INSIDE Press Release EMCO WHEATON has supplied four Marine Loading Arms for the first Mexican LNG Terminal in the Port of Altamira Kirchhain/Altamira (hgd). A consortium formed by Ishikawajima Harima Heavy Industries (IHI), ICA Mexico and Fluor Daniel has received the award of contract for the Engineering, Procurement, Con- struction and Commissioning of the liquefied natural gas (LNG) re-gasification terminal in the port of Altamira, Tamaulipas, on Mexico’s Gulf coast. Awarding authority is the Terminal de LNG de Altamira S de RL de CV, a joint venture Company owned by the Royal Dutch/Shell Group and the Total Group. It is expected that the facility will start its operations in the second half of 2006. It will supply 5 billion m³ per annum of natural gas for 15 years. IHI is the consortium representative and the technical leader. ICA Fluor will act as overall project manager and provide all local services. The facility will include LNG unloading and ship berthing facilities, storage consisting of two 150,000 m³ double containment LNG tanks, regasi- fication, send-out installations, and all related utilities. Marine Loading Arms are an essential part of the LNG Terminal EMCO WHEATON have been awarded the contract to supply and install four Marine Loading Arms. EMCO WHEATON GmbH is based in Kirchhain, is a Gardner Denver affiliated company. EMCO WHEATON is one of the leading suppliers of total so- lutions for customers needing to transfer or store hazardous gasses and liquids in bulk. Apart from EMCO WHEATON’s technical expertise and its reliability in respect of ad- herence to delivery dates, the consortium chose the German specialists, because their Marine Loading Arms comply with the special re- quirements for LNG-terminals defined by Shell. EMCO WHEATON’s B0300 series Marine
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INSIDE
Press Release
EMCO WHEATON has supplied four Marine Loading Arms for the first Mexican LNG Terminal in the Port of Altamira
Kirchhain/Altamira (hgd). A consortium formed by Ishikawajima Harima Heavy Industries (IHI), ICA Mexico and Fluor Daniel has received the award of contract for the Engineering, Procurement, Con-struction and Commissioning of the liquefied natural gas (LNG) re-gasification terminal in the port of Altamira, Tamaulipas,
on Mexico’s Gulf coast. Awarding authority is the Terminal de LNG de Altamira S de RL de CV, a joint venture Company owned by the Royal Dutch/Shell Group and the Total Group. It is expected that the facility will start its operations in the second half of 2006. It will supply 5 billion m³ per annum of natural gas for 15 years.
IHI is the consortium representative and the technical leader. ICA Fluor will act as overall project manager and provide all local services. The facility will include LNG unloading and ship berthing facilities, storage consisting of two 150,000 m³ double containment LNG tanks, regasi-fication, send-out installations, and all related utilities.
Marine Loading Arms are an essential part of the LNG TerminalEMCO WHEATON have been awarded the contract to supply and install four Marine Loading Arms. EMCO WHEATON GmbH is based in Kirchhain, is a Gardner Denver affiliated company. EMCO WHEATON is one of the leading suppliers of total so-lutions for customers needing to transfer or store hazardous gasses and liquids in bulk. Apart from EMCO WHEATON’s technical expertise and its reliability in respect of ad-herence to delivery dates, the consortium chose the German specialists, because their Marine Loading Arms comply with the special re-quirements for LNG-terminals defined by Shell. EMCO WHEATON’s B0300 series Marine
Whilst the content of this leaflet has been edited with the greatest care, we are not liable for any errors and/or omissions. Subject to change without notice.
EMCO WHEATON Marine Loading Arms for the 1st Mexican LNG Terminal in Altamira
Loading Arms will be utilised for the loading and unloading of ships with a capacity of 70,000 – 200,000 m³. The basic design feature of the B0300 loading arm is the use of a supporting structure to carry the product pipe. They are used where it is essential to keep the product pipe the same size for either economical or technical reasons, e.g. cryogenic products, piggable systems and PTFE-lined product pipe. The design of the Marine Loading Arms includes a support structure for the standpost, inboard and outboard arm and separates any mechanical loads imposed on the product pipe, except for the deadweight and internal pressure loads. The balancing of the arm is achieved by a rigid link pantograph system with independent counterweights direct linked to the inboard- and outboard arm. This provides accurate balance throughout all manoeuvring and connecting positions.All loading arms are equipped with, Nitrogen Purge Line, Drainage Connections, Emergency Release System (ERS), Manual Quick Coupler, Insulating Flange, Hydraulic power station and electric controls.The manual quick coupler used for this project is a further development to the units available to the industry so far. It introduces an intermediate option between a bolted flange, a conventional cam-lock coupler and traditional hydraulic quick coupler.
Marine Loading Arms passed Yard Test successfullyBefore final delivery the marine loading arms had to pass various tests. One of them was the so called Factory Acceptance Test, which ensured that the loading arms complied with the customer’s specifications. By the end of August 2005 all attachment parts were in place and the loading arms proved to be in full compliance with the requirements of the customer. Each Marine Loading Arm when parked is 29 m high and weighs 65 t. During the loading process the product pipe is cooled down to -162° C. The flow-rate is 4 000 m³/h. The entire structure of the loading arm is designed to withstand a wind speed of 200 km/h (125 miles/h).
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Press Release
Advanced Technology: The loading of bio-diesel, fuel of the future.Bio-diesel is recognized as fuel of the future. Today, over 180,000 vehicles use the renewable fuel alternative. With a distribution of 1.5 million tons in 2005, bio-diesel is arguably the most important and marketable bio-fuel. For the loading of the fuel, individual solutions covering the entire process are needed. The loading equipment
must be conformed perfectly to the physical requirements of the bio-diesel manufacturers. Safety is a main issue, along with efficiency, dependability, and unsurpassed quality. In 2006, EMCO WHEATON delivered ten installations for the manufacture of bio-diesel with loading arms and folding access stairs for vehicle inspection and filling.
Bio-diesel is a valid alternative to conventional diesel. It is manufactured from renewable raw materials and significantly lowers carbon particle emissions. In the burning process, bio-diesel emits as much CO2 as plants absorb while maturing. It is also easily biodegradable. The most used raw material is rapeseed (also known as Canola) oil, which has beenextracted from the seeds of the plant through an oil press. A short description of the m a n u f a c t u r i n g process: Oil and fat molecules have the same chemical composition. Both involve fatty acid components, or esters. In a so-called Transesterif ication process, plant oil and methanol are heated together with a catalyst. The results produce fatty acid-methanol ester chains – bio-diesel, and glycerine. What is achieved in
mineral fuels only after many additives or by complex production processes is given to bio-diesel by nature. It is almost completely free of sulphur and extremely solvent, making it gentler on the motor. Because bio-diesel molecules contain 11% oxygen, the burning process is more efficient and produces significantly fewer particle emissions. A further advantage over conventional fuels is that in accident
situations, bio-diesel poses no threat to the earth or groundwater. It is classified at minimum risk to water. In Germany, there already exist approximately 1800 filling stations offering bio-diesel. For it to arrive there, this fuel of the future must first be loaded into tank vehicles for transport. EMCO WHEATON delivers loading arms which are custom-designed and fitted to the needs of the manufacturer. They are exceptionally service oriented, and above all, easy to operate.
Perfected Technology: The loading of bio-diesel, fuel of the future.
Loading Arms for Bio-diesel Transfer Stations
Due to many years of experience, in 2006 EMCO Wheaton received the additional assignment to supply for the manufacture of bio-diesel, loading arms and folding access stairs for vehicle inspection and loading. The production plant sites are located across Germany, predominantly in the eastern states of the Federal Republic. The emphasis in the case of these orders was the engineering and fabrication of equipment capable of loading of bio-diesel and its by-product glycerine in various grades, and fatty acids. For certain facilities, an extra loader for the handling of raw materials like Methanol was also delivered.
Individual Solutions for Special Challenges
Because mainly tanker trucks and sometimes railway tank wagons must be loaded and unloaded, EMCO delivered loading arms for top filling, which had to be
adapted to the exact geometry of each on-site loading platform. To save time during the filling process, transport vehicles should not have to be moved – a wish from the manufacturers that EMCO was able to fulfil: the wide reaching range of the loader was conceived in such a way that all top loading points (domes) along the length of a semi-trailer truck could be accessed. For the loading of bio-diesel, specialized seals are employed in the EMCO swivel joints. The gaskets were specially developed in cooperation with a manufacturer specifically for this use. A further challenge in handling glycerine and fatty acids is that for these elements, the loading arms must be heated. This has been realized by the installation of electrical trace heating elements. For the unloading of Methanol it was additionally required to build in the appropriate precautions in accordance with explosion prevention requirements. EMCO planned and manufactured the equipment to meet all existing safety rules and regulations.
Loading Arms with a Greater Range
The facilities manufacturing bio-diesel were outfitted with 3 different types of loading arms, according to their special requirements. The standard loading arms E2800 and E2808 are specially developed for the top loading of mineral oils into tanks and tanker wagons through their open domes. Both loading arms have a large range, perfectly outfitted for filling stations where the dome openings cannot be positioned exactly. The robust and extremely high quality construction of the swivel joints along with the balancing assures that the equipment is very easy to use. At some plants, a solution for safe loading at ground level was needed. Here, the loading arm E2825 came into use, likewise particularly suitable for the task due to its extra wide range. The loader for the filling of road tanker wagons with bio-diesel is equipped for a flow-rate of 80 m3/h. Glycerine and fatty acids are loaded at 30 m3/h.
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Moving Forward with Safety
When preparing the vehicles to be top loaded, there is always a great danger of service personnel slipping and falling. To prevent this, special protections were requested. EMCO was able to deliver safe passage in the form of folding access stairs with the precise amount of steps needed to reach the tank or tanker wagon from the loading platform. With both handrails and safety rails on both sides, hot-galvanized skid-proof steps, a contact bracket covered with an oil-resistant rubberized bumper, stabile support frame, and parallel guide arms, the folding access stairs fill all occupational safety standards and effectively prevent accidents due to falling. The retractable folding stairs are easy to use manually, but can also be delivered with pneumatic or hydraulic guiding systems. They are examined and certified by professional association experts responsible for structural mechanics.
A Tradition of Teamwork
From planning and construction to implementing the operation, as specialist for the transfer of flow-materials, EMCO covers the entire spectrum, from foodstuffs to chemicals. The awarding of the contracts for outfitting the bio-diesel facilities was received by EMCO based on its long history of good teamwork in connection with its highly developed technology, service, amicability and last but not least, fair market prices. The operators of the manufacturing plants are highly satisfied with the delivered goods and services, especially because the equipment is safe and easy to operate.
Whilst the content of this leaflet has been edited with the greatest care, we are not liable for any errors and/or omissions. Subject to change without notice.
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Press Release
First Marine Loading Arm for CNG, Compressed Natural Gas
Natural Gas is an important cornerstone of power supply. Its total share of primary energy consumption in Germany in 2004 was 22,4%, earning it 2nd place, directly behind oil. Used commonly for both heat and fuel, combusted natural gas produces less CO2, which is one reason why the market share for natural gas in the future is predicted to increase sharply. Alternative transport facilities for natural gas are currently being introduced. These have the possibility to overcome obstacles for a long term supply of European natural gas.
The current alternatives to pipeline gas are LNG (Liquified Natural Gas) and CNG (Compressed Natural Gas). In both logistical processes, transportation of the resource over seaways and without pipelines is now possible. For the unloading of CNG, Emco Wheaton has recently developed for the first time ever a marine loading arm capable of handling the special requirements posed by compressed natural gas. The unique feature of the marine loading arm is that it can be optionally installed directly onto a CNG regas vessel.
There is currently a growing demand for sources of energy that are environmental and climate-friendly as well as economical. The history of natural gas as a primary energy source is relatively young, gaining prominence first in the mid 1960`s with the discovery of a large natural gas field on the European continent. In just 30 years, the market share of natural gas in primary energy consumption climbed to over 20 percent. But what is natural gas really? Natural gas is a product of nature that includes all gaseous hydrocarbon components that originate from the earth and are combustible. At least 85 percent of the volume consists of methane, and up to 10 percent from nitrogen and carbon dioxide. Natural gas is stored in underground caverns and porous rock formations. Based on current yearly demand and considering the technically intensive methods necessary to procure it, the supply of natural gas is estimated to be sufficient for the next 170 years.
In addition to an underground network of pipelines, the transport of natural gas increasingly employs the use of high sea vessels. A condition to make this possible is the application of technical procedures to reduce the volume of the gas. For LNG (Liquified Natural Gas) this takes place by liquefying and supercooling the gas to minus 162 degrees Celsius. Through this process the natural gas takes on a fluid form and can be transported with specially outfitted high sea vessels. A further option is compression. The resulting CNG (Compressed Natural Gas) is methane in a gaseous state which is pressurized to between 50 and 150 bar. CNG is used primarily as fuel for automobiles powered by natural gas. Natural gas motors employ an extremely ecological form of propulsion technology. In comparison to petrol engines, natural gas produces 25 percent less CO2, making it the cleanest burning of all known fossil fuels. A growth rate in the area of circa 40 percent further reflects the importance of this development. For the new model year 2007, 55,000 natural gas vehicles were certified in Germany. World-wide, 4.5 million such vehicles are already in use.
New Development of a Marine Loading Arm for CNG
As the specialist for the transfer of liquid materials, EMCO WHEATON covers the complete range from foodstuffs to chemicals. Based on the successful Marine Loading Arm B0300, which has been employed for many years for the loading and unloading of sea vessels, a new marine loading arm specially designed for CNG transport has been developed. The assignment was to create a CNG marine loading arm that could be operated at pressures up to 150 bar with a feature allowing emergency release of the loading arm from the ship. In addition, the loading arm had to be designed to allow installation on a regas carrier, and be stable enough to accept all mechanical loads, as well as accelerations and movements that can occur on a sea going vessel. The client, Excelerate Energy, selected EMCO WHEATON based on the plausible solution to the challenge that was offered by the Kirchhain firm. The result, after 12 months of research, development and testing, has recently been introduced and can be seen successfully in use. EMCO
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WHEATON specially developed and delivered the 12 inch marine loading arm for the transfer of CNG. It encompasses hydraulic drives, electric controls and safety features, including a hydraulic quick connect / disconnect coupler for the emergency disconnect system.
Individual Solutions: Quick Coupler with Retractable Connector Claws
A special challenge in the development of the marine loading arm was to devise a solution for high pressure process. In addition to the high pressure, the loading arm must be capable to withstand the severe conditions that occur on board a sea going vessel. EMCO Wheaton has developed a marine loader with structural components capable of meeting the extreme loads and conditions. A hydraulic quick coupling system was developed specifically for use in high pressure conditions. This system includes a quick coupler with connector claws that can fully retract beyond the connecting flange It is capable of withstanding the resulting high
pressure and guarantees a safe connection. During the development process, Emco Wheaton carried out extensive computer based simulations as well as field tests to safeguard that the delivered unit would meet all official safety regulations for the transport of CNG. All subcomponents as well as the entire unit have been intensively tested and are certified by the Bureau Veritas.
The first CNG marine loading arm is being employed on the eastern coast of England in the port of Teesside Middlesbrough. It will transfer the compressed natural gas from the regas tanker directly into the national gas grid of Great Britain. With a daily capacity of 11.3 million cubic meters, the facility in Teesside covers circa 3 percent of England’s daily peak demand for natural gas, avoiding the need to construct additional storage tanks and regas facilities on land.
Customer Oriented Specific Solutions
With the CNG marine loading arm, EMCO Wheaton has proven once again to be a first class and dependable partner when it comes to the development of highly customer specific solutions in the loading arm business. The delivered solution not only fulfils the client’s requirements, but exceeds them as well. EMCO Wheaton assisted the needs of the client, Excelerate Energy and provided support to many other project participants during the entire project, encompassing the successful planning, erection and installation. After the successful pilot project in Teesside, Excelerate Energy immediately contracted EMCO Wheaton to install further CNG marine loading arms, which are currently in production.
Whilst the content of this leaflet has been edited with the greatest care, we are not liable for any errors and/or omissions. Subject to change without notice.
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Press Release
German Innovation Lands Emco Wheaton in the 100 `TOP` CompaniesSince September 2005, Emco Wheaton can be counted as one of the 100 `TOP` businesses in Germany. As the host of TOP, a nationwide innovations initiative, Emco Wheaton committed its resources and expertise to strengthen the quality of innovation in Germany. The `Technology Oriented Exchange and Information Program` is a nationwide initiative of the National Ministry for Economics and Technology, and the F.A.Z. Institute for Management, Market and Media Information GmbH. In association with leading corporations such as Airbus, Vaillant, Unilever Germany, Tesa, Vorwerk and Carl Zeiss, Emco Wheaton shared its knowledge of new technologies and strategies with other businesses on the topic of `Employees in the Center .
Global Leader
Emco Wheaton is the world leader in the development and manufacture of customer-oriented solutions for the loading of fluids and gasses. Founded in 1957 in Kirchhain as part of the `Fluid Transfer Division (FTD) of Gardner Denver, today the strongly performing unit employs over 250 workers and delivers products and services to circa 180 countries. Worldwide, the Kirchhainer company has earned the trust of all the largest mineral oil enterprises, international chemical concerns, high profile engineering firms, and the food industry. For decades, these industries have depended on Emco Wheaton for the loading and unloading of their products and raw materials on both land and sea. The product program includes loading arms for ships or road and rail use, Swivel joints, Dry Break
couplings, API couplings, loading valves, folding stairs, emergency operation systems, and safe access equipment, as well as loading platforms. With its wide assortment of proven equipment and services, Emco Wheaton serves the entire process spectrum in fluid transfer from food to chemicals.
Innovative Improvement Process
At Emco Wheaton, innovation has many facets. Customer requirements are unique and often unusual, requiring solutions to be individually developed to create a perfect fit for each situation and medium. The loading systems from Emco Wheaton meet this challenge through their efficiency, safety, ease of use, high quality and dependability. Repeatedly, the Kirchhainer firm sets new standards by refining and developing new technologies and often good solutions come directly from individual employees. To encourage this exchange of ideas, a company-wide process has been implemented: the
Whilst the content of this press release has been edited with the greatest care, we are not liable for any errors and/or omissions. Subject to change without notice.
A Turn-key solution that follows the highest safety demands
Continuing Improvement Process (KVP in German). By following up on suggestions from workers, Emco Wheaton has been able to successfully increase operational capacity of the Loading Division by 185%. This outstanding result was cited publicly first by the Industry and Chamber of Commerce in Kassel, and subsequently recognized by the National Ministry for Economy and Employment. As host of the TOP`program, Emco Wheaton invited other selected companies to join them at their Kirchhain headquarters for a day-long conference to examine the KVP process, and to witness its applications, from the workshop through the production operation, known as the `EMCO-Flow . Conference participants were offered a look at the process from an original assignment with specific customer requirements, to an operation with a longer lead time, one with a shorter delivery time, the reasons for occasional outsourcing during the production process, and the successful implementation of problem solving procedures. In every department, employees develop suggestions and ideas of how the process and the organisation can be improved. Step by step, these ideas can be introduced and become part of the work flow. After only 5 years, Emco Wheaton has reached significant improvement in their internal operation: In the road & rail loading unit, the operational capacity between 2000 and 2006 increased by circa 185 % (in the ship loading unit by circa 120 %) the production cycle shortened from 21 to 12 working days and the reliability of delivery increased from 56 to 85%. Also exemplary: all improvements were achieved without
any change in the number of workers or payroll statistics. Currently indicators within the company show that the Continuing Improvement Process is still achieving results. Emco Wheaton established KVP within all areas of the company, and employees are concentrating their efforts on how production can be further optimized.
Safety for People, Materials and the Environment
The most important aspect of the loading and unloading procedure, the operation and handling and the maintenance of equipment, is safety. Thanks to well-planned safety engineering, the loading arms manufactured by Emco Wheaton provide clients with the most comprehensive and safest fluid transfer solution worldwide. Situations such as uncontrollable overfilling due to overcapacity can be avoided, through an overflow safety mechanism that indicates the filling level and switches off the loading process as soon as the allowable capacity is reached. Fall protection, equipped with a safety cage, folding stairs and a fall arrest grating system guarantee the highest level of safety for the operational team. Special technology developed specifically for the loading of fluids make safe liquid transfer possible. Regularly scheduled preventative maintenance ensures the high level of safety built into Emco Wheaton Loading systems remains constant throughout its lifetime. Emco Wheaton has a permanent service and assembly team on-call at all times to provide clients around the world with first class service.
