Yokogawa EPMS and SCADA for the UK’s BPAL pipeline system

Yokogawa has received an order from the British Pipeline Agency Limited (BPAL) to supply a management and control system for one of the UK’s major multi-product fuel pipeline systems, to replace the current BPAL pipeline management and SCADA systems.

The BPAL UK pipeline system consists of three integrated multi-product fuel pipelines that link two, refineries, one at Ellesmere port on the Mersey near Liverpool and the other on the Thames in Essex, to inland distribution terminals. These pipelines, operational since 1969, meet over 50% of the jet fuel needs at London’s Heathrow and Gatwick airports, and are altogether some 650 km in length. BPAL, jointly owned by Shell and BP, are the operators of these pipeline systems (known as UKOP and WLWG), which are owned by a consortium of partners.

This order is for Yokogawa’s Enterprise Pipeline Management Solution (EPMS), which will manage functions such as delivery scheduling and oil storage, and their Fast-Tools SCADA software, to monitor and control the oil pipelines and related equipment such as compressors. The EPMS uses specific gas and liquid applications that enable a pipeline operator to manage delivery contracts in a time and energy efficient manner. With the SCADA system covering monitoring and control, the EPMS will integrate the management of the SCADA data. Delivery of these systems will be completed by March 2018.

Further order for UAE Power and Desalination Station

Yokogawa also recently received its first ever DCS order for a power and desalination plant in the UAE. The company is to supply the Sharjah Electricity & Water Authority (SEWA) with control and safety systems, plus field equipment, for Units 7 and 8 at the Layyah Power and Desalination Station.

Each unit comprises a 75 MW oil and gas-fired thermal power plant and a 27,000 m3 per day multi-stage flash (MSF) desalination plant: a technology that involves the heating and evaporation of seawater in multiple vacuum distillation tanks to produce steam, which is then condensed to produce fresh water. Such systems are energy-efficient because they use the heat from the steam that is created in the vacuum distillation tanks.

Yokogawa Middle East & Africa will deliver the CentumVP integrated production control system for the boiler, turbine governor, turbine protection system and the desalination plant at each of these units, as well as the ProSafe-RS safety instrumented system for burner management and boiler protection. The field instruments will include Yokogawa products such as the DPharp EJA series differential pressure and pressure transmitters, continuous emission monitoring systems (CEMS), and steam and water analysis systems (SWAS). In addition to being responsible for engineering, the company will provide support for the installation and commissioning of these systems, with all work scheduled for completion by September 2017.

Demand for electricity and water is soaring throughout the Middle East due to their rapid economic growth. Power and desalination plants that rely on the region’s abundant oil and gas resources make up an important part of this region’s infrastructure.

Alfa Laval sees marine market growth in ballast and SOx

Readers of this blog will recall the Alfa Laval launch on their “PureBallast” water treatment system for marine vessels way back in 2007. The IMO international convention for the ‘control and management of ship’s ballast water and sediments’ was the legislation that would drive the adoption of such systems world-wide: at last this convention became legally binding on shipping and ship-owners worldwide on 8th September 2016. Inevitably there is a 12 month time lag before it will be legally enforced, and then, hopefully, tankers will not be allowed to ply their trade without having an approved ballast water treatment system fitted.

Ballast water treatment market

Peter Leifland, current president of the Marine & Diesel Division of Alfa Laval presented some interesting views of this market in support of the recent Alfa Laval Capital markets Day presentation to analysts and stockbrokers.

Leifland commented that “With the ratification in place, the market for retrofit installations is expected to start to move.”  Alfa Laval expects that 35 000 ships will install a ballast water treatment system between 2017 and 2025. This is split between 15 000 newly built ships and 20 000 retrofit installations. The average order value per ship for the Alfa Laval chemical-free solution is EUR 200,000 – 225,000.

The Alfa Laval system fully complies with IMO standards and requirements, but as ever different countries can impose further approval and performance requirements and testing, effectively policing their own waters so that only ships with their approved systems can trade in their waters. This means more approval testing, fees, and even design changes for suppliers like Alfa Laval. They have their PureBallast system nearing completion of the long testing procedure needed by the US Coast Guard to check that it meets with their USCG criteria.

Shipboard sulphur oxide emissions (SOx)

The IMO convention for the reduction of sulphur oxides (SOx) emissions from ships has been ratified and since 2015 it has been implemented in some Emission Control Areas (ECAs). This IMO regulation will become global by 2020, requiring that that emission levels will be cut to 0.5%.

Leifland commented that Alfa Laval estimates that 5 000 ships, new as well as existing, will install a scrubber solution in the period 2017-2025.” Given the continuing development of new solutions, Alfa Laval’s average order value per ship is expected to be EUR 1 million. Leifland sees these two developing markets as a useful opportunity, during a period where “falling ship contracting is impacting our order intake”.

Postscript 27 December 2016: 

Alfa Laval PureBallast 3 receives U.S. Coast Guard type approval

Peter Leifland, President of the Marine & Diesel division in Alfa Laval, reports that:

“I am very pleased to receive this type approval, as it confirms the reliable performance of our ballast water treatment system. We now have a system approved by both US Coast Guard and the International Maritime Organization”.

Alfa Laval PureBallast 3 has received US Coast Guard type approval for usage in all water salinities, including fresh water. It follows upon two and a half years of compliance testing, according to the strict demands of the Environmental Protection Agency’s “Environmental Technology Verification” (EPA ETV) testing protocol. The tests were performed at DHI’s test facilities in Denmark, supervised by DNV GL as the independent inspection laboratory.


2M EM Flowmeters in 40 years

Since 1977, Endress+Hauser has produced over two million electromagnetic flowmeters. The company claim this is more than any other manufacturer, and that E+H is the market leader in electromagnetic flowmeter technology. “This magic number stands for high-quality measuring technology and, above all, satisfied customers in all kinds of industries,” says Bernd-Josef Schäfer, Managing Director of Endress+Hauser Flowtec AG, the center of competence for flow measuring technology.

The Endress+Hauser success story as a manufacturer of electromagnetic flowmeters began in the middle of the 1970s. In order to enter the water and wastewater market which was emerging at that time, E+H purchased the company ‘Flowtec’ in Bern, in 1977, and moved it to a new location in Reinach (Basel-Landschaft, Switzerland). This is where Endress+Hauser started to produce flowmeters with just three employees, in a former military barracks.


The 1977 production unit at Reinach

Then, work was done on an on-demand basis. “Whereas today,” says Bernd-Josef Schäfer, “our production spans six sites around the globe – in Switzerland, France, the USA, China, India, and Brazil – and boasts state-of-the-art logistics. This infrastructure is what has enabled us to produce two million electromagnetic flowmeters to date in accordance with required quality standards.” These two million electromagnetic flowmeters could measure a volume corresponding to four times the flow rate of the Amazon. Each production site also features precise calibration facilities which are regularly checked by national accreditation bodies and which guarantee consistently high measuring quality for each individual device.

Constant innovation for customer satisfaction

The company’s success, which spans almost 40 years, is due to many factors. In particular, its inventive talent has enabled Endress+Hauser to keep offering its customers new, groundbreaking devices capable of measuring all kinds of fluids, such as water, milk, acids, alkalis, or ore slurry, with the greatest accuracy. With clever innovations such as the precision measurement of difficult fluids (Autozero, 1981), microprocessor control (Variomag, 1984), two-wire technology (Eximag, 1987), or the operating matrix (Tecmag, 1990), Endress+Hauser has always managed to stay one step ahead of the competition.


In 1985, 800 and 2000mm bore flowmeters were produced for monitoring drinking water supplies delivered around Algiers

In 1993, all of these device variants were brought together to form a single product family under the name of “Proline”. Alongside this family, however, Endress+Hauser also produces flowmeters for very particular applications – for example, filling bottles at one-second intervals.

Looking to the future with Proline

Since 1993, the Proline device family has undergone constant development to ensure that it meets the prevailing requirements in a wide range of industries. Following the second generation launched in 2000, the third and most recent Proline generation (2012) offers a multitude of unique functions and device properties. This means that system operators will not only be able to retrieve measurement and diagnostic data via display, WLAN, web server, or fieldbus, but will also be able to monitor the process comprehensively and, if necessary, check the functioning of a flowmeter during operation.


One modern production line for Proline electronics units

Bernd-Josef Schäfer sees the future of Endress+Hauser optimistically: “Innovations such as these enable us to align our product portfolio consistently with the needs of every industry. We are looking ahead to our three-millionth electromagnetic flowmeter with great confidence.”

This E+H release was first published by Eoin O’Riain in Read-out.net in Ireland

Water Use Cut 75% at IoT Connected Farm

Avocado trees monitored around the clock by a Spirent Communications system are given water only when needed; the farmer uses soil moisture meters, IoT technology, LoRa WAN communications and cloud computing to control the irrigation, reducing his annual water consumption by 75%.

It takes 74 gallons of water to produce one pound of avocados, and drought-stricken California produces 95 percent of avocados grown in the United States. Nearly all are grown in Southern California, in a five-county region that straddles the coast from San Luis Obispo to San Diego. Like the rest of the state, the southern coastal region is locked in a drought and largely cut off from the flow of surface water from the state’s big irrigation projects. Avocado groves have been hit badly with sky-high water costs and reliance on water pumped from underground aquifers.

Water consumption is regulated in California with the state entering its fourth year of drought resulting in water regulators imposing sweeping and draconian restrictions on the use of water. The State Water Resources Control Board has even urged Californians to let their lawns die.

Some avocado farmers in California feeling the heat have turned to new methods in growing avocados such as higher density planting which enables some to produce twice as much fruit for the same amount of water. But a new initiative from Spirent Communications in bringing about connected avocado farms might just be the perfect solution to make further inroads into lowering spiralling water costs.

Useful day-job expertise

It just so happens that Kurt Bantle is a senior solution manager at Spirent Communications and at home has some 900 young avocado trees planted in his “back garden” in Southern California. Within his work remit, which is to develop Spirent’s IoT offering, he decided to experiment into how avocados could be grown using less water through soil moisture monitoring, by using this as an input to automate the irrigation, using a just-in-time approach.

Bantle divided his farm into 22 irrigation blocks and inserted two soil moisture measurement units into each block. The units contain a LoRa (www.lora-alliance.org) unit for narrow band data communication to a LoRa gateway which has a connection via a broadband cellular uplink.

The gateway also contains an Oasis (a partner company with Spirent) re-programmable SIM which becomes the enabler in remote water provisioning. All soil moisture data from the avocado trees is collected in a cloud and visualised by a presentation layer. When a tree needs to be watered, the solution turns the sprinklers on automatically to get the correct level of soil moisture for each tree. It then turns them off when the correct moisture levels are reached. The connected trees are monitored constantly day and night. In all Bantle spent $8200 for LoRa stations, gateway and cellular backhaul, moisture sensors, and irrigation valve controllers.

“Avocado trees typically take 4 acre feet (1 acre foot = 326000 gallons) of water per acre per year. This is not only to supply the needed water, but also to leach the salts which build up in the soil,” says Bantle: “The soil moisture sensors let me drastically reduce water usage by telling me when to water and how deep to water to push the salts past the bulk of the rooting zone. The majority of the roots are in the top 8 inches of soil so there is a sensor there and one at 24 inches so I can see when I’ve watered deep enough to get the salts out of the rooting zone”.

The previous annual cost of watering his 900 trees was $47,336. By connecting this IoT technology, his annual bill dropped to £11,834, a 75% reduction. The hardware investment was recouped in the first 6 months.

“The case study showed a water usage reduction by 75%, but the usage will climb as the trees get bigger. The goal is to reach a 50% reduction of water usage when the trees are fully grown. By keeping the salts in check along with keeping nutrients supplied, stress on the trees is reduced and they are able to have better crop production,” says Bantle.

Future Consequences: both positive and negative

The downside for Bantle in harnessing the power of IoT to reduce water consumption was that he was placed under state surveillance for suspected meter tampering, when his water consumption reduced so dramatically.

The connectivity solution provided by Spirent together with its IoT ecosystem partners for avocado trees applies to every other type of vegetable and fruit farm, which would include almonds, olives, apples, oranges and tomatoes.

IoT technology pioneer Spirent Communications plc is leading the charge with its open eco-system partners such as Oasis Smart Sim through its connectivity and embedded subscription business and recently showed various such connected solutions at the IoT World exhibition.

Spirent’s Embedded Connectivity solution will be launched during 2016 in a phased manner so that the commercially available solution conforms to the corresponding GSMA specification releases.

Spirent conclude with the message that the Internet of Things (IoT) is destined to touch every aspect of human endeavour making factories smarter, supply chains intelligent ….and now farms such as this first IoT connected avocado farm more water efficient, saving farmers vast amounts of water (and therefore money) in the avocado growing process.

The original story from Spirent was first published by WaterActive.co.uk in their July issue.

Power and water for the developing world

In the Journal ‘South African Instrumentation and Control’ I provide a regular column  giving some commentary on the I&C scene as seen from Europe, wherever possible referring to items that could be of relevance to their South African readers. This was the story published in the May 2016 issue.

Some of the products created for the consumers in the developed world have had perhaps surprising benefits in the less well-developed countries too. One example has been the use of mobile phones throughout Africa, enabling the development of a simple banking and payment system.

But there are other engineering developments that are specifically designed for use by people living far from the normal facilities offered in an urban setting, and many universities, philanthropists and aid organisations are active in supporting these ideas. desolenatorOne such development idea from the UK is known as a ‘Desolenator’. This is a portable, solar-powered water purification system, designed to produce clean drinking water, starting from seawater, or polluted groundwater. The device is the size of a flat-screen TV and is equipped with rugged all-terrain wheels to assist transport: it can produce 15 litres of distilled drinking water per day, enough for one family to use for drinking and cooking.

The device uses a solar panel to produce electricity: a thin layer of the water to be treated flows over the photovoltaic surface, absorbing the heat also produced by the sun, and cooling the panels to improve their efficiency. The heated water passes into a boiler, powered by the electrical output from the panel: the steam is condensed to produce distilled water, giving up its latent heat to the incoming water flow. A small drain from the boiler discharges a concentrated dirty liquid stream.

The Desolenator device is claimed to have a life of 20 years, and requires little maintenance: it has recently won two Innovation Award prizes from the UK’s Institute of Engineering Technology.

Further harnessing solar power

Whilst the Desolenator shows one potential application of solar power, making electric power available from such a widely available source is a major objective in both the developed and under-developed world. This is particularly needed in areas without any other source of power at night, when it is dark, which is a slight problem. How can children do their homework, or study anything, without some light?

In the developed world there is a need to store the power generated by wind farms and solar farms, to make it available in periods of high demand, or when the wind or sun are not there. So there is a lot of research into storing large amounts of power. Hopefully some of this might spin-off and make smaller domestic or small village units available soon.

csm_Photoelektrochemie_219a069346At the Technical University of Vienna (TU Wien), current research is following the principles of photochemical cells, as used in nature, where plants absorb sunlight and store this energy chemically. The main problem was that quoted above, in relation to the Desolenator design, that at high temperatures, the efficiency of any current photovoltaic solar cell decreases. While the electrical energy produced by a solar cell can be used in an electrochemical cell to split water into hydrogen and oxygen, the energy efficiency of this process is limited, because of the high temperatures involved.

At TU Wien researchers have now developed new highly specialised materials, which form a photovoltaic that operates at a high temperature (400°C), so concentrated light beams can be used to produce a large energy output: currently achieving 920 mV. These cells use Perovskite metal oxide materials in the photovoltaic, which creates free charge carriers – electrons – that travel into the electrochemical cell. Here they ionise oxygen into negative ions, which can travel through a membrane, separating hydrogen and oxygen. Work continues to increase the power further and produce an industrial prototype, where a hydrogen cell would be used later to produce on-demand electrical power.

Other techniques

More conventional techniques, such as those having banks of rechargeable batteries, and even mechanical flywheel systems, are being installed in areas where short-term interruptions in supplies are common. But the spin-off from such university research will eventually lead to novel ideas to help the less-developed world as well.

Multiple approval barriers to free trade in environmental protection systems

As a product development manager, I used to think that the supply of industrial instrumentation equipment was made particularly difficult by the plethora of International, European, American and specific industry (and country) specifications and requirements. In an age of International co-operation it seemed these approvals were designed to act as protective barriers for home industries. But these seem trivial compared to the problems faced by suppliers to the World shipping industry, in particular in relation to environmental protection.

Readers of this column over the years will have been aware that I reported enthusiastically on the Alfa Laval PureBallast treatment system for purifying ballast water discharges from ships, launched back in 2007, at Greenwich. This enthusiasm was because of both the professionalism of the launch, as well as the laudable product objective and aspiration: it was one of the best such events I had attended, despite atrocious windy weather, freak waves and thunderstorms on the boat cruise taking the Editors down to Greenwich! With slightly bigger waves there might have been no Editors left to report on the event!

BWT – Ballast Water Treatment systems

In the Alfa Laval system, light energy, from a broad spectrum source, acts on a Titanium catalyst in the flow, to produce hydroxyl ions, which oxidise and kill any organic material in the ballast discharge. This was developed in co-operation with Wallenius Water, who had done the shipboard tests on some of their ships over the previous three years. Alfa Laval launched this product in January 2007, to make it available for ship-owners in time to meet the IMO regulations that would require such equipment to be installed on all new build ships after 2009, in participating countries.

Another Scandinavian company, Optimarin from Norway, was at the same time addressing the ballast water treatment market, using Ultra-Violet light from high power UV sources (35kW) to kill any potentially harmful invasive organisms straight away. Optimarin was established in 1994 to develop this system, and supplied the first ever BWT system installed in 2000 on the Princess Cruise Line ‘Regal Princess’.

Extended approval timescales

It is significant that it is now 2016, over 20 years since Optimarin was founded, and at least 12 years after the first Alfa Laval systems were installed for sea trials on Wallenius ships. It is also 7 years after the first of the IMO regulations came into force – these did allow several years grace for older ships still operating from prior to 2009. All this makes for a very long lead time for any new product development to grow and become commercial!

Yet only in December last year did the US Coast Guard finally confirm that it would not type approve BWT systems if they failed to totally kill potentially invasive marine organisms transported in ballast water. This will exclude many ‘conventional’ UV purification systems which use lower power lamps as sources, since these render the organisms “unviable” (ie they are still alive but cannot reproduce). The approval tests carried out by DNV to prove performance to the USCG criteria (applying the CMFDA staining test method) takes up to a year, and Optimarin suggests that the testing – due for completion this year – will cost them around US$3m.

Alfa Laval also expresses confidence that their PureBallast system will meet the current USCG test criteria, and their tests will also be completed this year: at the moment, Alfa Laval points out that although US ballast water regulations took effect in 2012, no systems of any technology have yet been type approved by the USCG.

IMO, the World shipping legislative body

Indeed the IMO regulations themselves are not universally applied as yet: the “International Convention for the Control and Management of Ship’s Ballast Water & Sediments” is legislated to enter into force one year after being ratified by 30 states, representing 35% of the world’s tonnage. At present, March 2016, 46 states have ratified, representing 34.8% of the world’s tonnage – almost at the action stage! So the product is on the point of what should be a worldwide legislated requirement…..one more country to ratify the IMO proposal, with one more tanker, and a year later the market will be confirmed. Its only taken nearly 20 years for these products to become a market requirement!

The USCG requirements will have no effect on shipping using previously approved UV BWT systems in the seas and oceans outside US territorial waters.

Individual ship approvals, Insurers, and Ex regulations

The problems for the suppliers are not yet finished: for shipboard use the equipment also requires certification by a whole further range of classification organisations, like DNV GL, Lloyd’s, Bureau Veritas, MLIT Japan, and American Bureau of Shipping. Some tanker operators also require hazardous area approvals, i.e. to Zone 1 ATEX standards in Europe: Optimarin have supplied 10 such systems for the Turkish tanker fleet of Atlantis Tankers, which are designed for the transport of IMO II classified chemical cargoes.

Suppliers and users

Optimarin publish their existing major customers as comprising Saga Shipholding, MOL, Grieg Shipping Group, Gulf Offshore, Farstad Shipping, NYK, Nor Line and Evergreen Marine Corp. Since that initial installation in 2000, Optimarin have sold over 350 units, with 270 already installed. Optimarin in March announced a fleet agreement with UK shipowner and management company Carisbrook, which has the potential to cover retrofits across their entire fleet of 46 bulk and multi-purpose vessels.

Alfa Laval do not publish a customer list nor figures for the total number of their systems installed, but a PR from September 2015 discussed an Asian based shipping line placing an order for 33 systems. Another user has been quoted as MSC Containers.

Ballast water treatment retrofit work has been a major activity for Goltens Green Technologies (www.Goltens.com), a marine engineering contractor, who have already installed over 100 systems, from a current order book of 163. They supply systems from many manufacturers, listed as Optimarin, Bio-UV, Headway, Severn Trent DeNora, Alfa Laval, Auramarine, NK, Hyde Marine and Wärtsilä. Like Alfa Laval, Goltens are also involved in the supply and installation of other shipborne equipment required by and subject to environmental legislation, like SOx and NOx effluent control.

Whilst the retrofit market is important, the new build market is more significant, and obviously supplier attention is concentrated on the shipbuilders of South Korea.

© Nick Denbow, Processingtalk.info


Further Yokogawa CCGT and Desalination business in Qatar

ras abu fontas

The QEWC Ras Abu Fontas plant

A press release this week from Yokogawa announces that the Yokogawa South Korean engineering operation has won another major contract from Samsung C&T for Centum VP control and ProSafe-RS safety systems for a 2.4GW Combined Cycle gas turbine power and desalination plant. The plant is to be built in Qatar, using local natural gas as the fuel, and will make up an important part of the future Qatari infra-structure: it will be located 20km south of Doha. It will be operated by Umm Al Houl Power, a joint venture consortium which includes Mitsubishi/Tokyo Electric Power and Qatar Petroleum, the Qatar Foundation, and the Qatar Electricity and Water Company (QEWC).

Another order from Acciona Agua covers the supply of an associated Yokogawa Centum VP control system for a reverse osmosis water desalination plant to be created as a part of the power plant. Separately, Yokogawa received an order placed by Hitachi Zosen Corporation for a Centum VP control system on a further multi-stage flash desalination plant. Combined, the two desalination plants will produce 590,000 cubic meters of water per day.

Yokogawa will be responsible for the engineering of these interlinked systems, which will be able to monitor and control the operations of all three plants: plus they will provide support for installation and commissioning.

Yokogawa Experience

Yokogawa in South Korea has developed extensive expertise in working alongside Korean and Japanese power plant contractors, and claims a solid global track record in executing large CCGT projects, based on over 100 systems for combined cycle power plants. This capability was demonstrated in Qatar on a previous desalination plant for QEWC, known as the Ras Abu Fontas A2 project, and previous CCGT projects alongside Samsung C&T have included a 2.1GW plant at Rabigh on Saudi Arabia’s Red Sea coast.

Yokogawa anticipates major growth in demand for CCGT plants worldwide, particularly where there is access to local supplies of natural gas. However, some recent projects have been more unconventional, with a recent installation in Ireland using a high speed controller to manage a fly-wheel energy storage system for smoothing the output power from wind farms! Another project in Cornwall, UK, will use Centum VP and ProSafe-RS to control the boilers and auxiliary systems on a waste to energy plant, their fourth such installation in the UK.

(c) Nick Denbow:  www.ProcessingTalk.info