefit to a plant. Fuel costs money. The variety of plant uses. Process demands set the heater
bill shows up easily as a direct charge from the fuel duty requirement, causing steam generation to vary.
company. However, the basic rule in all energy proj- The stack temperature out of the steam generator
ects is to track down the energy flows to something (convection) section stayed close to 520°F.
that you pay for. In plants, both simple and complex, Temperature-cross pinches (www.ChemicalPro-
Transfer prices this often may result in the age-old discussion of cessing.com/articles/2007/070.html) in the feed/ef-
transfer prices versus overall site economics. fluent exchangers limited heat recovery. One energy
can result in Consider the situation faced by a plant with a conservation project considered adding two feed/
strange high-temperature reactor system. A fired process effluent exchangers to make a total of seven shells
heater provided duty to get up to the required in series. At first glance, the energy recovery seemed
conclusions. reaction temperature. A conventional feed/effluent to offer reasonable return on investment. Figure 1
exchanger system recovered duty upstream of the shows a simplified plant sketch along with the heat
heater, reducing the heater duty. The feed/effluent balance boundary used for project analysis (solid
heat recovery used five TEMA E-type shells in series. boundary line). The new feed/effluent exchangers
reduced process heater firing.
The Bigger Picture
Has this analysis found the “right” answer?
Extended Heat Energy Balance Boundary Further investigation raises serious doubts. Reduced
TempB Stack Boiler firing on the process heater decreases the stack-gas
Economizer
flow rate to the convection section. The nearly con-
Water Section stant stack temperature on the process heater results
from a large convection section. The stack tempera-
ture pinches against steam production temperature.
Steam Therefore, the reduced heater firing, as set by the
process requirement, also gives a nearly linear drop
in steam production.
Boiler
However, plant steam demand stays the same.
Fuel Gas So, some other part of the plant must provide the
steam. In this case, the boiler firing goes up and
boiler fuel demand rises. The added feed/effluent ex-
TempH Stack Heater Steam changers shift more duty to the boilers. The extended
New Steam heat balance boundary (shown by the dashed line on
Feed-Eff Feed-Eff Generator
(5 exchs) (2 exchs) Section
Figure 1) gives the correct energy balance — includ-
ing the effect of the changes on the steam system.
Feed What is the net energy savings of the project?
A quick analysis compares stack temperatures. The
boiler stack temperature runs around 350°F while
Product the process heater stack temperature runs around
Energy
Project 520°F. Yes, the project saves energy — but not very
Addition Process much. Detailed analysis also would include effi-
Heater
ciency differences between different fuel types, air
Fuel Gas
Reactor
preheat changes and many other factors. But by itself
just comparing stack temperatures gives a rough
4%–4.5% energy savings on the extra duty provided
by the two new exchangers. Few projects will make
Original Heat Energy Balance Boundary the cut with this low a benefit.
Figure 1. Taking into account its impact on the boiler gave the project a marginal Here, the improper boundary resulted from
return. not thinking through all the consequences of

April 2011 chemicalprocessing.com  40

CP1104_40_41_InSites.indd 40 3/25/11 11:51 AM

 PLANT INSITES

changes. However, one other issue continually
arises: transfer prices. The current example uses
cost of a stream (fuel gas) that the plant must
purchase, allowing a relatively straightforward
analysis because money changes hands. When
money doesn’t directly change hands, the evalua-
tion can become tougher.
Complex plants may have operations run by
many different business groups that are judged, and
rewarded, by their specific results. Energy streams
handed over from one group to another typically get
transfer prices. Many different methods can be used
to set these prices. Even in good faith, different pric-
ing philosophies and logic can lead to transfer prices
that result in strange conclusions.
For our example, imagine the steam generated
by the process heater has a price set by its heat con-
tent. Th is ties its value to fuel. In contrast, imagine
the price for the boiler steam has a fuel component
plus an extra cost added for “guaranteed avail-
ability.” The total boiler steam price will be much
higher. So, the business unit responsible for run-
ning the process heater might want to reduce feed/
effluent exchanger efficiency to generate more “low
cost” steam. Opening bypasses will quickly lower
efficiency. If the entire plant takes similar steps,
the efficiency differences between the boilers and
the process heaters add up. In extreme cases, boiler
steam demand may drop so low that boiler operat-
ing problems occur.
Ideally, transfer prices should give the same
answer as looking at an overall energy envelope.
Sometimes they don’t. When evaluating projects
based on transfer prices always attempt to check the
overall envelope as well. If the answers don’t match,
it’s time for a thorough and careful look at the deci-
sion criteria.
ANDREW SLOLEY, Contributing Editor
ASloley@putman.net

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CP1104_40_41_InSites.indd 41 3/25/11 11:52 AM

 Product Exclusive
Process Gas Chromatograph Eases
Maintenance
Device also enables multi-oven parallel chromatography
The GC8000 process gas 21st Century GC
chromatograph (GC) has great
commonality with the company’s
GC1000 Mark II but reportedly
meets the ever-growing demands
for analytical reliability and preci-
sion while improving the total cost
of ownership through built-in,
automated maintenance functions
never seen before.
The maker, which has offered
GCs since 1959, says it is leveraging
that experience in GC design to
produce a new GC platform with
faster, more reliable measurement,
an easy-to-use graphical HMI and
built-in internal diagnostics, so per-
formance and operating condition
can be tracked on a 24/7 basis.
The GC8000 is supplied with
a 12-in. color touchscreen HMI
suitable for Class 1, Division I in-
stallation and powerful predictive Figure 1. Pictured is the
diagnostics. The GC8000 also three-oven version of the
has a number of innovations in GC8000.
its gas chromatograph analytical
capabilities. It features a unique
GC Module (GCM) concept that makes multi-
oven, parallel chromatography practical. Each
virtual GC is treated by the system as a completely the following):
separate device, bringing the benefits of virtualiza-
tion to the process GC. This simplifies maintenance
without sacrificing benefits of parallel chromatogra-
phy. Up to six system clocks (SYS) per GC8000 for
complete independent operation allow each GCM
to be optimized for speed and reliability. Built-in
graphical overview screens show each of the indi-
vidual GC Modules.
The valves and detectors are the same proven
hardware used for years in the GC1000 Mark II. In
addition to many common spare parts between the
two models, the new GC8000 uses the same Ethernet ating at peak performance. Storage and trend display
communications network.
The maker claims superior analytical perfor-
mance. A wide range of analytical oven configurations
tackle what the company calls the most demanding
applications. A high-sensitivity thermal conductivity
April 2011 chemicalprocessing.com  42
CP1104_42_Exclusive.indd 42
detector (TCD) design is capable
of measuring to the very low
parts-per-million range. There are
user-defined programs for cus-
tomized measurement solutions.
Calculations and reporting can be
customized, with programming
based on Y-Basic.
The GC8000 can implement
user-defined event-based actions,
such as performing a certain
analysis based on a specific plant
condition. Historical data are
stored in the GC allowing histori-
cal trending at the GC for quick
maintenance reviews, with long-
term storage on a network PC. The
Ethernet communications network
allows multiple GCs to communi-
cate on the same network.
The GC8000 can be sup-
plied with single- or dual-channel
(redundancy), 100BaseT or fiber-
optic Ethernet links. Data transfer
can be Modbus TCP/IP. Standard
digital output contacts include two
common alarm contacts and four
relays for external I/O interception. Also, GC8000
can be supplied with optional I/O (five modules from
• Analog input: four channels
• Analog output: eight channels
• Digital input: eight channels
• Digital output: five channels
• Digital input/output: three DI and three DO
• Serial communications module: one channel
(maximum one per GC).
The company says the GC8000’s HMI is easy to
learn, and the new HMI can emulate the GC1000
Mark II to make upgrade training simple. Preventive
maintenance software assists in keeping the GC oper-
of analysis results and key performance indicators aid
in troubleshooting the analyzer.
Yokogawa Corporation Of America
1-800-888-6400
www.yokogawa.com/us
3/25/11 11:50 AM

Sanitary Lump Breaker Fea-
tures Side Removal Screens
New sanitary lump breaker has side
removal bedscreens for rapid, thor-
ough washdown. Model RDC1515-
SS reduces agglomerates and friable
materials being discharged from
process equipment, storage vessels
and shipping containers. Material
entering the 15-in. (381-mm) square
inlet is reduced in size by dual rotors
with three-point, single-piece, stain-
less-steel breaking heads rotating
with minimum clearance inside a
curved, perforated bedscreen. Mate-
rial exits through apertures in twin
bedscreens ranging from 1/32 to
2-½ in. (25 to 64 mm) in diameter.
Powered by a 3-hp (2.24-kw) motor
with gear reducer and serpentine
timing drive, the synchronized
shafts rotate at approximately 100
rpm to avoid heating the product.
Munson Machinery Company, Inc.
800-944-6644
www.munsonmachinery.com
Two Speed Drive Excels At
Vacuum Pump and Com- Low Speeds
pressor Has Larger Capacity The two-speed drive package can
The Nash Vectra XL 950 liquid-
ring pump and compressor is
specifically designed for the process
industries. The new model provides
extended capacity at 5,300 CFM
(9,000 m3/h). The series features low
operating speeds to help ensure a
long, reliable operating life; vacuum
pump operation to 28.5 in. HgV (50
CP1104_43_44_E&S.indd 43
mbar abs); compressor operation to
30 psig (3 bar abs); O-ring sealing;
and oil-lubricated bearings option.
Its single-point inlet and discharge
connections are said to eliminate
the need for manifolds, simplifying
process piping, saving space and
reducing the installed cost.
Gardner Denver Nash
800-553-6274
www.GDNash.com
Digital Pressure Gauge Of-
fers Selectable Units
The Series DPGWB/DPGAB pres-
sure gauges provide 0.5% full-scale
accuracy with user-selectable units
of measure that allow one gauge
to be used for a variety of pressure
scales. The DPGAB, which has
push-button zeroing, is said to be
not only economical but ideal for
monitoring the pressures of air and
compatible gases. The DPGWB
model features stainless steel for
wetted surfaces. making it suitable
for a wide variety of liquids or gases.
The pressure gauges come with a
rubber boot to protect against short
drops and rough handling.
Dwyer Instruments, Inc.
(800) 872-9141
www.dwyer-inst.com
be added to the back of a standard
motor brake to provide inching
speeds of 5:1 to 60:1. Variable speed
motors can lose torque or develop
heat problems at very low speeds,
and the Force Control Two Speed
Drive is said to eliminate those
problems with secondary speeds as
low as 60:1 while still maintaining
43 
Equipment & services
full torque continuously. This drive
includes a brake motor with a low
speed drive built in. Totally en-
closed units are considered ideal for
dusty, dirty or wet environments,
even outdoors. Options include IEC
or NEMA motor frames, explosion
proof, and marine duty.
Force Control Industries, Inc.
(513) 868-0900
www.forcecontrol.com
Motor-Blowers Boast Switch
Reluctance Technology
A new line of high cubic-feet-per-
minute (CFM ) motor-blowers
based on proprietary high-speed,
brushless Switched Reluctance (SR)
motor technology targets applica-
tions that require high airflow and
medium pressure. The INFIN-A-
TEK motor-blower line features an
advanced lamination design that
reportedly allows the motor to run
faster and achieve over 724 peak air
watts, while consuming less than
a third of the energy of traditional
blower types. The motor-blowers
are available in 120-V and 230-V
single-phase with air pressure up to
2.6 psi and air flow to 300 CFM for
one single unit or 4.1 psi and 500
CFM when used in an air series-air
parallel configuration.
AMETEK Floorcare & Specialty
Motors
859-221-1169
www.ametekfsm.com
chemicalprocessing.com March 2011
3/28/11 11:33 AM
 Equipment & services
Sensors Combine Accuracy
with Low Maintenance
The S651CD submersible pH/ORP
electrode and S656CD insertion
electrode feature upgrades that
lower maintenance requirements
and lengthen life. The S651CD
is designed for measurements in
tanks, flumes and sewer lines,
in addition to other applications
with high suspended solids, where
flocculation operations require low
velocities and in tanks with high
agitation. Both models feature a
quick-disconnect design for lower
operating costs, a flat surface to
resist coating and the option to be
mounted against the flow to further
increase scrubbing action across the
measured surface.
Sensorex
714-895-4344
www.sensorex.com
Inline Flow Meters Cope
With Particulates
Vortex-shedding flow meters
monitor the flow of cooling fluid
for steam boiler feed water, slurry
pump seal water, machine cool-
ant and resistance welders. These
inline flow meters suit applications
utilizing water, water/glycol coolant
and other low-viscosity fluids. The
meters feature no moving parts to
clog or wear out, providing life-long
reliability and requiring little main-
tenance. Further, with no moving
parts, the meters are said to be well
suited to monitor media with small
particulates. The meters operate
March 2011 chemicalprocessing.com  44
CP1104_43_44_E&S.indd 44
with NPT ports ranging from ¼
in.–2 in. and can handle flows from
4–200 GPM, with occasional over-
ranging up to 125% of capacity
without damaging the meter.
Parker Fluid Control Division
800-825-8305
www.parkerfluidcontrol.com
Bulk Bag Unloader Elimi-
nates Extra Headroom
A new single-trip bulk bag unload-
er allows rapid, low-cost discharg-
ing in low headroom areas, and
conveying of the material at any
angle to downstream processing.
The unloader relies on a forklift or
plant hoist to lower single-use bulk
bags onto a four-bladed bag-pierc-
ing knife that cuts the bag bottom
from seam-to-seam, promoting
complete discharge without the
use of flow promotion devices
otherwise needed to move material
through narrow bag spouts. The
bag bottom self-seals against a
thick gasket affixed to the rim of
the hopper and discharges through
a wide-diameter hole in the center
of the gasket, eliminating the cost
and additional headroom required
for bag spout interfaces used on
conventional unloaders.
Flexicon Corporation
888-353-9426
www.flexicon.com
Manual Limit Switches Suit
Ball, Butterfly Valves
LHB Series Manual Limit Switches
feature a new design that reportedly
is lightweight and robust and offers
ease of installation, exact control
and long-lasting performance. The
LHB Series is available in two sizes
and with either two or four limit
switches. The switches fit all sizes of
Hayward TB series ball valves and
BY series butterfly valves up to 8 in.
Both sizes are available in a glass-
filled polypropylene housing with
FPM O-ring seals and 304 stainless
steel stem. Standard handles include
T-handle or hand-lever. The series
also features ½-in. conduit part,
integral lockout and terminal blocks
for ease of wiring.
Hayward Flow Control
888-429-4635
www.haywardflowcontrol.com
Process Weighing Termi-
nals Boast Small Footprint
The IND131/IND331 industrial
process weighing terminals are said
to provide maximum connectivity
and small footprints. The models
feature high-speed analog-to-digital
circuitry and flexible connectivity,
and are designed for easy integra-
tion into process control systems.
The terminal has the speed to pro-
vide accurate on-time readings and
connection options to transmit data
to a wide array of control systems.
The models are reportedly compact
and easy to set up. Terminals fea-
ture enclosure styles to match any
process environment, and include:
IND131 DIN rail mount, IND131
J-box, IND331 panel mount, and
IND331 Harsh/desk/wall mount.
An OLED graphic display provides
simple plain text menus and icon
driven operation.
METTLER TOLEDO
800-638-8537
www.mt.com/industrial
3/28/11 11:33 AM
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CP_PanelSeries_Half_1104.indd 1 3/29/11 10:44 AM

CP1104_46_49_CLASS.indd 46 3/29/11 10:49 AM


Maintain Spray Nozzle Life
Improved reliability, proper perfor-
mance, and maximum wear life of a
spray nozzle often start with correct
material selection. Let BETE Engineers
help you select the most compatible
material for your chemical processing
nozzles. Our expertise will help you
stand up to harsh abrasives.
BETE Fog Nozzle, Inc., (413)772-2166, www.bete.com
Fast, High Capacity Precision Mixing
The new Bella XN double shafted
Fluidized Zone Mixer by Dynamic Air
includes access doors which not only in-
crease accessibility but also make it much
easier to clean when necessary. The Bella
mixer achieves fast, high capacity, low
shear, precision mixing of either dry bulk
solids or liquids with solids. Regardless
of particle size, shape or density, materials are mixed with a fast,
efficient, and gentle action - typical mixing times are 60 seconds
or less. A weightless zone created by low-speed counter rotating
shafts generates very low friction without shear. This makes it
ideal for fragile products that cannot tolerate rough handling.
Even flakes or spray-dried bodies remain intact. The Bella XN
mixer includes twin bomb-bay door openings for fast, efficient
discharging and to minimize segregation during discharge. The
Bella mixer is available in stainless steel for sanitary applications.
Custom sizes, finishes and materials of construction are avail-
able upon request. Dynamic Air Inc., (651) 484-2900, www.
dynamicair.com
Pump load control
The PMP-25 pump load control guards
against dry running, cavitation and
overload. It monitors true pump power for
maximum sensitivity. The display shows
pump load, trip points and delays. Its
NEMA 4X enclosure is small enough to
fit on Size 1 starters and can be door-, panel- or wall-mounted.
Load Controls Inc., (888) 600-3247, www.loadcontrols.com.
Best-in-Class Coriolis Filling Meters
Higher throughput, more rapid
changeovers, on-set-point fills, less
product waste, and fill sizes down to
1ml. Upgrade your filling process with
the most compact, fastest fill measurement technology available –
Emerson’s Micro Motion Coriolis Filling Meters. Micro Motion,
(800) 522-6277, www.micomotion.com
CP1104_46_49_CLASS.indd 47
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Ad-LITS
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We manufacture a broad line of throt-
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pressure reducing regulators, and back
pressure regulators in line sizes from 1 ⁄4
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.002 to 4,406. Models are available to
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fugitive emissions. Contact Cashco for complete product
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cosolutions.com
Fike Explosion Protection Testing Services
Is your facility at risk for an explosion?
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procedures. Fike offers a wide range of
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and combustion scientists. And Fike has a complete line of
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save lives. Fike Corporation, (816) 229-3405, www.fike.com
2011 NLB water jet catalog
Automated water jet cleaning systems for
tube bundles, tanks and reactors are
featured in the latest NLB accessory
catalog. The 2011 edition features
106 pages of manual and automated
high-pressure equipment (up to 40,000
psi) and a reference section. Request it
from NLB or download it at the
company’s website, www.nlbcorp.com.
NLB Corp., (248) 624-5555, www.nlbcorp.com
New Expanded Line of Tank Cleaning Equipment
Additions to the TankJet® line from
Spraying Systems Co. include several
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stubborn residues, motorized units that
provide a targeted directional spray and
compact nozzles for cleaning small
containers. Request Catalog 15 and get
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CP1104_46_49_CLASS.indd 48
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49  chemicalprocessing.com April 2011

CP1104_46_49_CLASS.indd 49 3/29/11 10:50 AM

 END POINT
U.K. Wants More Chemical Engineers
Proposed legislation eases immigration of non-European-Union technical specialists
A much-awaited redraft of immigration legis-
lation in the U.K. should ensure that chemical engi-
neers continue to get preferential treatment there.
Published on February 16 by the U.K. Border
Agency (UKBA), London, the redraft applies to
skilled migrants such as engineers and scientists. The
Institution of Chemical Engineers (IChemE), Rugby,
New legislation England, broadly welcomed the proposal.
“We must show governments how critical engi-
is an important neers and scientists are to universities and industry.
victory for And we need to keep updating the evidence that
chemical engineers are in demand, and that skilled
the science and migration is a good thing. Our industries are global,
engineering our companies are global, our challenges are global
— and to tackle them, engineers should be mobile
sector. around the world,” says IChemE CEO David Brown,
who has been campaigning to keep chemical engi-
neers on the official “shortage occupations” list.
The new rules apply to so-called “Tier 2” mi-
grants, who must have a graduate level job on offer. A
cap of 20,700 per year has been set for these migrants.
However, the new rules do not apply to “Tier 1”
migrants, the category reserved for individuals of
exceptional talent. There are only 1,000 visas available
under this category in the first year, across all job
categories.
Brown says he will work with colleagues from
other organizations to ensure the migration of top sci-
entists and engineers continues in sufficient numbers.
Meanwhile, the Campaign for Science and Engi-
neering (CaSE), London, the U.K.’s leading indepen-
dent advocate for the science and engineering sectors,
says the new immigration rules represent a victory for
these sectors — not least because the new proposals
give significant rewards to applicants with science and
engineering qualifications.
Understanding how important international
mobility is for research and development, academ-
ics, industrialists and researchers at non-profit groups
sounded the alarm over the government’s new
“migrant cap” for workers from outside the European
Union (E.U.). More than one in seven academics
in the U.K. higher education sector alone hail from
outside the E.U. Last October, eight Nobel laureates
signed a letter organized by CaSE saying the U.K.
“must not isolate itself” from the global world of
research.
The new proposals from the UKBA mean that an
applicant who has a Ph.D or equivalent-level job offer,
April 2011 chemicalprocessing.com  50
CP1104_50_EndPoint.indd 50
earning £23,000 ($37,000), would be preferred over
someone earning £74,000 ($120,000) but who did
not have a Ph.D-level job offer, such as professional
athletes and financiers.
CaSE director Imran Khan said, “Part of the
reason the U.K. is world-leading in science and engi-
neering is our ability to attract talent from around the
world. The migrant cap could have left a sizeable dent
in the U.K.’s scientific credentials.
“I’m delighted that the government, and the
UKBA in particular, have listened and responded to
our concerns. They’ve responded with a package that
rewards people who want to come and invest their
intellectual capital in this country. I think we can
see this as an important victory for the science and
engineering sector.
“For a long time now the visa allocation system
has rewarded wealthy investors and Premier League
footballers [soccer players], and discriminated against
top scientists and engineers — it’s great to see this
finally being addressed.
“We’ll continue to work closely with the UKBA
to make sure this package works for Britain, as well
as making sure that other aspects of the immigration
system — including student visas — don’t prevent
the recruitment of non-E.U. researchers that are so
important for our research base.
“While we still disagree that a cap on scientists
and engineers is something the government should
implement, these proposals should mean that the
U.K. can still bring in the necessary individuals from
around the world.”
However, while all categories of chemical engineers
make the shortage occupations list, the UKBA’s require-
ments are very stringent for those with other back-
grounds. For example, design and development engi-
neers need experience in the electricity transmission and
distribution industry; production and process engineers
need the same experience; and quality control engineers
are particularly welcome if they have backgrounds in
health, safety and environmental engineering.
“Although today’s statement of intent is not defini-
tive — as the rules will be subject to Parliamentary
scrutiny — it is intended to provide migrants and
employers with enough information to make effective
plans,” notes the UKBA.
Seán ottewell, Editor at Large
sottewell@putman.net
3/25/11 11:35 AM
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