Seal Water Control System Proposal

TECHNICAL PROPOSAL Seal Water Control Systems

PT TJIWI KIMIA - Mojokerto

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ISSUE REV.

13.08.08
DATE: DD/MM/YY

First Issue
STATUS

First Issue
DESCRIPTION

This Document is confidential. The copyright is vested in John Crane Singapore Pte Ltd. All rights reserved. Neither the whole nor only part of this document may be disclosed to any third party or reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, reprographic, recording or otherwise) without the prior written consent of the copyright owner.

TITLE:

Improving efficiency of Sealing Water System

DOCUMENT NO.:

PT. John Crane Indonesia

Cilandak Commercial Estate #401A Jakarta 12560
ISSUED BY: Rudy Wijaya, PT. John Crane Indonesia tel: +62 21 789 0068 fax: +62 21 789 0848 E-mail: Rwijaya@johncrane.co.id

Seal Water Control System Proposal

1. CONTENTS

1. Contents 2. Operating Conditions Overview 3. Objective 4. Smart Flow Feature 5. Cost Saving Analysis 6. Comments

Seal Water Control System Proposal

2. Operating conditions Overview

Equipment Mfr : Goulds 3196MT Pump material : Titanium Service : Brine Pump Temperature : + 50 C Disch. Press : 61 PsiG Suct. Pres : 10-15 PsiG Mech. Seal : John Crane Double Seal size 1.3/4 T8-1-DBL Barrier Liquid : Demin Water Brine Pump at Chemical Plant The process liquid being pumped is Brine, a chemical liquid which is very corrosive and should be avoided for contacting directly to human or environment. There are 2 units pumps that some time running together but most of the time only 1 unit pump running and the other is stand by. To avoid the process liquid leak to the atmospheric side a double back to back mechanical seal design is installed. The operation of this seal design is required external liquid (other than process liquid) that will be used as barrier liquid at pressure 1 bar higher than stuffing box pressure. The stuffing box pressure (seal pressure) is calculated as follows : S/box pressure (in PsiG) : suction pressure + (0.3 x differential pressure) : 15 + (0.3 x (61 15)) : 15 + (0.3 x 46) : 28 *) we assume the suction pressure is 15-20 PsiG Base on the above calculation the ideal pressure of barrier fluid should be around 35 45 PsiG at all the time, note : higher pressure is allowed to ensure the positive pressure in the stuffing box.

Double Back to Back Seal

Seal Water Control System Proposal

In the operation of double back to back seal, small amount of barrier seal will leak to process side when the inboard seal is damage and they leak to atmospheric side when the outboard seal is damage, this is because of the pressure of the barrier seal is higher than s/box pressure (pressure behind the impeller). Any barrier fluid pressure drop below s/box pressure (28 psiG) will lead the process liquid (brine) entering the seal cavity and easily damaging the mechanical seal. Base on site inspection that taken place on 6 August we discovered that Demin Water is injected to mechanical seal through the inlet port at pressure of 50 Psig there is a P.I (Pressure Indicator) to measure the pressure of Demin Water. The function of Demin Water is to isolate the process liquid to not entering the seal cavity, and also to cooling/lubricating the seal faces of mechanical seal. We discovered that Demin Water was pipelined out from the mechanical seal to the water drainage near by the pump. The flow rate of Demin water was measured at 2 litres per 9 seconds per pump (pressure at 50 PsiG). The flow and pressure of the Demin water prior to mechanical seal were controlled manually using valve regulator, P.I. is available but there is no F.I (Flow Indicator) to measure the flow rate.
Demin Water IN

50 PsiG

CURRENT OPERATION

2 ltrs/9 sec

Demin Water Out

The actual flow rate of Demin Water in these pumps is 1liter per 4.5 second or equivalent to 19.2 M/day. The pressure is maintained at 50PsiG, it should be 10-15 Psi higher than stuffing box pressure.

3. OBJECTIVE
John Crane customer, PT. Tjiwi Kimia is looking for solution to reduce Demin Water Consumption which is currently very high i.e. 19.2 M/day (7008 M/year). Base on empiric cost of Demin Water that usually used in European country which is estimated at Eu 0.5/ M, then the cost of Demin Water for this pump is around Eu 3504/pump/year. John Crane Safematic Finland is one of the leading company who supply technology to Pulp and Paper in the world. We are producing mechanical seal and sealing water device and help customer enhancing the plant reliability and reduce unnecessary operating cost. One of the John Crane technology in Sealing Water equipment is SmartFlow that designated to reduce sealing water consumption at very minimum level without interrupting the reliability of the
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Seal Water Control System Proposal

equipment/pump. Field experience shows average water savings of over 95% achieved compared with flow meter systems

4. SMART FLOW FEATURE

SmartFlow is an Intelligent Seal Water Control System which considerably reduces water usage and hence operating costs. The SmartFlow is available in two forms a Universal design suitable for all pumps an Integrated version designed for use with JC Safematic JCS2 seals

The Universal SmartFlow has water circulation to transfer heat to the operating valve while the SmartFlow IG is integrated to (and operates inside) the seal so does not need circulation.
Memory shape alloy spring The spring is manufactured from a Nickel Titanium alloy. NiTi is a temperature-activated material, when cool it is pliable and can be easily deformed to any shape. If the material is heated to its activation temperature it "remembers" its original programmed shape and returns to it - applying force against anything it its way. i.e. it changes from a pliable piece of material to a spring. Note, in the Universal SmartFlow seal water circulation is necessary for memory metal activation Filter The Universal SmartFlow includes a filter to ensure failure-less equipment operation, note this is for valve protection only and is not suitable for line filtration. The filter has to be checked and cleaned on regular basis in order to prevent clogging. Cleaning frequency is dependant on the quality of seal water used. Safety valve A safety valve based on seal water temperature is incorporated in the equipment. This is not shown on the above diagram (Universal SmartFlow) but is normally located at the outlet from the gland plate (inlet to the SmartFlow). The safety valve will open should such operational failure occur on the equipment causing the seal water temperature to exceed 90 C (195 F). In the Integrated SmartFlow a safety valve is built into the unit.

Seal Water Control System Proposal

SmartFlow operation is based on a heat-activated, shape memory, alloy spring that mechanically opens and closes the flow channel. The system automatically adjusts to new operating conditions, i.e. alternating pressure and temperature. The Universal and Integrated SmartFlow operate in very similar ways, the main differences being during cool operation, the Universal SmartFlow circulates seal water in a closed loop while the Integrated SmartFlow prevents seal water flow the Integrated SmartFlow has a safety valve built in to its construction, the Universal SmartFlow uses a separate safety valve

When the barrier/ buffer fluid is cold the spring is in its pliable state and the flow valve in the SmartFlow remains closed. This causes the fluid to be recirculated through the stuffing box. (Note, in the case of the integrated SmartFlow there is no flow). When the temperature increases to 60 C (140 F) the alloy changes and transmits axial force like a normal spring. This force opens the flow valve allowing hot seal water to flow to drain (or collection point) and the system is topped-up by cold water. This cools the circulation flow and returns the spring to its pliable state, the flow valve then closes and the cycle repeats. The equipment causes a pressure loss when it opens, the extent of the loss depends on the seal water pressure. At maximum pressure the loss is approx. 1.5 bar (21 psi). It is thus recommended that seal water pressure is set 2 bar (30 psi) above sealed liquid pressure. A separate safety valve, based on seal water temperature, is normally located at the outlet from the gland plate (inlet to the SmartFlow).

Seal Water Control System Proposal

The safety valve is normally held closed by a retaining ring made from memory shape alloy. Should an operational upset occur, causing seal water temperature to reach 90 C (195 F) the ring material will activate causing it to expand out of its groove. This allows the spring to open the valve and release hot water. Note, once the SmartFlow safety valve has operated it can be re-set and does not require replacement.

5. COST SAVING ANALYSIS

The primary use of SmartFlow is for controlling seal water flow in double-balanced mechanical seals. Customers are demanding reduced seal water consumption which can give them very significant savings in water supply (incl. lower filtration costs) waste water disposal compliance with environmental aspects / standards

SmartFlow delivers those savings with reduction in seal water usage of typically 95% compared to flow meter regulated flow-through systems (see table below). The average payback period for SmartFlow is less than 15 months. Note. Water consumption is affected by product temperature, rotation speed, seal water temperature (from line), surrounding temperature and seal water pressure. Estimate cost of current operation (per pump) : Water Usage : 7008 M/Year Cost of Water : 7008 M x 0.5 = 3504

Seal Water Control System Proposal

Expected Water Saving by 95% (base on field experience) Saving : 7008 M x 0.95 = 6.657 M In Euro : 6.657 M x 0.5 = 3328/pump

Pay Back Analysis : Cost of Smart Flow Cost of Water Pay Back (month) : 1066 per unit : 3504 per pump/year : Eu1066 (

Eu3504 ) 12

: 3.65 months

6. COMMENTS
Return of investment can be achieved in 3.65 months, most of management will continue the Business Plan if the R.O.I. less than 24 months.

Seal Water Control System Proposal

Cost Saving Analysis :

Case Study Tjiwi Kimia P & Paper

Case Study Tjiwi Kimia P & Paper

FACT FINDINGS) : Demin Water Press : 50 PsiG (PI) No Flow Indicator Actual Flow : 2ltr/9 sec (13.3 ltr/mnt)
(Note : using glass measurement)

ACTUAL COST OF OPERATIONS : Demin Water : 13.3 ltr/mnt X 60 X 24 X 365 days 6.990.480 ltr/yr or 6.990M/Yr Cost/Price : Rp. 6.000/M Total Cost : Rp. 41.940.000,- per pump

Seal Water Control System Proposal

Case Study Tjiwi Kimia P & Paper

One of the John Crane technology in Sealing Water equipment is SmartFlow that designated to reduce sealing water consumption at very minimum level without interrupting the reliability of the equipment/pump. Field experience shows average water savings of over 95% achieved compared with flow meter systems

Case Study Tjiwi Kimia P & Paper

The Universal and Integrated SmartFlow operate in very similar ways, the main differences being : during cool operation, the Universal SmartFlow circulates seal water in a closed loop while the Integrated SmartFlow prevents seal water flow. the Integrated SmartFlow has a safety valve built in to its construction, the Universal SmartFlow uses a separate safety valve

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Seal Water Control System Proposal

Case Study Tjiwi Kimia P & Paper

COST SAVING ANALYSIS : The use of Safe Unit will reduce Demin water consumption from 13.3 ltr/mnt to 4 ltr/mnt (or 6.990 M/year to 2.102 M/year)
Cost of Demin Water reduce from : Rp. 41.940.000,- per year to Rp. 12.614.000 (cost saving Rp. 29.325.600 per year)

The use of Smart Flow will reduce 90% of Demin Water Consumption by 90% from Rp.12.614.000,- to become Rp.1.261.400,- (Cost Saving Rp. 11.352.600,- per year) PAY BACK ANALYSIS :
Cost of Safe Unit + Cost of Smart Flow : Rp. 6.000.000,- + Rp. 16.000.000,- = Rp. 22.000.000,Cost saving due to the use of Safe Unit + Smart Flow : Rp. 29.325.600,- + Rp. 11.352.600 = Rp. 40.678.200,- per year Pay Back : Rp. 22.000.000/(Rp. 40.678.200,-/12) = 6.48 mths

Case Study Tjiwi Kimia P & Paper

Return of investment can be achieved in 6.48 months, most of management will continue the Business Plan if the R.O.I. less than 24 months.

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