Results Flowcontrol 2-2015 PDF

Metso customer magazine for the flow control business
ISSUE 2/2015
A long
h i s to r y
in exper t
ser vices
Efficient
plant shutdowns
Good planning is the key to success
Page 4
3D printing:
The ultimate
supply chain
24
40 years of
butterfly valve
performance
28
Increasing
pump wear life
at a copper mine
28
35
24
Our flow control service

network is very unique and
enables good service levels for
our customers globally.
TIMO HNNINEN
Vice President,
Flow Control Services
results flow control

Results flow control
customer magazine is
published two times
a year in English.
ORDERS
To receive your personal
copy, please contact your
nearest Metso office or
the e-mail provided.
results flow control 2/2015
PUBLISHED BY
Metso Flow Control Inc.
P.O. Box 304,
FIN-01301 Vantaa, Finland
tel. +358 20 483 150
flowcontrol@metso.com
metso.com/valves
EDITOR-IN-CHIEF
Kati Tattari,
kati.tattari@metso.com
DESIGN AND LAYOUT

Brandkind, brandkind.fi
Copyright 2015
Metso Flow Control Inc.
PRINTING
Hmeen kirjapaino Oy,
December 2015
All rights reserved.
ISSN
2343-0540
ADDRESSES
Metso customer data
Reproduction permitted
quoting Results flow
control as source.
All product names used
are trademarks of their
respective owners.
20
FOLLOW US
metso.com
flowexpertblog.com
twitter.com/metsoflow
linkedin.com/company/metso
facebook.com/MetsoWorld
youtube.com/MetsoWorld
Metso is the worlds leading industrial company

in the flow control business. Our knowledge, people
and solutions help drive sustainable improvements in
performance and profitability in our customers business.
EDITORIAL
Making the big difference
04
08

PLANT SHUTDOWN
3D PRINTING
The ultimate supply chain
R&D
12
16
READY FOR THE CHALLENGE

Valves to enhance fluidized-bed polymerization
SIL 4 AM I SAFE NOW?

Evaluating important aspects of safety valves
Metso experts at your service
20

40 YEARS OF SERVICE EXCELLENCE

World-class flow control service & the people behind it
Technological development
22
24
27

FROM IDEA TO ORDER IN SIX MONTHS

The cooperative design of the BWX valve from Metso
40 YEARS OF BUTTERFLY VALVES

The birth and development of Neles butterfly valves
CURRENT
Latest product & solution news
The world is our showroom
28
31
32
34
INCREASING PUMP WEAR LIFE IN A COPPER MINE

Adding a pumping stage at Kanmantoo copper mine in Australia
INCREASING RELIABILITY WITH EMERGENCY SHUT-OFF VALVES

Bringing the NIS Gazprom Neft refinery in Serbia to Euro Level 5
KEEPING THE HEART OF A COAL MINE PUMPING

Major pump delivery to KTK Kaskad 2 plant in Siberia, Russia
NEWS
Latest Metso News from around the World
PROVEN RELIABILITY, increased

process efficiency and safety are
counted as key targets by many of
our customers, which is why they are
targets that we simply must meet.
WE HAVE a unique set of assets for
serving our customers today and
in the future. We have more than
90 years of experience delivering
engineered performance and
reliability, and more than 40 years
of experience in providing flow
control services.
BY UTILIZING our strong global
operational network and combining
our industry-leading solutions and
services with our vast knowledge of
various industry requirements and
our competent valve and pump
professionals, we can make the big
difference to our customers. To our
valued customers, this means that
we can offer the best possible valve
and pump solutions that truly
support their performance.
We are at your service.
JOHN
QUINLIVAN
President,
Flow Control
MORE EXCLUSIVE CONTENT ONLINE:

CUSTOMER CASES FROM AROUND
THE WORLD: metso.com/showroom
METSO TECHNOLOGIES IN THE WORDS
OF OUR EXPERTS: flowexpertblog.com
COVER STORY
NESTE REFINERY, FINLAND
Plant
shutdown
TEXT: Marjaana Lehtinen
PHOTOS: Aleksi Koskinen

Turnaround, shutdown, outage or revision there are
many names for the complex event in which an entire process
unit in oil or gas production is taken off-stream for renewal.
In June of 2015, Nestes Porvoo refinery in Finland completed
the largest turnaround in its history. Metsos service solution for
the turnaround consisted of valve maintenance planning,
spare equipment, maintenance and spare parts, as well as
real-time project process follow-up.
WATCH VIDEO FOR MORE

about successful shutdown planning:
https://goo.gl/cjdFWU
IMAGE: A well-planned and efficiently executed

shutdown ensures a safe and reliable process
until the next planned shutdown.
It is the level of planning

that determines the success
of shutdown execution.
ANNE HASSINEN, MANAGER, SHUTDOWN
BUSINESS MANAGEMENT, METSO
ABOVE: In terms of valve maintenance

and services, the planning procedures for
each shutdown are carried out by dedicated
experts from Metso.
ON THE RIGHT: Careful planning ensures
the availability of all the correct materials
and people during a shutdown.
OPPOSITE PAGE: By analyzing equipment
condition, we can pinpoint the equipment that
needs proactive maintenance by Metsos
dedicated service experts.
ROFESSIONAL PLANNING,
efficient execution and on-time
startup ensure safety as well
as high valve availability
and reliability until the next
planned shutdown. A major shutdown
interval in the oil and gas industry usually
ranges from three to six years. Metso was
already involved in the previous shutdown
in 2010 at the refinery in Porvoo. The
maintenance carried out during the latest
shutdown, which ran from April to
mid-June of 2015, should ensure the
reliability of the valves for the next five
years. During any shutdown, it is essential
to minimize all delays in order to stay on
schedule as well as to ensure a smooth
transition to normal production and to
recover productivity as quickly as possible.
The successful turnaround project at
the Neste Porvoo refinery was the biggest
ever for Metsos valve services business in
6
Finland. All in all, about 270 Metso valves

were maintained during the shutdown,
providing the customer with significant
improvements to valve availability. The
targets set for such huge projects are
typically clear: to maintain and improve
availability, performance, safety and
environmental compliance. Achieving
them calls for a partner who not only
understands the plants needs and targets,
but also has expert services and proven
methodology.
EXPERIENCE AND CONTINUOUS
DEVELOPMENT | Valve maintenance
planning for the turnaround project was
preceded by close cooperation between
Neste and Metso. Metsos installed base
at the plant is quite large. So by using
their valve maintenance know-how, we
can be sure that the valves will operate
with maximum availability and reliability
until the next turnaround, says Jarkko

Niittymaa, Maintenance Manager, Neste.
The fact that Metso has vast valve
maintenance experience and in-depth
expertise in shutdowns around the world
provides customers with significant
benefits. This year alone, the company
has been involved in more than 100
shutdowns.
Timo Hnninen, Vice President, Flow
Control Services, Metso explains, To
help our customers achieve outstanding,
long-term process performance with high
reliability and safety, we continuously
develop our service knowledge, capability
and scope of offering. It is extremely
important that customers can rely on a
suppliers know-how during the tightly
scheduled shutdown project.
MINIMIZED RISKS AND IMPROVED
SAFETY | Shutdowns are very complex
It is extremely important that customers

can rely on a suppliers know-how during
the tightly scheduled shutdown project.
TIMO HNNINEN, VICE PRESIDENT, FLOW CONTROL SERVICES, METSO
and expensive projects. Anything can

happen, leading to unexpected situations
that interfere with schedules and postpone
production startup. An extra day can
result in losses of millions of euros or
dollars. Being well prepared ensures
that the planned downtime will not
be exceeded. It significantly improves
occupational safety, too.
Our major concern is the safety of
the customers and our own personnel.
Therefore, our people follow the
customers and Metsos safety rules
stringently, whether the work is taking
place on site or at Metsos or the
customers service facilities. Following
the rules and planning the work well
are key to a safe workplace, Hnninen
emphasizes.
A shutdown can be considered a
strategic project for the plant, a way to
manage the plants assets, remarks
Anne Hassinen, Manager, Shutdown

Business Management, Metso.
Having us as a partner for shutdown
planning ensures the availability of the
correct materials and resources when
needed. It minimizes risks and also ensures
the safety and reliability of the process
until the next planned shutdown.
ATTENTION TO EQUIPMENT AND
PROCESS CRITICALITY | To ensure
the plants safe operation until the next
planned shutdown, its important to
carefully identify the equipment in need of
upgrading, maintenance or replacement.
This not only defines the shutdown
scope and activities, but also determines
the shutdown schedule and the needed
resources and materials.
The scope is built based on
maintenance needs, maintenance plans
and equipment service intervals. By
analyzing the equipment condition, we

can select the equipment that needs
proactive maintenance. Equipment
should be maintained before it causes
any disruption to production or presents
any safety risks, Hassinen explains.
Equipment and process criticality is
evaluated together by our service experts
and the plant personnel. Through
installed base analysis, we make sure that
the actions are defined based on actual
product types.
Through careful planning together
with the plants personnel, we are
able to optimize the shutdown scope
and the necessary actions, and thus
make certain that the correct materials
and resources are available during
the shutdown, Hassinen continues.
Equipment maintenance is carried out
with manufacturers parts, maintenance
procedures and recommendations,

IMAGE: In addition to numerous similar
projects around the world, Metso took
part in the Porvoo refinerys largest-ever
turnaround in the summer of 2015.
so it is possible to guarantee safe

operation until the next planned
maintenance.
PLANNING DETERMINES EXECUTION
SUCCESS | A shutdown is a chain of
closely linked events. A well-planned
shutdown scope, actions, materials and
resources result in efficient shutdown
execution and a smooth startup. Hassinen
continues: The actions of our people,
on site and at the valve maintenance
facilities, ensure that the plant is receiving
high-quality valve maintenance and
repairs during the shutdown execution.
All maintenance activities are performed
by our valve service experts and certified
smart product service experts according to

Metsos safety and quality standards.
Despite careful scope optimization,
its very likely that something unexpected
will come up during the shutdown. For
example, it may well be that a piece
of equipment needs to be added on
the maintenance scope at the very last
moment. In such cases, it is crucial to be
able to count on a shutdown partner who
is capable of adapting and reacting quickly
to the changing needs.
It is the level of planning that
determines the success of shutdown
execution. Any unexpected event can
have an effect on materials, schedules and
resources, and thus jeopardize both the
project schedule and budget, Hassinen

says realistically. During the planning
phase, shutdown scope and actions are
defined, but we must also be prepared for
the unexpected during execution. Detailed
planning with the plants staff enables us
to be prepared and minimize unexpected
risks.
To ensure a safe and on-time startup as
well as a quick return to full production,
expert support is available. Metsos service
experts, backed by the companys whole
extensive global network, promptly detect
any problems and help to quickly resolve
possible issues.
EVALUATION IS IMPORTANT, TOO | Once
the plant is up and running, its time to
evaluate and learn from the project for the
next planned shutdown. Additionally, we
provide the plant with tag-specific service
reports and test certificates as well as
recommendations for future maintenance,
upgrades and replacements to improve
process reliability and safety, Hassinen
concludes.
MORE INFORMATION:
Anne Hassinen
Tel.: +358 20 483 5189
E-mail: anne.hassinen@metso.com
2015 FIGURES
Shutdowns & turnarounds with Metso participation

NORTH AMERICA
Biofuels
4
Chemicals
8
Natural gas
1
Petrochemical 6
Refining
34
Pulp
20
Paper
17
Power
5
Transportation 1
SOUTH AMERICA
Biofuels
2
Refining
8
Pulp
10
Power
3
AFRICA
Chemicals
1
Petrochemical 7
Refining
14
Pulp
5
EUROPE
Biofuels
5
Chemicals
7
Natural gas 24
Petrochemical 18
Refining
33
Pulp and Paper 43
Power
7
Transportation 3
MIDDLE EAST
Chemicals
Natural gas
Petrochemical
Refining
Power
Steel/Metal
4
3
2
1
4
2
INDIA
Chemicals
Petrochemical
Refinery
Steel
1
2
7
2
CHINA
Petrochemical 1
Refinery
1
Paper
1
ASIA PACIFIC
Biofuels
Chemicals
Natural gas
Petrochemical
Refining
Pulp
Paper
Power
1
3
2
5
3
1
3
1

FROM THE GUEST WRITERS DESK
The ultimate supply chain
3D printing,
3D printin
is predict g
become m ed to
ainst
over the n ream
ext
decade
additive manufacturing
A convergence of technical and social advances is bringing 3D printing to
mainstream large-scale manufacturing. The technology has revolutionized
manufacturing, but its effects are felt throughout the supply chain. This article
explores the potential of 3D printing and its impact on industrial companies.
TEXT: Juha Turunen, Industrial Internet Lead, Accenture Digital
PHOTOS: Tomi Parkkonen and Metso

Every company should have a clear understanding
of how 3D printing will impact their business as well
as a strategy on how it can be used to improve and
change the business.
JUHA TURUNEN, INDUSTRIAL INTERNET LEAD, ACCENTURE DIGITAL
3D
PRINTING IS the
process of making
a physical object
layer-by-layer
based on digital
instructions. The process is also called
additive manufacturing. The 3D printing
principles were invented 1984. Since then,
the use and application of the technology
have increased annually.
Products that can be 3D printed come
in all sizes and materials. For example,
the first 3D printed pill was approved for
commercial distribution in the US this
year. In China, a five-storey building was

assembled from 3D printed modules. The
smallest 3D printed object is the size of an
ants forehead. Some of the components
in F1 race cars are 3D printed, because
their shape and performance requirements
prevent them from being produced in
traditional ways. An industrial equipment
company is manufacturing the blades
of gas turbines with 3D printing. The
manufacturing costs of a space rocket
have dropped from USD 50 million to
5 million thanks to 3D printing. And this
is just the beginning.
FASTER AND MORE EFFICIENT

PROCESSES | Companies and institutions
are currently investigating how to improve
their operations and processes by using 3D
printing. For example, the US Navy is studying
the possibility to produce all their spare parts
at sea by 2025. EasyJet has revealed a 3D
printing plan for speeding up repairs. For
industrial company customers, 3D printing
enables efficient maintenance operations,
as spare parts and tools can be 3D printed
on demand and on site, which is especially
beneficial for sites that are remote or difficult
to access.
3D printing is the process

of making a physical
object layer-by-layer based
on digital instructions.
The process is also called
additive manufacturing.
3D printers help companies reduce the
time and cost associated with prototyping
parts and refining their design. For instance,
General Electrics Oil division has been able to
shorten the development time from prototype
to products from 12 months to 12 weeks.
Besides rapid prototyping, 3D printing is
also used for rapid manufacturing. It is a new
method of manufacturing where companies
use 3D printers for short-run custom
manufacturing. In rapid manufacturing,
the printed objects are not prototypes but
the actual end-user product. The method
10

is used for manufacturing faucets and
eyeware frames, among other products.
Over the next decade, 3D printing is
predicted to permeate the enterprise as a
mainstream digital capability. By taking
steps now to understand how to leverage
this technology, oil and gas companies
will be positioned to disrupt their existing
markets and penetrate new ones. By
integrating 3D printing into the fabric
of their operations, they will be able to
transform the efficiency of their upstream
supply chains and introduce new markets
and new sources of revenue to their
downstream businesses.
UNLOCKING THE BUSINESS POTENTIAL
OF 3D PRINTING | 3D printing enables
industrial equipment companies to
generate profit from their long-tail
products without big inventory costs and
long response times. 3D printing also
enables more customizable products.
Companies can create one-of-a-kind
products cost-efficiently, accommodating
specific size and configuration requests
as well as rounding out product lines by
custom-making hard-to-find variations of
a basic high-volume item.
3D printing and additive
manufacturing also raise some new
questions regarding the commercial use
of the technology. For example, how is
the quality of the 3D printed products
guaranteed? What products are most
suitable for additive manufacturing?
What is the warranty of the 3D printed
products? How can industrial companies
protect the IPRs? There are no ready
answers; each company needs to solve
these issues as they enter the business of
3D printing. The chosen approach to these
questions also opens up new collaboration
opportunities.
Every company should have a clear
understanding of how 3D printing will
impact their business as well as a strategy
on how it can be used to improve and
change the business. The industrial
equipment companies that make the first
successful moves in this area will have
a big head start, because they can help
their customers implement an end-to-end
digital supply chain, from prototyping to
manufacturing to maintenance without
warehousing and thus unlock the business
potential of 3D printing and IoT.
IN FOCUS
3D printing already
widely utilized at
Metso Flow Control
T METSO FLOW CONTROL we see 3D printing as a viable emerging

technology of the future. We are already exploring the possibilities
of utilizing this technology in future production. For example, 3D
printing might unlock new opportunities to supply rarely used spare parts
quickly to our customers wherever they are located. Today this technology
has already proven to be a valuable tool for the design and testing processes
at Metso.
We regularly utilize a fused deposition modeling (FDM) 3D printer in
the development of our valves and actuators. During product development
we 3D print prototypes in order to verify designs in e.g. eccentric butterfly
valves. Studying the mechanism with 3D CAD software is certainly done,
but it doesnt give you a realistic feel of the forces needed to open and shut
a valve, for example. When designing new positioners or limit switches, we
regularly use 3D printed prototypes to help visualize our designs and even
to collect early feedback from customers.
And when plastic product or component prototypes are not sufficient, we
use laser sintering for prototype parts. These metallic parts serve for testing
purposes. We have also used this method to produce actual components
needed in small batches. Our production also utilizes 3D prototypes when
designing assembly jigs and fixtures in preparation for mass production.
On the marketing side, 3D prints of valve components are often used for
demo and training purposes. Even complete models of pumps have been
known to get sent out to distributors and sales representatives as training
tools or show-stopping giveaways.
MORE INFORMATION:
Jukka Borgman
Tel.: +358 50 591 3128
E-mail: jukka.borgman@metso.com
11
R&D
TEXT: Sari Aronen
PHOTOS: Metso & Adobe Stock
Ready for
the challenge
Valves to enhance fluidizedbed polymerization
12
R&D
The global olefins market is expected to grow

by about 4% or more in the next several years.
The packaging and automobile industries are
examples of important users of polymers.
The major source of olefins, the building
blocks of polymers, namely ethylene, propylene,
butadiene and isobutene, is steam cracking.
OME VOLUMES OF OLEFINS are produced from catalytic

cracking. On-purpose technologies, such as propane
dehydrogenation, are also becoming more popular for
producing olefins, especially in locations short of olefin
supply from naphtha cracking. There are several licensors
offering technologies to produce polymers. Factors associated in selecting
an appropriate technology license include, but are not limited to, the
capability of the process to produce the desired polymer grades, diversity
of the process technology, ability to produce specialty grades, catalyst
options and cost.
There are three major types of low-pressure technologies, namely
slurry, solution, and gas phase. Each type of process has limitations
on the versatility of the resins it can produce. Gas-phase processes
are either a stirred-bed type or fluidized-bed type. Gas-phase reactors
have the widest operating window, but they encounter difficulties
in producing polymers with very low densities due to stickiness and
particle agglomeration. Gas-phase processes are very economical at
producing commodity-grade polymers, and thus are popular with
polymer producers. These polymers, for example, are linear-lowdensity-polyethylene (LLDPE), high-density-polyethylene (HDPE) and
polypropylene (PP). This article focuses on the fluidized-bed type of
gas-phase polymer process, and in particular on the challenges valves
face in providing solutions for polymer product discharge applications
to enhance process reliability and efficiency.
PROCESS OVERVIEW | In a gas-phase fluidized-bed reactor, gaseous
monomer, co-monomers and proprietary catalysts combine to produce
a dry, co-monomers resin. This resin along with hydrocarbon
vapor, unspent catalyst, and possibly polymer sheets
and chunks flows from the reactor to the product
discharge system (PDS) where unreacted gas is
separated from the product and returned to the
reactor. The PDS consists of one or more product
chambers, as well as an assortment of valves and
piping for product conveyance,
isolation, gas venting recycling
and piping connections.
Downstream from the PDS,
Metal-seated
the product is purged with
ball
valve with
nitrogen to remove
intelligent valve
controller
13
R&D
Metal-seated ball valves equipped with high-cycle piston actuators,
such as Metsos rugged trunnion-mounted ball valves, have been the choice
for many polymer producers for critical applications in the gas-phase
product discharge system, such as block valves and discharge line valves.
any remaining hydrocarbons. Finally, the granular polymer is

pelletized with application-appropriate additives.
There are a number of pipes, also called legs, attached to the
reactor to discharge the polymer from the reactor on a frequent
basis. The discharge is based on pressure and gravity. The reactor
pressure is around 30 bars. There is a continuous switching
between the reactor discharge piping. After the polymer flow to the
leg is switched to the other leg, the leg is cleaned by flushing it with
ethylene or propylene gas to ensure no polymer dust or chunks
remain trapped anywhere inside. The largest reactors are capable
of processing 400,000 to 600,000 tons of polymer annually.
CHALLENGES FOR VALVES | Valves should be able to withstand
a high-cycling rate, with a range from 200,000 to 1 million cycles
per year, depending on the type of reactor and discharge piping.
Meanwhile, in most applications, a fast cycle time of less than
2 to 3 seconds is required. Therefore, a high-cycle design and
construction of both the valve and the actuator are essential.
High-pressure differences over the valve, combined with pipe
vibration and blending forces, require that the valves are highly
rigid and have long-lasting tightness. Some medium may contain
hydrocarbon vapor, nitrogen, resin, unreacted polymer and
sometimes even sheets and chunks of polymer. The valve seat and
bearing must resist the growth of polymer in cavities and grooves
due to the continued polymerization of the media. Valve leakage
Valves play an extremely important

role in the successful product discharge
system performance of a gas-phase
polymerization reactor.
poses both an environmental and safety issue due to risk of fire,
toxicity and the volatility of gaseous hydrocarbons. Graphite
packing is usually not allowed due to the tight color specs of the
final polymer product; the polymer has to be very clean, bright
and clear. The modern catalysts that are used to improve the
end-product polymer quality, when combined with the produced
polymer, are harder and therefore more abrasive to piping and
valves.
The market requires clean and high-quality polymers. It is
important that the process is stable, flexible and under control.
14
Proper valve performance in the piping attached to the reactor,

product chambers and the whole polymer discharge system
improves the accuracy of throughput control and favorably
affects the plant performance. Valves play an extremely important
role in successful product discharge system performance.
Polymer resin producers are looking for longer plant runtimes, since downtime means production losses and represents
significant costs that include maintenance costs. This calls for
unquestionable equipment reliability.
WITHSTANDING THE HIGH-CYCLE POLYMERIZATION
DEMANDS | Metal-seated ball valves equipped with high-cycle
piston actuators, such as Metsos rugged trunnion-mounted ball
valves, have been the choice for many polymer producers for
critical applications in the gas-phase product discharge system,
such as block valves and discharge line valves. This choice has
been made due to the polymer-proof metal seat that prevents
polymer from penetrating behind the seat and seizing the valve,
and due to the anti-abrasive feature that makes it a perfect
choice for a hard polymer and more abrasive catalysts, which
are nowadays widely used to improve the end-product polymer
quality. The valve seating principle is very simple: the seat
has continuous contact with the ball, wiping the seat surfaces
with every cycle to prevent polymer build-up. This provides a
means for reliable, long-lasting tightness and cycle life in these
demanding applications.
The use of rotary valve technology provides a way to keep
the volatile hydrocarbon emissions low during the whole cycle
life. This is based on a certified, emission-proof stem sealing with
live-loaded packing that is designed to keep its tightness, even in
very high-cycle applications. This kind of high-cycle application
calls for an actuator that is tested and field-proven to withstand a
high number of cycles without failing.
An intelligent, integrated PDS valve controller, such as a Neles
R&D
SwitchGuard with unique embedded diagnostic features, enables

users to guarantee the availability of high-cycling PDS valves.
This type of controller gives the possibility to set the on-off valve
stroking times and profiles according to the process needs. This
means that the valve opening and closing times, as well as the
stroking ramp profile, can be defined independently. This feature
is especially useful in minimizing the pressure impacts on piping
(fluid hammering). Its high pneumatics capacity also gives the
possibility to reach fast stroking times without the need for any
additional accessories, such as volume boosters or quick exhaust
valves. An integrated controller reduces installation costs by
eliminating the need for external solenoid valves. In addition,
predictive maintenance can be practiced with the help of the
diagnostics provided to secure continuous PDS valve operation.
Published with permission of Hydrocarbon Engineering magazine.
Cooling
water
valves
Compressor
Purge
gas valve
Cooler
Reactor
Block
valve
Inlet
valve
Purge
gas
Product
chamber
Resin
outlet
FIGURE
Cooling
water
Catalyst
feed
Catalyst feed
valve
Product
discharge
system
(PDS)
Hydrogen
Comonomer
Outlet
valve
Main discharge line valves
MORE INFORMATION:
Sari Aronen
Tel.: +358 50 317 1518
E-mail: sari.aronen@metso.com
Gas to
flare
Catalyst
chamber
CONCLUSIONS | Global markets are calling for more polymers.

Gas-phase polymerization processes are very economical at
producing commodity-grade polymers, and therefore, are popular
with polymer producers. The market demands clean and high
quality polymers. It is important that the process is stable, flexible
and under control. Valves play an extremely important role in the
successful product discharge system performance of a gas-phase
polymerization reactor. High-cycle design and construction of
both the valve and the actuator are essential. An intelligent,
integrated PDS valve controller, with unique embedded diagnostic
features, enables users to guarantee the availability of highcycling PDS valves.
Emergency
safety vent
(ESV)
Monomer
This diagram is intended

to be a representation
and should not be
viewed as an actual
process flow diagram.
Feed control valves
Gas-phase polymerization PDS with valves
15
R&D
IMAGE: Neles ESD valve in a real operating environment,

colored according to customer specifications.
16
R&D
ESD valves should not be so-called install and forget

devices. The only way to maintain the safety integrity
is to have a test plan and to follow that plan.
VILLE KHKNEN, OIL & GAS BUSINESS MANAGER, METSO FLOW CONTROL INC
SIL 4
am I safe now?
Valve
selection
There are different aspects to think about

and evaluate in the case of a safety valve.
TEXT: Ville Khknen
PHOTOS: Erik Grnlund, Shutterstock & Metso
ESD VALVE | An emergency shutdown

(ESD) valve is part of a safety
instrumented system (SIS). It is a vital
part of the safety system and often
described as the final element. Normally,
the term ESD valve refers to all types of
safety system valves, such as shutdown,
emergency shutdown, emergency
ventilation or blowdown valves. There is
much confusion in the functional safety
area when it comes to what should be
considered with regards to safety valves
to make a plant safe. There are different
aspects to think about and evaluate in the
case of a safety valve. Excellent probability

of failure on demand (PFD) and safety
integrity level (SIL) are just two examples.
There is much more than the SIL
certification that is needed. For ESD
valves, there are three main steps.
VALVE SELECTION | The most important
step in the selection of an ESD valve is to
use the application-based valve selection
process. This step has not been observed
often enough in recent years, while
the functional safety calculations have
attracted excessive attention.
Functional
safety
Testing and
maintenance
FIGURE 1
ESD valve selection
17
R&D
FIGURE 3
Nelprof SIL tool
ESD valves have the same application

challenges as normal on-off valves.
Correct valve selection includes valve type,
pressure class, temperature, materials
and other details. If the selection does
not fit the application in question, valve
failure will be systematic, and we cannot
take advantage of the functional safety
calculations of the SIL and PFD value.
Systematic error in valve selection will
make the valve fail every time in the same
way, and random error rate will no longer
be the main source of failure.
A very good example of systematic
error is incorrect seat selection. We can
use the example of polymer service to
demonstrate systematic error. There are
a number of different types of valves and
seats in the market, but only some of them
can be used in polymer service. After we
know the correct pressure class, materials
and temperature range, we must consider
other details to make the valve work in
a real process. A rough categorization
could include seat types that have contact
between the sealing elements all along the
stroke and seat types that lose the contact
while operating like plug and rising stem
valves. The problem with seat types that
lose contact is the polymer accumulation
between the surfaces. The valve does not
fully work or starts to jam after that.
18
This problem can be solved by selecting

a rotary ball-type valve with a scraping
seat that wipes the sealing surface clean
while stroking the valve. This solves
one problem, but after selecting the
ball-type valve, there are still multiple
Polymer-proof seat
Valve body
No cavities in seat area
Cavity in seat area
FIGURE 2
Valve body
Ball
Ball
Closed- and open-seat design
different seats. The so-called open-seat

design (Figure 2) will get jammed when
the polymer enters the seat cavity. This
problem can be solved by using a closedseat design in which the functional feature
of the seat is protected. This type of seat is
an excellent choice for processes that have
impurities. For the ESD valve, it would be
a disaster if the valve seat is jammed when
the valve needs to operate.
FUNCTIONAL SAFETY TAKE FULL
ADVANTAGE | The previous example
highlights the importance of applicationbased valve selection. Even for an
incorrect seat type, it would be possible
to calculate a high SIL and a good PFD
value. If we look at the PFD value alone, it
cannot guarantee plant safety.
Following the international standard
IEC 61508 and 61511, we typically
have a safety integrity level to match
based on the hazard and operability
analysis (Hazop) and safety integrity
level assessment. The final elements
are a critical part of the safety loop. If
devices, such as valves, are not working
properly, the safety instrumented function
is not available. In recent years, there
have been a number of announcements
of manufacturers publishing SIL
certification and advertising SIL 3 valves.
R&D
The certification proves that the valve is
capable of working in an SIL 3 loop, but
it does not guarantee that the function
is SIL 3. The final element is part of the
safety loop, and, therefore, component
certificates are not enough to assure the
safety integrity level of the loop. The
complete final element as an assembly
must be calculated, taking into account all
components that are needed for the safety
function.
In the final element assembly, typical
components are the valve body, actuator
and intelligent safety solenoid. All these
components have their own component
SIL certification and PFD value, which
can be calculated according to the testing
intervals.
From the example, it is easy to notice
the effect of the testing intervals. Even if
the SIL 2 capability is achieved in both
examples, the PFD value will change.
Only by calculating the complete system is
it possible to know the final safety system
capability.
TESTING & MAINTENANCE | Service and
testing make up a large part of the ESD
valves life cycle. ESD valves should not be
so-called install and forget devices. The
only way to maintain the safety integrity
is to have a test plan and to follow that
plan. In the example above, the testing
interval for full stroke testing was 48 or
36 months; for partial stroke testing, it
was 3 months. If the testing according
to plan is not done, the safety integrity
level is not maintained. Using the Nelprof
SIL tool, it is also easy to see what the
testing intervals should be as well as what
the effect will be on the PFD value if the
testing is not possible at that interval. A
partial stroke test (PST) interval of one
to three months is typically done with
an intelligent safety solenoid, such as
Neles ValvGuard, to automate the testing
routine and documentation.
ESD valve testing is typically
categorized into two different types. A
partial stroke test (PST) can be done
FIGURE 4
Testing interval
PST testing provides extended plant uptime and enables efficient production in the plant.
SIL2
SIL3
1 2 3 4 5 6
time/year
Without online testing safety
integrity testing must be
performed more often
while the plant is operating, and a proof

test happens during shutdowns. The
difference between the testing types is that
the full stroke of a valve in a proof test
will impact the operation of the plant,
and the partial stroke test can be done
without causing any harm to the process.
During the PST, the valve is moved just a
few percent of the full stroke to analyze
its condition. In proof tests, the full stroke
test will complete a 100% stroke. The
advantage of carrying out the PST is that
the full stroke test then does not have to
be done so often and will help to match
the turnaround period of the plant.
From the graph above, it is easy to
see the advantage of the PST. The gray
colored line reached the SIL 2 level much
faster than the green colored line with
PST. We can also see that it is not possible
to completely avoid the proof testing by
doing the PST, but the interval for the full
stroke testing can be longer.
With Neles ValvGuard and

PST testing plant uptime
is extended
SUMMARY | ESD valve selection involves

more than just calculating the PFD and
safety integrity level. The basic work of
the application-based valve selection is
still a very important part of the ESD
valve selection process. After the valve
is capable of working in the application,
we can take full advantage of functional
safety calculations. After these steps are
completed to ensure the plant safety
during the full life cycle, the testing and
maintenance of the valves are important to
make sure the ESD valve will work when
it needs to work.
MORE INFORMATION:
Ville Khknen
Tel.: +358 50 354 4735
E-mail: ville.kahkonen@metso.com
Published with permission of
Hydrocarbon Engineering magazine.
Read more about this and many other interesting

topics in our expert blog: flowexpertblog.com
19
40 years of
service excellence
METSO VALVE SERVICE CENTERS
World-class
flow control
services
ETSO has been

developing its expert
valve services knowhow and solutions for
40 years. Ever since the opening of
the first valve service center in 1975,
Metso has invested in the strong
knowledge of its valve service experts,
which has resulted in continuous
development of its services solutions.
The first
service centers
outside of Finland
were in the UK,
France
and Italy
Our flow control service

network is very unique and
enables good service levels for
our customers globally.
Starting from its maintenance and spare parts business,
the company has expanded its services portfolio to include
more tailored solutions that meet customers ever-increasing
process challenges. Today, our extensive flow control services
also consist of business solutions and services for ensuring the
availability of plants and minimizing risks.
Our customers needs have changed considerably during the
past few decades. Nowadays, we often plan maintenance and
service activities together with our customers and tailor our offering
and solutions to ensure the best possible results for them, says
Timo Hnninen, Vice President, Flow Control Services, Metso.
MORE INFORMATION:
Timo Hnninen
Tel.: +358 40 585 3042
E-mail: timo.hanninen@metso.com
20
Flow Control
Service Center
Full Metso
service support
Service support

GIORGIO DE GUIO, ITALY
With 40 years of experience and expertise,

Metsos flow control services are available through
more than 40 service centers worldwide. There are
more than 400 dedicated service professionals with
in-depth valve application expertise at your service.
Let us introduce you to a few of them.
The first
valve service
center was
established
in Finland in
1975
I WAS WARMLY WELCOMED

into the Neles family as a young
and inexperienced guy back in
1988. Since then I have been
involved with valves in numerous
different roles. I have grown up
alongside the company, and today I drive the
service business here in Italy with my small but
efficient team. My task is to give my guys the
same opportunities for personal and professional
growth that I was given all those years ago.
CHYE-HUAT NEO, SINGAPORE
FOR 21 YEARS NOW I have

dedicated myself to serving
people through my work at
Metso Singapore. I began my
career as a Field Service Engineer
at Neles-Jamesbury. In the past,
I have been involved with operational services,
technical support and training, and smart
product sales. Today I handle Field services &
spare parts sales in the South East Asia Region.
I believe that a work environment based on trust
is the key to success. I look forward to continuing
to mentor young technicians and engineers on
their professional journey.
JOUNI HYYTIINEN, FINLAND
Our presence today

Service
400+ professionals
20+
Countries
40+
Service centers
I JOINED THE COMPANY

in 1974 as a summer worker.
I started in my first permanent
position as a service technician
the following year. Since then
I have worked in several different
positions in service and spare parts. Today
I am a member of the service development
and support team, offering my support to
new service centers that are being established
around the world, as well as to existing ones.
I am also actively involved in many other servicerelated responsibilities. What makes my job
interesting is that I can truly say that when I
come to the office in the morning I never know
where Ill find myself by the end of the day.
21
The BWX valve

was created in
collaboration with
Linde Group
BWX VALVE FROM METSO
From idea
to order in
six months
TEXT: Martin Dreen
22
PHOTOS: Linde Group and Metso
Successful collaboration with the German

Linde Group on the joint development of
a new cryogenic metal-seated butterfly valve
enabled Metso to win a greenfield project for
an air separation unit (ASU) that will be used
in a challenging industrial gases application.
The main factors that made this project
especially valuable for both parties are
the remarkably short development time,
100% compliance with the customers
requirements and strong partnership.
HE ABILITY TO QUICKLY ADAPT TO

CHANGES has enabled The Linde Group, the
worlds largest industrial and medical gases
company headquartered in Munich, Germany,
to remain steadily profitable, even during the
harsh years of the global financial crisis. Still, the requirements
of the industrial gases market in terms of product safety,
quality and compliance with all its certification criteria are
getting even tougher. This calls for constant development
from Linde as well as from its main suppliers.
When the need for a new valve solution arose, the
company began to look for a partner who would be able to
help Linde step up to the more stringent requirements and
succeed in its changing environment. Linde and Metso have
a long-term history of cooperation and in 2008 Metso aquired
MAPAG Valves GmbH from The Linde Group.
Past experience has proven Metsos commitment to
serve the company with high integrity and a focus on
uncompromised quality, even in the most challenging cases.
Therefore, Linde selected Metso for the development of an
innovative cryogenic valve that was required for a new ASU in
a very short time period.
100% REQUIREMENTS COMPLIANT | After completion
of intensive research and development, which was jointly
conducted by Metsos development team in Horgau, Germany,
and Lindes engineers, the new BWX valve was approved by
the customer in December 2014. The close collaboration of
the companies during the design phase ensured that the end
product is 100% compliant with all of Lindes requirements.
Immediately upon approval, the first order for the cuttingedge BWX valve was placed in March 2015, only six months
after the initial idea was born.
The cryogenic BWX valve will be installed at Lindes air
separation unit in Eisenhttenstadt, Germany, on the Polish
border. Once on stream, the units main purpose will be to
serve oxygen and nitrogen to the local ArcelorMittal steel
manufacturing facility. The valves will play a crucial role in
securing the plants reliable and efficient operations over the
long run.
BWX is the latest valve development from Metso. Its
metal-seated butterfly design provides high Cv values. The
valve is based on a platform design, but can also be customized
according to specifications. Thanks to its fully dry assembly and
oil-free production option, the valve is ideal for oxygen service,
where high cleaniness and an extreme level of tightness are
required.
BEING A PARTNER, NOT JUST A SUPPLIER | This first

BWX cryogenic valve order marks a milestone with one of our
key customers. Using our long field-proven experience in the
market and decades of process knowledge, we combined the
best design features of our existing product series to create
this state-of-the-art BWX valve, says Martin Dreen, Business
Manager, Oil & Gas Business Line, Metso. There was a clear
gap in the industrial gases sector when it comes to products
with extremely high tightness that fit the challenging
cryogenic and oxygen services. BWX is now capable to
successfully fill it.
BWX not only meets Lindes requirements, it also offers
value for customers in the industrial gases sector as well as
pump and turbine businesses by helping them fulfill stricter
compliance regulations in the future.
Ingo Leufgen, Sales & Service Director at Metso in
Germany and Switzerland, comments on the project:
Time-to-market was a considerable issue for Linde. Thanks to
the fast reaction ability and high level of professionalism of the
Metso team, we were able to deliver within the short project
turnaround time.
We are also proud of the value we can now provide
for Linde that comes with increased safety and improved
process performance. Metso has once again been able to
justify that we are not just a supplier, but a long-term partner
for Linde for the future, securing technical and commercial
competitiveness.
For Linde, the sustainable value from having BWX valves at
its air separation facility is the assurance of the plants efficient
operations and compliance with the latest safety and quality
standards.
MORE INFORMATION:
Martin Dreen
Tel.: +49 8294 8695 5406
E-mail: martin.dressen@metso.com
IN FOCUS
THE LINDE GROUP, the worlds largest gases company, supplies

industrial, medical, process and specialty gases, as well as plants,
hardware and application solutions to virtually every branch of
industry. In 2014, The Linde Group generated revenue of around
EUR 17 bn with approximately 65,500 employees working in
more than 100 countries worldwide.
23
The evolution from an idea to a successful product family that can stand
the test of time requires both dedication and persistence. It all starts with
a challenge and innovative thinking. The most important ingredient, however,
is determined people who are willing to invest time and systematic hard work
into overcoming all obstacles along the long road to sustainable success.
There are no shortcuts. Just hard work.
TEXT: Mikko Vuolanto
PHOTOS: Metso
years of
butterfly valve
performance
T
HE EVOLUTION OF THE
NELDISC PRODUCT FAMILY
is no different. The story of
the 40-year-old Neles butterfly
valve series began back in 1973 when the
co-founder of Neles Oy, Antti Nelimarkka,
asked his team to finalize a sketch he had
drawn in his legendary notebook. The
challenge had been to develop a butterfly
valve that could withstand temperatures
up to 600 C (1100 F) and still maintain
excellent tightness characteristics with

long-lasting tightness and durability. As
it was something that had never been
successfully done before, it was the perfect
challenge for an innovative company such
as Neles.
THE FIRST OF ITS KIND | From the
very beginning, it was clear that only a
metal seated valve could work in such
conditions. However, no such designs had
ever been drawn out before. After 2 years

of development, the Neles R&D team
came out with something that is known
today as the Neldisc valve. The U-shaped
metal seat and elliptic disc formed a
unique triple offset valve design, which we
are used to seeing in many butterfly valve
products today. At the time, this was a
first.
The first deliveries at the end of 1975
exceeded all expectations and the valves
were discovered to be bubble-tight even
in high temperature conditions. The
product contained many construction and
manufacturing technology innovations.
By the end of the development project
IPR protection had been gained for
the revolutionary elliptical disc design
combined with the metallic seat ring in 13
different countries.
NEW APPLICATIONS DISCOVERED
THROUGHOUT THE YEARS | Originally
the target industries included the refining,
chemical, petrochemical and other process
industries. Later on, in order to expand to
liquefied natural gas applications,
24
25
Neldisc
milestones
1973
Drawings of first butterfly valve to
perform in temperatures up to 600C
1975
First-ever Neldisc deliveries made
1982
Low-temperature cryogenic butterfly
valve for liquefied natural gas
applications was created
1985
S-Disc noise abatement technology
developed and patented
1990s
Continuous development of Neldisc
products for numerous new applications
2004
The worlds largest Neldisc unit, 80
L6 series butterfly valve delivered
2016
Scheduled launch of the newest
Neldisc high-performance butterfly valve
The first deliveries at

the end of 1975 exceeded
all expectations even
in high temperature
conditions.
26
a low-temperature cryogenic, high

performance butterfly valve was developed
in 1982.
Many other prominent possibilities
for this highly versatile product were
discovered over time. In the early 80s we
realized that butterfly valves are excellent
for control applications, as there is no seat
friction in the control range at all and the
rangeability of the valve is surprisingly
high.
To overcome the last true challenge in
control applications, the high dynamic
torque in big opening angles, S-Disc noise
abatement technology was developed
and patented in the mid 80s. The same
technology, which is still a top-notch
feature today, also enables the elimination
of cavitation and reduces the overall noise
of the valve. Further doors were opened
by the realization that the butterfly valve
could be closed much faster than other
corresponding quarter-turn valves, such as
ball valves, offering excellent performance
in ESD and other on-off applications.
TODAYS FULL PRODUCT PORTFOLIO |
Since the early days, the development has
continued. Today, the Neldisc product
family has many members. The product is
now available in all major end designs
(L6 double flanged, L1 and LW as wafer,
L2 and LG as lug) in the most usual
pressure ranges with many options for
demanding applications requiring highcycling resistance, steam jacketing, erosion
resistance and so on. Even some weld-end
designs have been done over the years.
In the past 40 years, we have supplied
more than 700,000 Neldisc valves all over
the world, comments Mikko Vuolanto,
Product Manager, Neldisc butterfly valves.
He continues, It is amazing how flexible
the basic design has been in adapting to
customer needs over the decades. For
example, the Neldisc family conforms to
even the newest, global fugitive emission
standards, such as ISO 15848, and is
fire-safe certified to the latest API 607
6th ed. while offering top-of-the-industry
efficiency and performance especially in
process industries.
There have been numerous memorable
Neldisc valve deliveries over the 40 years.
One of the most memorable was in 2004
when Metso delivered the biggest Neldisc
unit manufactured so far, the 80 L6
series Neldisc butterfly valve to a gas plant

in the Middle East. In 2013 a heavy 80
double flanged L6 valve was delivered,
together with over 280 other butterfly
valves, to the Sadara project in Saudi
Arabia where this heavy 80 valve is used
as a shut-off valve for the cracked gas in a
polyethylene plant.
DEVELOPMENT BASED ON CUSTOMER
NEEDS | Many success cases have actually
been manufactured based on customer
need and feedback. Thanks to the flexible
basic design concept, the functionality of
the valve has been easily extended to new
applications. This approach, for example,
has given birth to the erosion-resistant
butterfly valve design, built specifically
for a customer process requiring strong
butterfly valve properties (maintenancefree) combined with extreme erosion
resistance with metal seating providing
performance where a standard butterfly
valve cannot reach.
Today, Metsos butterfly valve offering
is the most comprehensive in the entire
valve industry. In addition to Neles
Neldisc and Neles B-platform engineered
butterfly valves, Jamesbury soft-seated
Wafer-Sphere butterfly valves together
create a complete offering all the way to
pressure class ASME #2500, including
the corresponding EN and JIS pressure
ratings a unique product portfolio in the
business.
SOLUTIONS FOR THE NEXT
40 YEARS | The development of
Neldisc butterfly valves is still in full
swing. The next-generation Neldisc
design is already in the works, aiming to
set the industry benchmark in the field
of high performance butterfly valves
still during 2016. With this facelift, we
at Metso are not only honoring the 40th
anniversary of the first-ever metal seated,
triple offset butterfly valve design, we are
also building continuity to the great story
of Antti Nelimarkkas famous Neldisc
butterfly valve family and, perhaps most
importantly, ensuring our success for at
least the next 40 years.
MORE INFORMATION:
Taija Hmlinen
Tel.: +358 50 317 4286
E-mail: taija.hamalainen@metso.com
VALVE CONTROLLERS
NELES NDX
Performance perfected
METSO WILL BE EXPANDING its existing portfolio during 2016 with the new NDX valve
controller. It is all about exceptionally simple, reliable and safe functionality. It is a positioner
designed from a linear valve perspective, but it also gives excellent support to rotary valves.
Its extremely fast and easy installation creates a huge time savings, especially in the case of
commissioning a globe valve.
Customers can cut installation costs in half with the simple mounting, magnetic position
sensor, intuitive local user interface and quick calibration. The NDX is capable of
controlling all valves, from the smallest to the largest sizes, minimizing the investment
tied up in inventory. The NDX further strengthens Metsos position as a leading
supplier of control valve positioners.
See the Neles NDX video online: https://goo.gl/GATZcg
EASY TO INSTALL,
OPERATE AND
MAINTAIN
MORE INFORMATION:
Marko Rissanen
Tel.: +358 40 569 8489
E-mail: marko.rissanen@metso.com
ACTUATORS
VD SERIES
Compact and efficient

THE PRODUCTION of the newly upgraded field-reversible version of the Neles VD
spring diaphragm actuator is in full swing. Its unique field reversibility allows for
the actuator spring to be changed easily in the field without the need for any additional
parts. It also features the optional side handwheel (as seen in the picture). The handwheel
is mounted on the opposite side of the yoke and positioner and can be fitted without
any other changes to the actuator. The new features make the VD series actuator
a compact and efficient overall package.
MORE INFORMATION:
JongYim (Daisy) Kim
Tel.: +82 43 852 7708
E-mail: jongyim.kim@metso.com
27
The world is our Showroom
KANMANTOO COPPER MINE, AUSTRALIA
Increasing
pump wear life
at a copper mine
TEXT & PHOTOS: Chris Wyper
28
Recognizing that a system design problem was

causing the pumps at Hillgroves Kanmantoo copper
mine to wear out much faster than expected,
Metso recommended adding an additional pumping
stage. This resulted in significant savings in
wear life, improved the mean time between failures
and reduced operating costs.
HE KANMANTOO COPPER MINE in South

Australia was constructed in 2011, combining
new equipment with refurbished equipment
from the Pillara Mine located in Western
Australia, which closed in 2008.
Kanmantoos tailings storage facility (TSF) is at a higher
elevation than the Pillara plant, so a new design was
required to include additional tailings disposal pumps. Once
commissioned, severe wear issues were discovered, which
caused regular downtime for the whole operation. During the
first year of operation, the cost of maintenance exceeded one
million dollars. The hardness of the garnet was believed to
be the major source of abrasive wear together with the high
head per stage.
When the wear life of the pumps is just 120200 hours,
its nothing. Thats a total of only ten days. So, every ten
days, we had to dismantle and then rebuild the pumps,
spending a lot of money each time, remarked
Greg Craddock of Hillgrove Resources.
In the first year alone, the cost of running such highwearing pumps was costing a fortune. Performing the
maintenance was also a very time-consuming task. Up
to 10% of our maintenance effort was spent on this one
problem, requiring a days work from three to four people,
he continued.
Several unsuccessful approaches to improve the wear life
were tried at the Kanmantoo operation. Researching the
market for available solutions to their problems, Hillgrove
Resources reached out to Metso. After conducting a series
of trials, the team determined that the fault was not with the
pumps, but the system itself.
MOVING FROM TWO STAGES TO THREE | It is common

practice to share the load across several pumps, or stages,
when pumping at high heads. The total head is divided
among the number of stages. In the initial design at
Kanmantoo, there were only two stages. After encountering
the numerous operational issues, it was agreed to trial a third
pumping stage.
TAKING CHARGE OF THE STOCK | Besides the technical
solution, the Metso team took care of the mines consignment
stock so that Kanmantoo could have stock of wear parts in
its inventory permanently.
IN FOCUS
The Kanmantoo copper mine

THE KANMANTOO MINE is a copper mine in
South Australia, near the town of Kanmantoo,
55 km southeast of Adelaide. The mine is owned and
operated by the Australian-based mining company,
Hillgrove Resources Limited.
The current defined mineral resource of 31.3 Mt
allows a throughput of over 3.0 Mt per annum,
containing about 20,000 tons of copper metal and
associated gold and silver, over a proposed 10-year
mine life. Associated with this deposit is garnet,
an auxiliary mineral, which is a very hard and abrasive
crystal. This is not mined as a product, but instead
reports to the tailings, or waste stream.
IMAGE: The Kanmantoo mine contacts Metso experts whenever any

crushers, screens or other mineral processing equipment require support.
29
This is a great example of Metsos

collaboration with the customer to solve
a problem. There was also superb cooperation
between everyone involved at Metso.
CHRIS WYPER, DIRECTOR OF SALES, MINING FLOW CONTROL FOR METSO
This demonstrated Metsos commitment to the customer in

providing long-lasting support. The mine is now also reaching out
for a Metso solution when any crushers, screens or other mineral
processing equipment requires support.
Today, because the Kanmantoo mine is lifting the tailings dam,
the number of pump stages has increased from three to four,
and a fifth stage is to be commissioned in early 2016. For Greg
Craddock, the choice was obvious, We really like using the Metso
pumps. The fitters think the hydraulic slidebase is fantastic, and the
Metso team has given us the support we need.
SIGNIFICANT COST SAVINGS IN MANY WAYS | This retrofitting
project has provided numerous benefits for Hillgrove Resources,
the most significant of which is the lifetime cost saving achieved.
Since multiple pump stages were commissioned, this allowed
the mine to reduce the head per stage as well as provided a wider
material choice for the pumps. More efficient rubber-lined pumps
were installed, bringing the lifetime of the previously failing
equipment up to an acceptable level while also reducing energy
consumption.
Once we commissioned the first couple of sets of wear parts
and they hit the mark of over 1,000 hours of operation, we
knew we were moving in the right direction. This gave us a lot of
credibility, and the relationships between the teams became even
more cooperative, says Chris Wyper, Director of Sales, Mining
Flow Control for Metso, who expresses how happy Hillgrove has
been with the solution.
Wear life has improved dramatically. Currently, the life of
30
a pump is reaching around 1,700 hours and there are plans to

increase it further still. Going from metal to rubber pumps and
operating closer to the best efficiency point has raised the pump
efficiency from 59% to 69%. The savings in energy reduction is
approximately $ 50,000 per annum thanks to a high-efficiency
hydraulic design. The savings in of parts alone amounts to
hundreds of thousands of dollars, along with the reduced
operational costs and the improved mean time between failures.
Due to the hydraulic slide base concept implemented by Metso
at the fourth stage, the Kanmantoo mine is able to benefit from
reduced maintenance time. Operations are now safer thanks to
the fact that less energy is being stored, and there is less risk of
trapped liners due to better alignment.
This is a great example of Metsos collaboration with the
customer to solve a problem, adds Chris Wyper. We both knew
that it was going to be a long road, with many hours spent testing
materials and keeping track of the results. But it was only by
going through this process as partners that Metso and Hillgrove
were able to best optimize the pumping system. There was also
superb cooperation between everyone involved at Metso. Id
especially like to give thanks to Michael Lally for his excellent
account management skills and tireless devotion to his
customer.
MORE INFORMATION:
Chris Wyper
Tel.: +61 8 9420 5579
E-mail: chris.wyper@metso.com

NIS GAZPROM NEFT REFINERY, SERBIA
Increased refinery reliability with

emergency shut-off valves
The NIS Gazprom Neft refinery in Panevo, Serbia, made a large
investment into its new mild hydrocracking and motor fuel
hydrotreatment facility. The aim was to upgrade production
quality to Euro Level 5. To do so, all European standards for
safety and emissions needed to be met.
EETING ALL THE

STRICTEST STANDARDS
meant that safety and
compliance with regulations
would be the key criteria
when selecting all systems and applications,
including the critical valves selected for the
burner management systems on the heaters
as well as the truck and jetty loading system.
Unplanned shutdowns cause excessively
high costs. For this reason, on-off and safety
valves are needed to ensure maximum
reliability. Moreover, a valves failure to
close in an emergency situation can have
a major impact on peoples health and the
environment.
As the valves handle explosive and toxic
hydrocarbons, they must retain their initial gas
shut-off tightness and be able to demonstrate
a low fugitive emission level that complies
with European standards over their entire
operational life cycle. To prevent potentially
dangerous valve stem leakages, there are
regular shutdowns for valve inspection
scheduled every four years.
long-term bubble tightness and prevent

overpressure during sudden temperature
rises. This is extremely important when
dealing with highly flammable media, such
as those used in the burner management
systems on the refinerys heaters.
Another requirement the NIS refinery had
for the valves was their official compliance
with the most stringent safety regulations.
All Jamesbury valves are fire-safe according
to API 607 and approved according to IEC
61508 SIL 3. Further safety protection is
provided through Neles ValvGuard, the
intelligent safety solenoid with a partial
stroke testing feature.
Moreover, on both the Jamesbury ball
valves and the high-performance WaferSphere butterfly valves, which were also
included in the delivery package, the shaft
sealing is designed to fulfill ISO 15848-1
BH and TA-Luft/VDI 2440. This means that
their fugitive emissions level is also in full
compliance with regulations.
TEXT: Andreas Pischke
SECURING HIGH-QUALITY
PRODUCTION | The total valve package
delivered to the NIS refinery included
several different valves types, actuators and
instrumentation with relevant approvals
and certificates for emergency shut-off and
venting applications. Now, the new valves
with long-term, tight shut-off help keep
the plant and truck-loading area emissions
levels compliant with the relevant European
standards, allowing uninterrupted operations.
This complete solution has enabled NIS
Gazprom Neft to reliably, safely and efficiently
achieve the desired run-time targets for its
hydrocracking process, securing continual
high-quality production of gasoline and
diesel fuels without any risk to personnel
or the environment. After all, every detail
is important in potentially hazardous
applications. The implemented modernization
program at the refinery ensured that
everything in the constructed facility is
now designed to meet its targeted Euro 5
standards.
MORE INFORMATION:
Andreas Pischke
Tel.: +49 172 833 8994
E-mail: andreas.pischke@metso.com
SAFE, RELIABLE AND SIMPLE | For the

safety shut-off and venting applications in
the newest truck and jetty loading station,
including the firefighting system and new
hydrocracking unit heater, the NIS refinery
selected Metso Jamesbury high-performance
valves.
The selected Jamesbury Series 7000
and 9000 ball valves fully comply with the
regulations relevant to the applications in
the refinery. With their patented Lip-Seal
design and the unique Xtreme seat sealing
technology, these valves provide superior
31

TEXT: Yana Merkulova
PHOTOS: Metso
KTK KASKAD 2 PLANT, RUSSIA
Keeping the heart of

a coal mine pumping
When the Russian coal producer KTK needed pumps for its new
Kaskad 2 plant in southwestern Siberia, Metso was the natural choice.
HE KUZNETSK BASIN in Siberia

is one of the largest coal mining
areas in the world. One of the
major companies in the area is
KTK, Kuzbasskaya Toplivnaya Company, the
largest producer of thermal coal in western
Siberia.
The coal processed in the companys
Kaskad 2 plant is mined from the
Vinogradovsky open pit, one of the coal
strip mines of KTK. The total installed
capacity of its three coal strip mines is 11
million tons of coal per year. Open-cast
mining is used because the coal is low in
ash and sulfur with a relatively high calorific
value, making it well-suited for power plant
fuel. The plant is the first one to combine
two enrichment methods into an integrated
production process. It uses both high-angle
separators for scalping and dense medium
separation. Together, these two methods
help reduce gangue from 50% to 12% as
well as adjust the ash content.
To save water and reduce environmental
impact, Kaskad 2 employs a closed
process water circuit where water is
recycled and reused in the process. This
allows for lower water costs and prevents
harmful discharges that pose risks to the
environment. Because of an increased
earthquake hazard in the region, the plant
has implemented some additional safety
32
measures. Special sensors deliver real-time

data to the EMERCOM duty officer, helping
monitor the operating environment and
status of the facilities on site.
LONGER OPERATION AND EASE OF
USE | It took merely a year and a half to
establish this new industrial facility on a
previously undeveloped site. The project
was strategically important for KTK, because
it is able to enrich up to 70% of the coal as a
result. This provides the company with highquality coal that meets global standards and
market demand.
To operate, the plant required a number
of different pumps for slurry and water
transport and for the dense medium
separation. The pumps play a key role and
have to be able to handle abrasive slurry
and dense media. To meet production
goals, Metso experts suggested horizontal
and vertical pumps designed for heavy and
super-heavy duty. In total, Metso delivered
70 units.
For the dense media separation, KTK
chose Metsos M200 pumps. Made of
high-chrome alloy, they provide excellent
durability and good resistance to abrasive
media. Well-balanced pump hydraulics,
together with the advanced application
analysis and optimized pump selection
through Metso Pumpdim for Windows,
greatly increased the operating life of the

wet-end parts. All the delivered Metso
pumps are characterized by ease of
maintenance, repair and scheduling of
preventive inspection.
WORKING TOGETHER TO ENSURE
PERFORMANCE | The pumps were
delivered to the site completely preassembled. The critical areas were fitted
with pumps mounted on a maintenance
slide base, which significantly simplifies
maintenance and reduces downtime.
Proximity of services to the production
site makes it possible to provide technical
support promptly, increasing the efficiency
of the pumps and minimizing total cost of
ownership.
Our equipment in the coal plant allows
the customer to reach its production
targets while minimizing operating
costs. This project is a good example of
cooperation between Metso and Kaskad
2 employees, extending from the design
stage to its full commissioning, explains
Pavel Cherepanov, Chief Technical Support
Engineer responsible for pumps at Metso.
MORE INFORMATION:
Pavel Cherepanov
Tel.: +7 812 333 4000
E-mail: pavel.cherepanov@metso.com
We launched a bid and selected Metso as the only

supplier of pumping equipment for all of the plants
operational needs. This includes slurries, circulating water
and dense medium. With its equipment, Metso is a world
leader in terms of liner durability, particularly in the area of
slurry pumps. The equipment was installed in 2012, and
the plant was commissioned in 2013. All pumps operate
normally and comply with our production objectives.
VIKTOR GRIBANOV, CHIEF MECHANIC, KASKAD 2 COAL PLANT
33
Discover the latest

Metso Flow Control news
stories from around the world
SDRA CELL, VR, SWEDEN
Comprehensive valve
solutions for pulp mill
expansion project
PHOTO: Sdra Cell, Ola Kjelbye
ETSO has been chosen

as the main supplier of
valve solutions for Sdra
Cells Vr pulp mill
expansion in Sweden. The
valve order was placed by Valmet, which
operates as a major supplier of rebuilt and
new equipment for the pulp mill expansion.
Upon its completion, Vr will be one of
the worlds largest softwood sulphate pulp
mills. The renewed pulp mill is scheduled to
start up in the third quarter of 2016.
The extensive valve delivery includes
a total of about 700 ball, segment and
butterfly valves for on-off and control
applications from the Neles and Jamesbury
product portfolios. The control valves
are equipped with Neles ND9000 series
34
intelligent valve controllers.

We are pleased that our reliable valve
solutions will support Sdra Cells mill
expansion by maximizing pulp process
availability and increasing efficiency. Based
To enable good service levels for Sdra

Cells pulp mill and other flow control
customers in Sweden, Metso has just
opened a new valve service center in the
Gothenburg area.
We are pleased that our reliable valve solutions

will support Sdra Cells mill expansion by maximizing
pulp process availability and increasing efficiency.
on the application knowledge of our experts,
a well thought out valve component scope
means that future valve maintenance will
be easier to manage and will bring cost
competitiveness for them, emphasizes
Tom Adolfsson, Sales and Services Director,
Sweden, Flow Control.
The new service center in the

Gothenburg area strengthens Metsos
position to stage, test and repair large
numbers of valves to meet customers highvolume, fast-turnaround repair and service
needs during scheduled plant shutdowns,
Adolfsson continues.

PHOTO: Adobe Stock
ORPIC, SOHAR REFINERY, OMAN
Ensuring safe ESD

at a refinery expansion
project in Oman
PHOTO: Tomi Parkkonen
INDIA OIL CORPORATION LTD., INDIA
Advanced valve
solutions secure
delayed coker
unit process
HE INDIA OIL CORPORATION selected Metso

to supply them with Neles valves for a delayed
coker unit in the Barauni refinerys capacity
expansion. Valve reliability and tightness is
especially important in the delayed coking process,
one of the most demanding sub-processes in oil refining.
Continuous operation is important for profitable delayed
coking. We are glad that the customer trusts our knowledge in
their process needs. With our valve solutions, the customer is
able to lower its life-cycle costs and can extend the overhaul
intervals, says Vinay Pradhan, Director, Flow Control,
India Metso.
The delivery will include a complete package of valves
for the critical specialty valve system, including special Neles
valves in Pressure Class 900, ball valves ranging from 2-20 and
a technologically advanced 4-way switching valve. Metso will
also provide a programmable logic controller for the continuous
control of devices and control panels.
Metsos intelligent solenoid valves

selected to ensure safe operations
at Orpics Sohar refinery in Oman.
AELIM, A SOUTH KOREAN EPC

COMPANY, selected Metsos intelligent
solenoid valves to ensure reliable
emergency shutdown (ESD) valve
operation for over 600 safety-critical
valves being used in the expansion project at Orpics
Sohar refinery in Oman. The valves ensure that all
safety actions can be implemented reliably on
demand, if needed.
The valves were chosen because of their ability
to perform partial valve stroke tests on a regular
basis, to verify performance for the plants predictive
maintenance purposes as well as to maintain the
required safety integrity level (SIL) for the safety loops.
The high pneumatic capacity and integrated limit
switches of Neles ValvGuard optimize installation costs,
allowing refineries to enjoy improved plant safety
in a highly cost-efficient way. Neles ValvGuards are
also fully compatible with the Foundation Fieldbus
communication protocol, and they ensure safe and
reliable operations on top of 3rd party and Metso
valves.
35
Control valves engineered to optimize

uptime and lower your costs.
Thats how we make the big difference, the Metso Way.
There is a place where the process always flows. Where efficiency
reigns. Where safety is supreme. And where costs are always lower.
That place is called uptime. Metso makes it possible with control
valve solutions that have been field proven to outperform competitive
products. And then we back them with a wide range of expert services.
Discover more at metso.com/valves.
#TheMetsoWay

Results Flowcontrol 2-2015 PDF

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Results Flowcontrol 2-2015 PDF

Încărcat de

Drepturi de autor:

Formate disponibile

Metso customer magazine for the flow control business

Our flow control service

results flow control

results flow control 2/2015

DESIGN AND LAYOUT

All rights reserved.

Metso is the worlds leading industrial company

Making the big difference

READY FOR THE CHALLENGE

SIL 4 AM I SAFE NOW?

Metso experts at your service

40 YEARS OF SERVICE EXCELLENCE

FROM IDEA TO ORDER IN SIX MONTHS

40 YEARS OF BUTTERFLY VALVES

The world is our showroom

INCREASING PUMP WEAR LIFE IN A COPPER MINE

INCREASING RELIABILITY WITH EMERGENCY SHUT-OFF VALVES

KEEPING THE HEART OF A COAL MINE PUMPING

PROVEN RELIABILITY, increased

MORE EXCLUSIVE CONTENT ONLINE:

results flow control 2/2015

Making the big difference

results flow control 2/2015

Making the big difference

NESTE REFINERY, FINLAND

Good planning is the key to success

WATCH VIDEO FOR MORE

IMAGE: A well-planned and efficiently executed

results flow control 2/2015

Making the big difference

It is the level of planning

ABOVE: In terms of valve maintenance

results flow control 2/2015

Finland. All in all, about 270 Metso valves

until the next turnaround, says Jarkko

Making the big difference

It is extremely important that customers

and expensive projects. Anything can

Anne Hassinen, Manager, Shutdown

analyzing the equipment condition, we

Making the big difference

so it is possible to guarantee safe

smart product service experts according to

project schedule and budget, Hassinen

Shutdowns & turnarounds with Metso participation

results flow control 2/2015

Making the big difference

The ultimate supply chain

PHOTOS: Tomi Parkkonen and Metso

results flow control 2/2015

Making the big difference

year. In China, a five-storey building was

FASTER AND MORE EFFICIENT

3D printing is the process

results flow control 2/2015

Making the big difference

T METSO FLOW CONTROL we see 3D printing as a viable emerging

results flow control 2/2015

results flow control 2/2015

The global olefins market is expected to grow

OME VOLUMES OF OLEFINS are produced from catalytic

results flow control 2/2015

any remaining hydrocarbons. Finally, the granular polymer is