Flow Control: Technology information & new products for fluid handling engineers

The Accelabar - 05 Differential-Pressure Flowmeter
By Veris Inc
www.veris-inc.com

The new two-inch 05 Accelabar provides high accuracy over a wide operating range with no straight-run requirements. Key features include:
• Ability to measure mass or volumetric of gas, liquids and steam;
• No straight-run requirements;
• Wide rangeability (turndown);
• Integral pressure and temperature measurement within the 10-inch face-to-face dimension of the meter;
• Available in a wide variety of materials and ANSI flange ratings;
• Direct mounting of the DP transmitter (no additional connections required);
• Face-to-face dimension can be adjusted to easily retrofit (replace) an existing inaccurate or inoperable flow meter; and
• Tested in accordance with API 22.2.

Prior to the introduction of the two-inch Accelabar, differential-pressure flowmeters were limited by accuracy & straight-run requirements, turn-down requirements, and mounting limitations. Where space is limited, common in skid mounted installations and at natural gas wellheads, the two-inch Accelabar provides flow conditioning, flow measurement, and pressure & temperature measurement - all integral to the meter and within a 10-inch face-to-face dimension. In addition, secondary equipment, such as DP transmitters, can be directly mounted to an integral three-valve manifold. Installation of other meters requires additional straight-run (piping), taps for pressure and temperature measurement, and additional tubing/fittings to complete the
installation, greatly increasing the footprint and complexity of the installation.

Application Note: At a mineral processing plant, the two-inch 05 Accelabar was installed in two-inch natural gas lines (to boilers) and two-inch steam lines. They replaced turbine meters that had required frequent maintenance. Unlike the turbine meters, the two-inch Accelabar has no moving parts, requires no calibration, and is easily field serviced and verified. Some of the Accelabars were installed to satisfy EPA requirements for greenhouse gas reporting.

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VIP Insertion Panel Flow Conditioner
By The Vortab Company
www.vortab.com

The Vortab VIP Insertion Panel Flow Conditioner's tab-type flow conditioning technology greatly reduces pressure drop compared to alternative technologies such as tube bundles, screens and perforated plates. Minimizing pressure drop is a significant design consideration in flow conditioning for process engineers to minimize plant energy consumption and energy costs.

The VIP Flow Conditioner enhances flow meter accuracy and repeatability of measurement. Many flow meter technologies, and particularly center-point types, require several diameters of straight pipe run to meet their meter's accuracy specifications. The straight-run is necessary to provide a highly repeatable symmetrical and swirl-free flow profile to the flow sensor for accurate and repeatable flow measurement. Unfortunately, most process industry plants are rich with elbows, valves, tees and real estate limitations that make the flow meter's required pipe straight-run configuration difficult to achieve.

The VIP Flow Conditioner solves the pipe straight-run dilemma. A VIP installed in just three pipe diameters downstream from the flow disturbance and with the flow meter installed at just three pipe diameters downstream of the VIP neutralizes the flow disturbance and produces the symmetrical and swirl-free repeatable flow profile that ensures a flow meter installation meets its accuracy and repeatability specifications. The thin, lightweight panel design of VIP is easily installed between flanges or can be welded in place.

Application Note:In wastewater treatment plant aeration systems, accurate airflow measurement ensures proper oxygenation for optimum bacteria growth while not over-running air blowers that lead to excessive energy consumption and costs. However, most aeration systems have only short pipe runs with elbows and control valves, resulting in an asymmetric, distorted and non-repeatable flow profile that renders the flow meters inaccurate.

In a recent field test, a VIP Flow Conditioner was inserted between two flanges, just three pipe diameters downstream from the elbow and three diameters before the flowmeter. The VIP created a symmetrical, swirl-free flow profile to the flowmeter, resulting in the flowmeter reading per its published specifications for accuracy and repeatability. Additionally, because VIP had the lowest pressure drop of the flow conditioning technologies being considered, the plant did not have to boost blower output, which resulted in even greater energy savings and the fastest payback.

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CONTROL

ASCO 0.55W Low Power Solenoid Valves
By ASCO Valve Inc
www.ascovalve.com

These low-powered solenoid valves - available in two-, three-, and four-way designs from ¼-inch NPT to one-inch NPT in brass, aluminum and stainless steel - consist of a molded one-piece design with a highly efficient solenoid cartridge and 0.55 W low power coil. The valves are designed for use in automation of plant control systems to provide:
• Energy savings
• Increased battery life
• BUS network and traditional wiring compatible
• Reduced temperature rise
• Reduced wiring cost

Options include 2/2 normally closed, 3/2 normally closed (including Quick Exhaust), 3/2 universal, 4/2, 5/2, and 5/3. This technology innovation represents the first complete line of 0.55W low-power solenoid valves that does not require special filtration. The line complies with ANSI/ISA 7.0.01 1996 quality standard for instrument air defined as clean, dry air or inert gas with max particle size of 40 micrometers. Current products on the market require special, more expensive, filtration that reduces the particle size to five to 20 micrometers.

The valves' 0.55W power level offers a significant improvement over previous models, which operated at 1.4W.

Application Notes:
1. On traditional point-to-point applications, the ASCO 0.55W Low Power Solenoid Valves eliminate the need for additional power isolation relays. They also permit the use of smaller, less expensive wiring gauges and allow the use of downsized, less-costly power supplies, as well as smaller PLC or DCS output cards.
2. On Bus network applications where devices are powered directly from the network, such as DeviceNet and ASI, a lower wattage solenoid valve allows for a larger amount solenoid valve to be connected on each bus segment.
3. On remote installations, such as oil pipelines and remote gas extraction stations, low-power solenoid valves allow optimization of battery banks for size and longevity.

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FireBag Thermal-Activated Shutoff Device
By Assured Automation
www.assuredautomation.com

FireBag is a thermal-activated shutoff device that immediately stops the flow of gas when outside temperatures exceed 203-212 F (95-100 C). The device is installed in gas systems to automatically turn off gas supply in the event of fire, preventing explosions and the spreading of fire. This automatic shutoff device is activated when the temperature reaches the activation temperature and does not require a fire or a heat detector to automatically intercept gas flow. It is certified and meets international standards.

The device consists of a steel external body and an internal thermo-sensitive device. When the outside temperature reaches 203-212 F (95-100 C) the metal alloy that keeps plug and cartridge together melts and the spring pressure pushes the plug against the gas opening and closes it completely.

The FireBag is a standalone device that can withstand temperatures up to 1,697 F (925 C) for 60 minutes. It is designed to replace actuated valves that require a signal and energy source for operation.

The FireBag meets rigorous European certifications for automated, thermal-activated gas shut-off. The FireBag has been successfully installed in more than a thousand applications throughout the world, protecting industrial equipment, homes, hospitals, stores, office buildings and more from gas fire hazards.

Certifications:
• European UNI EN 1775 Standard for indoor gas installations
• European Directive 90/396/CEE certification for durability in mechanical or thermal stress
• German DVGW TRGI 86/96 Standard for thermo-activated locking systems on gas heaters, water heaters and domestic gas fittings
• German Standard Muster-Feuerverordnung (FeuVo v. 02/95 - edition 09/97) for thermal-activated devices
• Italian UNI 7129 Ed 2001 Standard for fire protection and gas supply line components

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Equilibar Instrument Series Back Pressure Regulators
By Equilibar LLC
www.equilibar.com

The Equilibar Instrument Series is a family of precision dome-loaded backpressure regulators with a very wide range of pressure, temperature and flow capability. These regulators can precisely control pressures up to 5000 psig using SS316 diaphragms. By using Kalrez o-rings, the device can operate at temperatures of up to 327 C (620 F). With a flowrate turndown ratio of 10,000-to-1, these regulators excel at ultra-low flowrate applications, controlling down to a Flow Coefficient (Cv) of 1E-08. Maximum Cv range from 0.1 to 0.6.

Inlet pressures are typically controlled to within 1 percent of setpoint through widely varying flow ranges. Aggressive chemistries are also accommodated by SS316 bodies and diaphragms of either SS316 or PTFE. The setpoint for these devices can be provided by either a manual pressure-reducing regulator, or by an electro-pneumatic controller for process automation. The Instrument Series backpressure regulators are available in 1/8-inch or ¼-inch NPT ports, as well as VCR-style fittings.

Equilibar's new Instrument Series expands its high precision performance to much higher pressures (5,000 PSIG versus 1,000 PSIG) and much higher temperatures (327 C versus 200 C) than the company's previous product line. This is done by the introduction of SS316 diaphragms and Kalrez® o-rings. Users report that this product is unique in its ability to provide precision throughout these extreme pressures and temperature ranges.

Testimonials: One researcher for a leading worldwide energy corporation is using the Equilibar Instrument Series regulator to control reactor pressure in the company's petrochemical research application. He reports that the pressure stability with the Equilibar instrument series regulator was "flat as a pancake in two phase flow".

In another success story, an astrophysicist has used the Equilibar Instrument Series backpressure regulator to control liquid Helium at temperatures near absolute zero (4°K). By tightly controlling the evaporation pressure, this scientist was able to reduce the temperature variation in the optics for this astronomical observatory by a factor of 4X compared with previous pressure control methods.

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E-Series Air-Operated Diaphragm Pump
By Almatec Maschinenbau GmbH
www.almatec.de

The new E-Series all-plastic diaphragm pump, available in seven sizes from DN 8 to 80 with maximum capacities from 0.9 m3 to 48 m3, replaces ALMATEC's popular A-Series. With its patented design and maintenance-free and lubrication-free air control system PERSWING P (also patented), the E-Series provides a solution focused on economic, ecological, efficiency and ergonomic goals - that is what the "E" stands for.

The pump offers an optimized flow pattern for increased efficiency. Compared to the A-Series, the same airflow achieves a higher fluid flow, hence less airflow is required for the same fluid flow. This provides the user a greener production, less production costs and a stronger position in their business competition.

The pump also offers reduced noise levels to protect workers in the factory, as well as the environment in general.

The pump's innovative ring-tightening structure is a unique feature only found on E-Series pumps. Usually the housing parts are tightened to each other via housing bolts. This increases a punctual stress on the material. In contrast, all housing bolts of the E-Series are tightened against a diaphragm-sized ring on a much bigger face, which reduces the surface pressure significantly. This structure results in a more even spread of the housing bolt force and an increasing of the permissible bolt torque. This provides a higher pump safety and a lower sensitivity against temperature variation (environment temperature or temperature by the fluid).

The solid housing parts are machined on modern CNC-machines, which enable the smallest possible tolerances. The solid housings absorb mechanical vibrations and noise level much better than thin-walled and give the flexibility to realize special customer developments (based on standard parts).

Application Note: A major chemical plant processing dangerous fluids (acids and solvents) in an exposed position is under special safety surveillance. Since installing a two-inch PTFE E-Series pump, the factory's regular inspections have shown the pump is less likely to suffer from decreased housing bolt tension when temperatures change. Based on this experience, the factory has started to enlarge its inspection periods for these pumps, which is expected to save maintenance costs in the long-term.

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ML-800-3 Primary Gas Flow Piston Prover
By Bios International
www.biosinst.com

Traditionally, constant-pressure gas provers have been used in the range of five standard cubic centimeters per minute to 50 standard liters per minute. The ML-800-3 is a primary gas flow piston prover that measures gas flows from 0.5 to 50.0 standard cubic centimeters per minute. Obtaining accurate flow measurements at sub-1 SCCM flowrates has been very difficult, until now. The ML-800-3 piston prover accomplishes this by using a 0.1-inch diameter high-precision piston with a microscopic clearance between the tube and piston. By measuring the displacement of this miniature piston, accurate and fast gas flow measurements can be performed at very low flowrates.

The ML-800-3 uses precision manufacturing techniques to produce a miniature piston that fits into a glass tube with a typical clearance of five microns. The tube and piston are manufactured from materials with a low coefficient of expansion, so the piston-to-cylinder clearance is maintained constant across a wide temperature ranges. A small amount of gas leaks through the five-micron gap, typically 0.01 SCCM, this leakage is factory-measured and the internal computer in the piston prover adds this leakage (tare) into the reading as a correction.

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Type 8611 eCONTROL Modular Control System
By Bürkert Fluid Control Systems
www.burkert.com

The 8611 eCONTROL is designed to save time, space and headaches in closed-loop cooling systems and is the first modular control system designed for seamless integration into countless cooling loops.

With the increasing quality demands in injection molding, die casting, grinding and other applications, the 8611 is the only intelligent device that allows the user to completely decentralize control to gain overall lower equipment and installation costs while at the same time increasing product quality.

The system provides proportional/integral and cascaded temperature control with dual indication of process values (i.e. temperature and flow). The open system architecture of the unit's internal hardware and software design allows it to be customized exactly to the application.

Technical features include:
• One controller for flow, pressure and temperature
• Proportional/integral and cascaded temperature control
• Dual-indication of process values
• Easily customized
• Seamless integration
• Completely decentralized
• Works with pneumatically- or electrically-driven systems
• Two-way communication with PLC or other controllers

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HPX Rupture Disc
By Continental Disc Corporation
www.contdisc.com

The HPX rupture disc is the first rupture disc on the market to withstand more than 250,000 pressure cycles from full vacuum. The device can also be manufactured for non-sanitary and sanitary applications, as well as for systems requiring a 90 percent operating ratio or a 95 percent operating ratio. The device is capable of meeting 0 percent, 5 percent or 10 percent manufacturing range requirements.

The durability of a rupture disc means the disc is less likely to break prematurely. The customer saves money by not having to replace as many rupture discs. The versatility of a rupture disc means the user will not have to inventory or document a wide variety of rupture discs.

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INTUNE with Valve Diagnostics
By ControlSoft Inc
www.controlsoftinc.com

INTUNE with Valve Diagnostics is a valve performance diagnostics tool, which is an add-on to ControlSoft's established INTUNE control loop tuning tools. Beside the proper design and tuning of control loops, the performance of any loop depends highly on the performance of control valves. The variability caused by control valves is very difficult to regulate without proper diagnosis and treatment of the source. The purpose of this tool is to detect and quantify stiction in control valves.

INTUNE is an integrated package of PC-based software tools that monitors and tunes control loops, diagnoses control loop problems, and measures and reports loop performance in real time. Easy to set up and initiate, the new Valve Diagnostics tool detects stiction while monitoring performance online from the existing control system or using historical data to analyze performance. Multiple loops can be analyzed simultaneously. Analysis can be performed with or without valve position feedback.

The results display combines an XY-graph of the controller CO-PV with control loop time-trended performance data. The severity of stiction is quantified as a percent value. The display also provides a qualitative determination, confidence level index, and the daily worse-case stiction data. Results are time-stamped, saved and recovered as HTML reports. Diagnostic results are also available to third-party software through OPC addressability.

The tool includes several novel features in both implementation and operation aspects.
• Most valve diagnostics tools need extra hardware and direct access to the control valves. The ITUNE tool does not require any additional hardware nor instrumentation, utilizing the information readily available in existing control systems, specifically process values, controller outputs, set points and the value position (if available).
• Analysis can be performed with or without valve position feedback signal.
• In online mode, the tool analyzes the performance of valves in normal closed loop operation and reports status in real time. No need for intrusive testing methods.
• In online mode, the tool can measure and detect in real time the gradual degradation of loop performance due to valve problems. Aids in predictive maintenance.
• A similar analysis can be performed on data collected by any historian (offline mode).
• The results display enables users to also visually evaluate the trend and data plot provided by diagnostics tool.
• Using pattern recognition technology, the tool provides both qualitative and quantitative stiction diagnostic results, complemented by a measure indicating confidence of the analysis with time stamp.

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VLT Low Harmonic Drive
By Danfoss Drives
www.danfoss.com

The filter portion of VLT Low Harmonic Drives has the same working principle as a set of noise-canceling headphones, where the noise or distortion is measured and a computer phase signal is imposed to compensate for that noise.

VLT Low Harmonic Drives don't merely reduce or mask current distortion; they attack it at the source by performing real-time analysis and actively imposing currents, as needed, to restore and ensure the highest possible quality sine waves from the power supply grid. They are well suited for:
• Meeting harmonics recommendations/standards
• Installations that are generator-powered or have generator backup power
• Soft power grids
• Grids with limited excess power capacity

VLT Low Harmonic Drives feature a modular design, meaning that most elements are produced in large scale for cost-effective production. The drives are individually configured according to the customer's specific needs to deliver the value of a highly-customized quality drive for the price of a mass-produced unit.

With the increased use of ever-more powerful frequency converters, the issue of needing to prevent harmonic disturbances is growing significantly. Even after many years of growth for the drives market, only one out of eight motors is operated by a frequency converter. It's expected that the huge potential for energy savings by employing frequency converters will increase the number of drives in use - and hence the potential harmonic disturbance on the supply grid and the need for smarter harmonic mitigation solutions.

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ValveSight Diagnostic Solution
By Flowserve
www.flowserve.com

ValveSight is an intelligent diagnostic engine that provides proactive, actionable maintenance advice by constantly monitoring the valve, actuator, positioner and control signal for patterns of behavior that may indicate a problem. ValveSight uses a dashboard interface that gives the user an easy-to-understand view of the device health. The ValveSight software uses FDT/DTM technology, which allows seamless integration into your host control or asset management system. It is fully compatible with many third-party, stand-alone "frames" that can be run on any Windows-based computer connected to the user's network. ValveSight does not require any detailed knowledge of integrated control valves and simplifies the interpretation of complicated data. ValveSight communicates using HART, Foundation Fieldbus, and Profibus communication protocols.

ValveSight is the first diagnostic solution to alert users to a potential issue before it becomes a problem. Prior to ValveSight, a diagnostic system could only alert the user to a problem, not the factors that were causing it. ValveSight diagnostics focus on why the problem is occurring - not just telling you what the problem is - and offers possible maintenance solutions when a problem is detected.

Application Note: After seeing ValveSight in action, one user claimed that if he had been using the technology on a rotary actuator that had failed in his plant due to a sheared shaft key, he could have saved at least eight hours of unplanned downtime finding and resolving the problem.

Another customer has specifically purchased ValveSight to monitor packing friction in several critical valves that had potential for process material buildup on the valve stem, which could lead to the valve being unable to move during emergency situations.

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Diaphragm Valve Type 514 Series
By GF Piping Systems
www.gfpiping.com

Compared to traditional diaphragm valves, GF Piping Systems' Diaphragm Valve Type 514 Series offers double the Cv values and significantly-increased flow with less restriction. These features expand the valve's suitability for applications where diaphragm valves were previously not considered due to flow restriction. Considerable energy savings can be achieved in applications where pressure drops across valves mean a larger load on the pumps.

The Type 514's new design also eliminates traditional bolts typically used to connect the top-works of the valve to the weir body. Instead, the top-works are threaded directly onto the body like a union, so there is no need to re-torque the metal bolts due to thermal expansion. Eliminating the metal bolts also removes a corrosive weak point that is often problematic in corrosive environments.

The Type 514 Series is available in sizes 1/2-inch to two inches in PVC, CPVC, PP, PVDF, and ABS. A variety of connection options provide users with the flexibility to incorporate the valves into many types of piping configurations. Options include union, flanged, and spigot for weld-in or cement-in piping systems.

A comparison between GF Piping Systems' new valve generation and conventional technical solutions under normal test conditions shows clearly how the design of diaphragm valves affects their flow rates. At least 100% better Cv values are the result.

Many applications have variable-frequency drive motors on their pumps. The pumps often work in conjunction with flow or pressure sensors to maintain a desired flow or pressure. When the current valves are replaced with the new less-restrictive valves, these systems can immediately take advantage of the increased flow. Pumps will automatically scale back and start using less electricity.

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Gladiator Admittance Pump Protection Switch
By Hawk Measurement
www.hawkmeasure.com

Hawk Measurement's Gladiator Admittance Pump Protection Switch is immune to buildup and suitable for a variety of production situations. The switch can be used in applications where pipe- or wall-mounting with minimal protrusion is required. It can also be used to detect the presence of liquids to ensure the pump will never run dry. The switch has immunity to buildup and monitors materials with a wide range of dielectric constants, so the system is applicable to a large variety of liquids.

Hawk has designed the unit to operate in tough industrial environments. It is simple to set up and calibrate and has excellent temperature stability. Several probe types are available to meet specific application requirements, and all types are resistant to product buildup. The Gladiator communicates using Modbus, HART, or Profibus protocols.

The instrument can monitor liquids applications in the petrochemical, food and beverage, and water and wastewater industries. The Gladiator can also monitor levels of dry powdered material for industries including cement, glass, pharmaceutical, mining and minerals, power generation and fertilizer.

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Model SLP25i Positive-Displacement Pump
By Mouvex, A Dover Company
www.mouvex.com

SLP25i is a positive-displacement vane pump with a sealless design, which means shaft sealing is not made by packing or mechanical seal. It features an all-316L stainless steel construction, with PTFE-encapsulated FKM o-rings. It provides a maximum flowrate of 110 GPM, can support a maximum of 174 PSI differential pressure, and can handle viscosities up to 278000 SSU. Larger pumps providing flows up to 440 GPM will be available towards end of 2010.

This pump is the first rotary positive-displacement pump that offers sealless operation without using a magnetic drive system. Shaft sealing is provided by a double-stainless bellows, which houses an eccentric shaft. By rotating, this shaft drives the bellows end in a rotating movement. This rotation is transmitted to the pump rotor shaft by a crank system. The sealless drive system cooling is provided by the whole flowrate crossing the bellows chamber and then driving it to the pumping chamber by a side tube. As such, cooling does not require diversion of part of the flow, which would reduce pump efficiency, or a separate cooling system, which would make the pump more complex to operate and maintain.

Application Note: This pump has been used on a polymer dispersion application at a chemical plant in Germany. The pump is located in the basement of the production building, and it has to push liquid up to the 7th floor (100-plus ft). Previous pumps employed for this application were equipped with a double-mechanical seal, and they showed seal leakage after only a few weeks operation, resulting in cleanliness and safety issues (flammable liquid). Furthermore, flow irregularities occurred due to variable pressure and viscosity. This magnetic drive technology was rejected by the customer after an unsatisfying trial.

Thanks to its sealless design, the SLP25i has solved the leakage issue, making the operation both cleaner and safer. In addition, it provides much more constant flow despite variable-discharge conditions. Finally, it simplifies the installation by eliminating the seal flushing system.

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PACE Hf - Maximum Flow Proportional Valve
By Parker Hannifin: Precision Fluidics/Fluid Control Divisions
www.parker.com

The PACE Hf is an ultra-high-flow proportional valve that couples low energy requirements with precise control. The valve's features are made possible through a patented Parker Advanced Technology Actuator built into the miniature-sized package. Unlike other solenoid actuator-operated valves, the PACE Hf generates little heat and operates reliably in over 100 million cycles.

The PACE Hf valve's wide controllable range (0.5 to 500 SLPM) and tight control (0.001 VDC increments) makes it a great fit for medical device applications, requiring low hysteresis and fast response, such as acute, sub-acute and non-invasive ventilators.

Because of the Parker Advanced Technology Actuator, the PACE Hf has precise control at both the top end and bottom end of the valve's flow capability. Compared to its peers, the valve is up to 10 times smaller and weighs only a fraction of what is currently on the market.

The PACE Hf also has an internal capability to operate as a closed loop control valve via a directly-mounted input sensor. The closed-loop capability allows for real-time pressure and flow control - a plus for applications requiring quick manual adjustments to flow and pressure rates.

The PACE Hf can deliver 180 SLPM while consuming less than one watt of power. Such minimal power requirements mean not enough heat can be generated to affect the valve's performance. As another advantage, the valve has been tested to perform reliably at over 100 million cycles, far more than the average actuator-operated valve.

Application Note: A ventilator manufacturer can utilize just one PACE Hf valve for a single platform of ventilators because of the valve's following characteristics:
1. Wide range of flow rates for neonates to adults with precise control rates throughout the performance range.
2. Miniaturized, lightweight package well suited for semi-portable devices that need to move with the patient and take up as little space as possible.
3. Low power requirements enable longer standby times when moving patients from surgery to ICU, as well as minimizing the battery size and weight in the ventilator.

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CorrTran AQUA Corrosion Monitor
By Pepperl+Fuchs
www.pepperl-fuchs.com

CorrTran AQUA is a complete low-cost corrosion monitoring solution specifically designed to meet the corrosion-monitoring needs of municipal and industrial water and wastewater treatment facilities. CorrTran AQUA continuously monitors water and wastewater processes for general and localized corrosion, enabling users to determine the effectiveness of their corrosion inhibitors and to detect and correct corrosion issues through upkeep and preventative maintenance before they become a costly problem.

CorrTran AQUA is rooted in field-proven technology that represents a truly revolutionary approach in corrosion monitoring by taking corrosion evaluation out of the laboratory and bringing it into everyday process control. CorrTran AQUA is sold as a complete kit that includes the main unit, a 100-PSI working pressure probe, 10 ft. interconnect cable, and steel or copper electrodes.

CorrTran AQUA transmitters use a new algorithm of the LPR (Linear Polarization Resistance), HDA (Harmonic Distortion Analysis) and ECN (ElectroChemical Noise) measurement for maximum corrosion monitoring accuracy. They also automatically calculate and update the Stern-Geary value (B-value) due to changes in other process variables to maintain maximum accuracy. At the completion of each measurement cycle, the respective corrosion rate and pitting value is calculated and made available to the plant personnel in the form of a 4--20 mA HART signal.

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MizAir Energy Savings Device for AODD Pumps
By Proportion-Air Inc
www.mizair.com

MizAir is an energy-savings device designed for use on air-operated double-diaphragm (AODD) pumps. It can save as much as 50 percent of the air consumed by AODD pumps, therefore using less energy. It operates as a "normally-open" two-way valve with a micro-controller that uses "fuzzy logic" to read where the pump is in its stroke and, using this information, determines when to close the valve and stop the air flow. It does this with little-to-no effect on pump output, fluid flow or flowrate. It requires no pump modification to install, just add 24VDC.

MizAir provides design engineers with significantly greater flexibility and efficiency when designing a system using AODD pumps. AODD pumps require a tremendous amount of air to operate. MizAir not only can save a company money in energy usage, it may also help reduce the load on the air compressor system, reduce the number and/or capacity of the compressors required, or increase output by running more pumps with the same compressor capacity. MizAir also allows the design engineer to consider using AODD pumps where they would normally have been excluded for their inefficiency.

Application Note: The MizAir has been installed in a number of facilities for a number of different needs. Many are simple compressor overload situations, where installing the MizAir on all pumps has reduced the load on the compressor to the point that compressed air expansion is no longer an issue. Others have installed the MizAir for simply saving money in the facility process from electrical savings, and still more have used the MizAir to increase capacity without increasing compressed air usage.

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Smart Stator Technology (SST) Progressive Cavity Pump
By seepex
www.seepex.net

Standard progressive cavity pumps are constructed with a single body metal casing held in place by tie rods, which holds the rotor and stator. Through time and use, these internal parts wear and need to be replaced. In the past, depending on the application, this could result in massive amounts of downtime. Piping might have to be removed, along with discharge valves and tie rods. Some worst-case scenarios might involve cutting the stator in half.

The four-segment Smart Stator Technology (SST) system was devised as a perfect solution to this problem. SST weighs about 1/10th of its original counterpart, making replacement of parts a one-man job. In the past, maintenance meant lifting piping, risking injury and machinery damage. The Smart Stator Technology (SST) was designed specifically to address the issue of cumbersome maintenance requirements. The end result provides reduced maintenance time, reduced weight (simplifying repair), and reduced cost of production, which also reduces spare parts cost.

The SST system enables easy removal of blockage, reduced maintenance issues, pump dismantling without removing piping, and no special tooling required. Retrofitting of SST is also offered as a turnkey service by seepex.

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SmartTrak 50 Series Mass Flow Controller
By Sierra Instruments Inc
www.sierrainstruments.com

The new Sierra Smart-Trak 50 Series features the most advanced 316L stainless steel platinum-wound capillary sensor technology, ensuring the very best mass flow control for nearly any clean gas. The sensor's small diameter minimizes environmental effects.

Sierra's unique patented LFE is truly linear, allowing for K factors that really work. This linearity also allows for calibration in the field. Unlike other OEM flowmeters and controllers, the 50 Series allows for zero and span/calibration in the field of the meter, so OEMs do not have to remove the 50 Series to send in a meter for calibration.

The 50 Series features a direct-acting control valve, which minimizes leaks while offering a 300-msec response time to setpoint changes at +/-0.25 percent repeatability.

Another difference between the 50 Series and other flow controllers is its modular design that allows for upgrades and changes in communication. To change the communication or add features such as a display, just add a new piggyback PCA.
Application Note: Solar photovoltaics (PVs) are arrays of cells containing a material that converts solar radiation into direct current electricity. Materials presently used for photovoltaics include amorphous silicon, polycrystalline silicon, microcrystalline silicon, cadmium telluride, and copper indium selenide/sulfide. Due to the growing demand for renewable energy sources, the manufacture of solar cells and photovoltaic arrays has advanced dramatically in recent years.

Physical vapor deposition (PVD), or sputtering, is commonly used for creating films of material on a substrate in the solar energy and semiconductor industries.
In the physical vapor deposition process, a negatively-charged electrode is slowly disintegrated by molecular bombardment. The PVD medium is typically argon because this gas generates sufficient momentum to free atoms from the target. In a vacuum environment, these free target atoms deposit themselves on the surface of the material and form the desired coating or plating.

Maintaining a specified gas mass flowrate to the vacuum chamber is critical during the PVD process. Typically, vacuum pumping stations require a throttle valve or orifice-limiting device to control the pump's output when the PVD gas is introduced. This method is extremely pressure-sensitive and can result in inefficient gas delivery and poor product quality.

Sierra's 50 Series automatically compensates for changes in system pressure (vacuum pump fluctuations) or loss of pressure from the gas source (cylinder depletion). The 50 Series also delivers precisely-controlled gas mass flowrate to the vacuum chamber to maintain high-quality end product.

The economy, simplicity, stability and performance of the 50 Series make it the photovoltaic industry's instrument of choice for the PVD sputtering process.

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SSC (Sanitary Subcooled Condenser)
By Steriflow Valve, A Division of Jordan Valve
www.steriflow.com

The SSC (Sanitary Subcooled Condenser) is a finned, sanitary, condensate-collection chamber and steam trap assembly that was created to solve two common problems of biopharmaceutical customers regarding SIP (Sterilize in Place) Condensate drainage - SIP delays caused by temperature sensor faults; and tubing design space limitations.

The finned-chamber geometry of the SSC offers the best available technology for ensuring uninterrupted sterilization, while offering a more economical alternative (regarding space utilization and capital costs) to conventional downcomber designs.

The finned SSC eliminates the need for 12-18 inches of downcomber between the sanitary trap and SIP temperature sensor, replacing it with a compact, condensate-to-air heat exchanger. The compact design reduces that downcomber length to less than 2.5 inches, while providing the holding capacity of six feet of traditional ¾-inch sanitary tubing. It more than doubles the effective heat transfer area of the traditional downcomber and provides a means for better convective cooling. Cooler condensate contracts the steam trap's thermostatic bellows element, which expedites drainage, further minimizing the probability of SIP sensor wetting. Key product features include:
• Dramatic reduction in installation space requirements allowing for more compact installations
o Process skid height can be reduced up to 15 inches
o Proper SIP drainage can be fitted under equipment that is mounted close to the floor
• Decreases total SIP cycle time, increasing bio equipment asset availability
o Practically eliminates the possibility of temperature sensor faulting due to sensor condensate wetting during SIP
o Improves condensate drainage during SIP heat-up, expediting total SIP cycle time
• Total Installed cost savings are about 10 percent less than traditional, stick-built downcomber installations
o Eliminates cutting, welding, bending, and polishing required for traditional tubing downcombers.
o Purchasing, inventory and handling reductions because the thermowell, downcomber and trap come preassembled on one purchase order

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CONTAINMENT

LKS High PV Seal
By Bal Seal Engineering Inc
www.balseal.com

The LKS High PV Seal is a multi-component seal consisting of Bal Seal's Canted-coil spring-energized, graphite-reinforced PTFE sealing ring coupled with a high-temperature engineered thermoplastic anti-extrusion element and a metal locking ring. By providing up to 150 percent longer service life in critical high-pressure/velocity oilfield applications (as compared with an equivalent single material short-lip seal), the LKS Seal can dramatically reduce equipment downtime. It offers protection against leakage, and allows for greater predictability of maintenance intervals. It is designed to replace costly mechanical seal assemblies, and can be retrofit to replace other less-efficient seal types.

The LKS Seal incorporates an anti-extrusion element. Under high pressure and surface velocity, this guards against extrusion of the seal jacket material by supporting it with little or no clearance between the seal and rotating shaft. The seal's design forces the wear of the jacket material to take place at the lip contact point.

Progressive pump and pump systems rely on seals to protect costly bearings from damage and contamination. In these applications, the LKS creates a barrier between the harsh mud, sand, oil, H2S, water and other contaminants that may impede or prohibit the operation of the bearings, motor and other critical components. The LKS Seal also helps guard against adverse environmental impact by minimizing the possibility of external leakage.

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Flowserve ISC2 Series Cartridge Mechanical Seal
Flowserve Corp, Flow Solutions Group
www.flowserve.com

The Flowserve ISC2 Series is a family of standard cartridge mechanical seals designed to meet international standards and fit hundreds of pump models from global manufacturers across a variety of industries and applications.

Flowserve ISC2 seals feature patent-pending thermal management technology that tolerates short-term dry-run events without overheating, increasing reliability and preventing a common cause of leakage. Dual seals feature enhanced barrier fluid circulation for the highest flowrate and coolest running when compared to other standard cartridge seals in the industry. Single seals include a sizable throttle bushing to help protect against leaks.

ISC2 seals meet all major international standards, and ISC2-682 seals help users align their standardization programs with the sealing industry's most comprehensive best-practice standard: API 682/ISO 21049.

ISC2 seals are available in a wide range of materials for the best corrosion resistance against aggressive media. Seal chamber specifications from around the world, including ASME B-73, EN 12 756, JIS and ISO 3069, fall within the design scope of ISC2 seals.

Application Note:A paper industry customer has employed ISC2 seals in two 69 percent dissolved solids red sulfite liquor applications where hot acid and condensate water are used for cleaning the pump and piping. In this application, a one-to-two-hour clean-in-place (CIP) process follows a four-to-six-hour batch operation.

During the CIP process, the pump cavitates, often leading to seal failure for any seal designs previously used. Historically, seals in this application have averaged two months between failures.

The customer installed 1.75-inch ISC2 standard bore and enlarged bore dual-pusher seals, which are still operating without leakage more than one year later.

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Garlock Style 212-ULE Valve Stem Packing
By Garlock Sealing Technologies
www.garlock.com
www.212ULE.com

Style 212-ULE is a valve stem packing seal made up of two unique types of graphite-braided packing. It uses a "B-A-B" configuration. There are four "B" packing rings, with a single "A" ring in the middle. The "B" rings are manufactured from a proprietary yarn consisting of high-purity GRAPH-LOCK contained by an INCONEL* filament jacket. This INCONEL wire filament is 0.004-inch diameter, making the finished braid non-abrasive to valve stems and thermally-conductive. The center "A" ring is braided graphite fiber-reinforced flexible graphite yarns and graphite filament yarns. Style 212-ULE is self-lubricating, non-hardening, dimensionally stable and impervious to gases and fluids.

Style 212-ULE's materials incorporate a dual-acting corrosion inhibitor system designed to eliminate stem and stuffing box corrosion. A phosphorous inhibitor system and micro-particle zinc powder is applied to the product to insure corrosion resistance.

The packaging is a functional dispenser featuring a low-level indicator to warn the user that more material will be needed and a carrying handle. Bright orange tags with wire are included to cue the installer to re-torque the valve's gland bolts three days after installation, thus ensuring the best emissions performance. All product packaging is recyclable and environmentally-friendly.

Testimonials: Low emissions in a hydrocarbon or chemical processing plant are in compliance with regulations and consent decrees, resulting in elimination of fines and costly repair events.

A valve service company in the Gulf Coast region installed this product and immediately commented on how much easier it was to stroke the valve. "We won't have customers damaging valves trying to open them or getting hurt trying to actuate the valves anymore," was a statement that was made. A refinery in California stated, "The matrix on the box tells us how many valves can be repacked, and that is a big time saver for us when planning an outage."

* Trademark of Inco Alloys International, Inc

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Voting for the 2010 Innovation Awards is CLOSED - THANK YOU!