2007-10-23 - Accurate flow data delivered by eleven swirl meters from ABB Limited is enabling whisky distiller William Grant to identify areas for potential energy savings at its Glenfiddich distillery in Dufftown Scotland.
William Grant uses steam in its distillation process to heat the fermented liquid to boiling point. The company had a twofold plan to improve energy efficiency and to gather data to inform the purchase of a new boiler. To achieve these aims, it first needed accurate data on current levels of steam consumption.
Steam for the whisky distillation process is generated from a central boilerhouse previously using two boilers. Recent investment in a third boiler, has increased the total steam producing capability of the site by approximately 25%. The design of the steam distribution system allows steam to move in both directions from the boilers and back from the site if it is not needed. To measure this steam required a very accurate, multi-directional steam meter capable of being retrofitted into William Grant’s existing pipe network.
ABB Instrumentation Alliance Partner JWF Process Solutions (formally J.W Fairbairn Ltd) suggested using ABB swirl meters back to back. These meters are unique in design, highly accurate and require just three pipe diameters upstream and one pipe diameter downstream, making them ideal for retrofit applications. Measuring mass flow rather than volume, the meters are accurate to within +/-0.5% of reading, with a turndown up to ten times greater than that of an orifice plate. JWF supplied and project managed the complete installation of the meters with the assistance of William Grant’s project team.
With the installation of the meters, energy consumption can now be pinpointed to exact departments and processes, enabling William Grant to achieve its aim of cutting energy waste, limiting environmental impact and cutting costs. Information from the meters can be used to find and address problems such as poor lagging or steam leaks leading to steam wastage.
Data from the meters is also being used to better manage the steam production around the site by highlighting consumption and trends. The swirl meters allow William Grant to look at fluctuations within the system to reveal the best way to balance steam requirements around the site. As William Grant’s Project Engineer Tony Allen explains, “Without steam meters you don’t know what’s being used, when or where. Previously, the system just ran and you used steam when it was required. Sometimes the steam would run out, delaying the process.
ABB’s swirl meters accurately measure steam demand and reveal how much steam is being used by each piece of equipment. By analysing this data we can balance the steam use around the site and optimise our energy usage. The meters are beneficial and have already proved their value in terms of better controlling energy and steam usage around the site.”
Since installing the meters, William Grant has achieved a much-improved picture of steam consumption at the site, enabling it to get a better idea of the size of the new boiler. “The data has already been used to size the replacement boiler. The increased boiler efficiency and steam-raising capability of the new system have created energy savings and spirit quality has been enhanced by maintaining a constant supply pressure to the stills. We are now looking into enhancement possibilities for future development and the information from the meters is a very good way to justify the improvements needed onsite,” says Allen.
ABB's swirl meters provide stand-alone volume flow measurement for a wide variety of substances and direct mass flow of dry or saturated steam, enabling greater accuracy with virtually zero maintenance – especially in applications where the flow varies over a significant range. Rather than an accuracy of two percent of the upper flow range, which is typical for an orifice plate installation, swirl meters offer an accuracy class as good as +/-0.5 percent of reading over their entire flow range.
For more information, email moreinstrumentation@gb.abb.com ref. ‘Grant swirl meter application’.
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