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January 2013

SOLUTIONS FOR THE PROCESS INDUSTRIES

Valves & Actuators


Electric Modulating Actuators
Electric modulating actuators in Rotorks new CMA series are suitably
sized for linear, quarter-turn and rotary control valve and pump applications requiring precise position control and continuous modulation. They
can be powered by single-phase or direct current supplies, eliminating
the need for the air hoses and compressors used with pneumatic control
valve actuators. Setup and configuration is easy via pushbuttons and
an internal, six-segment LCD display. Resolution is 0.25% on linear and
quarter-turn applications and 2.0 degrees on the multi-turn configuration.
Other features include a permanently lubricated and maintenance-free
drive train; a 4-to-20 mA loop-powered feedback signal; and digital communication options including HART, Foundation Fieldbus, Profibus,
Pakscan, RIRO and Modbus. For more information on valves &
actuators, turn to page 34.

Rotork Controls, Inc.


www.rotork.com
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Featured Article
Large volumes of ethane obtained as
a by-product in shale gas production
have changed the cost position of North
American cracker operations from an inferior rank to second best. Natural gas is
changing the process industry landscape,
leading analysts and consultants to categorically conclude that the U.S. chemical
industry is back. Read more on page 12.

Weighing Systems Standardize Batching and


Filling Operations
In 2009, Rice Lake Weighing Systems acquired the Santa Rosa,
Calif-based FlexWeigh Div. of Enduro Systems. Since then, Rice
Lake has been busy supporting the brands existing product lines
and engineering a new generation of the popular FlexWeigh
DWM-IV. As FlexWeighs replacement for the DWM-IV Series,
Rice Lakes 920i FlexWeigh Systems are pre-engineered and preprogrammed for many of manufacturings most common weighing
tasks. For more information on weighing & feeders, turn to page 40.

Rice Lake Weighing Systems


www.ricelake.com/920iFlexWeigh
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www.ProcessingMagazine.com

Featured Columnist
The natural gas being exported from Australia
is of the conventional, and not the shale, sort.
But transported as liquefied natural gas (LNG),
its use is set to transform the regional economy
and is already resulting in on-going megaprojects, including the Gorgon project and LNG
plants expected to produce 15.6 million metric
tons of LNG per year. Its all about meeting
energy demand in Southeast Asia, and for flowmeter makers the question is, Whos gonna measure all that?
To read flowmeter expert Dr. Jesse Yoders column, turn to
page 28.

Bulk Bag Conditioning System


Discharging bulk bags containing material that has
solidified, hardened or agglomerated can cause serious operational bottlenecks. Conditioning and emptying bulk bags can be dangerous if the right equipment
isnt used. A new, patented system uses hydraulically
actuated, twin heavy-wall tubular-steel pivoting conditioning arms. Each conditioning arm features v-shaped tubular steel
breaker profiles that safely and efficiently return solidified materials to a
free-flowing state. For more information on powder & bulk solids, turn
to page 44.

Material Transfer & Storage


www.materialtransfer.com
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Guided Wave Radar


Technology
VEGA introduces the latest innovation
in guided-wave radar technology, the
VEGAFLEX 80 Series. The unit has sensors
specifically designed for measurement of
liquids or solids, as well
as for hygienic and
high temperature/pressure environments. For
liquids measurement,
level and interface measurement are available
from a single sensor.
Perhaps the most innovative feature of the VEGAFLEX 80 Series is
the user interface. Because one of the most
important aspects of providing a reliable
level measurement is ensuring the sensor is
properly configured, VEGA has introduced
a new guided setup procedure that makes
commissioning simple and safe.

VEGA Americas, Inc.


www.ohmartvega.com
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In This Issue
12 US chemicals industry again globally
competitive
Natural gas as fuel and feedstock; demand growth from emerging
economies.

18 Plastic connectors: Many factors


weigh in when choosing the right
ones
Metal connectors continue to be supplanted in many industrial and
laboratory applications.

22 Larger Coriolis mass flowmeters


take center stage
A brief discussion of measurement needs and practices in North
Americas oil and gas industry.

Productivity Perspectives

Industry Briefs

32 Valves
40 Weighing & Feeders
42 Filtration/Separation
44 Powder & Bulk Solids
46 Info Center
47 Classifieds
48 Index

January 2013www.ProcessingMagazine.com

January2013 volume26,number1

28 LNG: key to supplying Asia Pacific


energy needs
Australia uses about half the natural gas it produces and exports
the rest in the form of liquefied natural gas.

38 Industrial-grade computer peripherals:


more than just a NEMA enclosure
Rugged internals and components keep joysticks, mouse pointers
and keyboards from breakdown in harsh, messy environments.

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Productivity Perspectives
Dual capabilities, four business segments and
many global macro trends
R&D today isnt about white coats. Its about
working with customers, Ashish Kulkarni, Dallasbased Celanese Corp.s recently appointed chief
technology and innovation officer, says. But,
Kulkarni adds, you need to go beyond the bromide of listening to your customer.
Customers focus on their most immediate
challenges, Kulkarni says. We need deeper
engagement than that.
Kulkarni will continue leading Celanese R&D
efforts for advanced engineered materials and
emulsions, but hell take on additional duties
to accelerate collaboration across four business segments to enhance dual capabilities in
technology-enabled chemistry and customeroriented solutions. Capabilities address global
macro trends including environmental concerns,
resource scarcity, the growing middle class and
safety, health and wellness. Mark Rohr, chairman
and CEO, says. In 2011, the companys revenues
were around $6.8 billion.
An example of technology-enabled chemistry and customer-oriented solutions is found
in a Celanese study that won best paper at the
recent Society of Plastic Engineers Automotive
Composites Conference and Exhibition.
Interest in use of polymer composites by transportation OEMs is growing, the paper notes, so
suppliers of polymer composite materials are
working to improve thermo-mechanical performance, increase processing speeds, reduce part
mass and costs, enhance surface aesthetics with
fewer post-mold operations and generally make

it easier to position composites against high


strength steel and aluminum.
While carbon fiber-reinforced plastics (CFRP)
regularly receive auto industry attention for
their high-tech glamour, lightweight stiffness
and strength, cycle-time constraints and fiber
availability make these materials pricey. One
alternative is to increase stiffness and strength in
workhorse composites like glass-reinforced polypropylene.
Here, with the switch from customer solution
to chemistry, it starts to get sticky. But a typical
means for improving composite performance
would be by an increase in retained fiber length
and fiber-volume fraction as well as by using
fibers in a more intelligent manner.
The tailored D-LFT process for compression
molding composites was developed for the automotive industry in Europe. The study details how
a tailored D-LFT process might be used to boost
the mechanical properties of D-LFT composites.
Asked to name several larger trends impacting
Celanese materials science, Kulkarni first alludes
to the 20th centurys most significant technology
development, the computer. He says its the ability to model complex processes, combinatory
chemistry and the amount of information available from customers today, which really makes a
difference.

KevinParker,EditorialDirector
kparker2@grandviewmedia.com

SOLUTIONS FOR THE PROCESS INDUSTRIES

Group Publisher, MikeWasson


Ph: 973-539-7715, Email: mikew@grandviewmedia.com
Editorial Director, KevinParker
Email: KParker2@grandviewmedia.com
Managing Editor, NickPhillips
Email: nphillips@grandviewmedia.com
Associate/Web Editor, ChristyUnderwood
Email: christy@grandviewmedia.com
Art Director, JamesArmstrong
Email: jarmstrong@grandviewmedia.com
Marketing Manager, MaryBethTimmerman
Email: marybeth@grandviewmedia.com
Advertising Sales Assistant, CookieRayford
Email: cookie@grandviewmedia.com
AdministrativeTeam:
General Manager, BarryLovette
Vice President of Operations, BrentKizzire
Vice President of Marketing, HankBrown
Vice President of Finance, BradYoungblood
Group Director of Circulation & Fulfillment, Delicia Poole
Circulation Manager, AnnaHicks

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Reader Advisory Board


RobertJ.Bockserman,President, Conatech
PeterS.Cartwright,President,
Cartwright Consulting Co.
BarryCharnay,President & CEO, Whisper
Ingredients Inc.
KenDelafrange,President, Jadee Inc.
DonGraham,President, Graham Sanitary
Design Consulting, Ltd.
StanleyHerzog,President, Princeton
Process Technology Consultants
B.GeorgeKniazewyz,President, Renovare
EricLanger,President, BioPlan Associates
EdMarshall,President, Maintenance
Management Technologies
JohnStansield,Plant Manager,
Accelerated Curing Inc.
Dr.JesseYoder,President, Flow Research
RobertM.Donnelly,Vice President of
Marketing, Flo-Tite Valves & Controls

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Industry Briefs
Sasol commences FEED phase for $21 billion Louisiana gas-to-liquids facility
LAKE CHARLES, La. South African-based energy and chemicals company, Sasol, says it will proceed with front-end engineering and design
(FEED) phase for an integrated, 96,000 bbl/d gas-to-liquids (GTL) facility
and a world-scale ethane cracker with downstream derivatives, at its Lake
Charles site in southwest Louisiana.
At a media conference with Louisiana Governor Bobby Jindal, Sasol CEO
David Constable said there is significant opportunity to benefit from abundant gas reserves in the U.S. by leveraging Sasols GTL experience and
technology. Sasols GTL process diversifies the use of natural gas through
the production of liquid fuels and chemicals.
By incorporating GTL technology into the USAs energy mix, states such
as Louisiana will be able to advance the countrys energy independence,
through a diversification of supply, said Constable.
This project will be the largest single manufacturing investment in the
history of Louisiana and it also represents one of the largest foreign direct
investment manufacturing projects in the history of the entire United
States, said Governor Jindal.
The GTL facility, said to be the first of its kind in the U.S, will produce four
million tons per annum (mtpa), or 96,000 bbl/d of high quality transportation fuel, including GTL diesel and other value-adding chemical products.
Current project costs for the GTL facility are estimated between $11 billion and $14 billion. The GTL project will be delivered in two phases, with
each phase comprising 48,000 bbl/d. The first phase is planned to come
into operation in the 2018 calendar year and the second phase the following calendar year.
The world-scale ethane cracker, Sasol says, will allow it to expand its ethylene derivatives business in the U.S. The cracker will also benefit from the
current low U.S. natural gas prices and the abundance of ethane.
Current cracker project costs are estimated between $5 billion and $7
billion. Sasol expects beneficial operation to be achieved during the 2017
calendar year. It will produce an estimated 1.5 mtpa of ethylene with
downstream derivative plants.
The integrated GTL and ethane cracker projects will, Sasol estimates,
together, create a minimum of 1,200 permanent positions, 7,000 construction jobs at peak and thousands of indirect jobs both in Louisiana and in
the rest of the U.S.

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January 2013www.ProcessingMagazine.com

Dow delineates long-term strategy


MIDLAND, Mich. At its 2012 Investor Forum, The Dow Chemical
Co. shared with investors strategic interventions and key catalysts that
will enable Dow to achieve near-term targets and drive sustainable earnings growth.
We have built a more simplified organization concentrating only on
those things that increase cash flow, improve return on capital and drive
earnings growth, said Dow Chairman and CEO Andrew N. Liveris.
During the event, Liveris presented several key drivers that will fuel
Dows near-term earnings growth:
Dow says it has deployed $2.5 billion of aggressive measures in 2012.
These actions are expected to deliver $1 billion in cost and cash interventions in 2013, of which $500 million will impact EBITDA. With nearly 40
project cancellation and plant shutdowns announced this year, the company is taking swift steps to improve asset utilization, drive down structural
costs particularly in Europe and enhance return on capital.
The company says it remains on schedule to restart its St. Charles
Operations ethylene cracker, which is expected to deliver a $150 million
increase in EBITDA in 2013. Taken on the whole, Dows U.S. Gulf Coast
investments in ethylene and propylene integration, coupled with favorable
shale gas dynamics, are expected to deliver $2 billion in additional EBITDA
in 2017. The company also reaffirmed that its Sadara joint venture remains
on track, with an anticipated construction workforce peak of about 60,000
people next year, and operations slated for start-up in 2015.
CEOs see emerging nations surge as U.S., Germany and Japan face
changing game
WASHINGTON Over the next five years, 20th-century manufacturing stalwarts like the United States, Germany and Japan will be challenged to maintain their competitive edge against emerging nations such
as China, India and Brazil, according to the 2013 Global Manufacturing
Competitiveness Index from Deloitte Touche Tohmatsu Limiteds Global
Manufacturing Industry group and the U.S. Council on Competitiveness.
The Index confirms that the landscape for competitive manufacturing
is in the midst of a massive power shift based on an in-depth analysis of survey responses from more than 550 CEOs and senior leaders at

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Industry Briefs
manufacturing companies around the world.
The Index lists the United States as the worlds third most currently competitive manufacturing nation, but ranks it fifth just five years from now,
only slightly ahead of the Republic of Korea. The three other developed
nations currently in the top 10 also fall in five years: Germany drops from
second to fourth place, Canada slides from seventh to eighth place and
Japan drops out of the top 10 entirely, falling to 12th place.
America and Europe have continued to watch emerging markets mature
and become formidable competitors over the past decade, said Craig
Giffi, vice chairman, Deloitte LLP and consumer and industrial products
industry leader, who co-authored the report and lead the research team.
Giffi points out that in five years key emerging nations are expected to
vault forward in the Index: Brazil jumps from its current eighth place slot
to third place and India jumps from fourth to second place. China remains
firmly in first place.
Brazils processed plastics industry losing ground to imports
SAO PAULO, Brazil Brazil is seeing growing domestic demand
for plastics, but the industry there is finding it impossible to meet the
increase. The country is therefore relying on imports to provide feedstock for the required plastic products, with China emerging as a leading
supplier, the PlastEurope website reports.
In 2011, the Brazilian plastic processing industry reported a modest
1 percent growth to 6.5 million tons output. This proved insufficient to
match the 2.3 percent rate at which demand increased, reaching 6.89
million tons of processed plastics. While presenting the annual industry

report for last year, Jos Ricardo Roriz Coelho, president of Brazils plastics industry association Abiplast, warned that domestic producers risk
being pushed out of the market by foreign manufacturers.
Other figures that Roriz Coelho cited from the report for 2011 confirm his concerns. Brazils exports of plastics feedstock went down 13.5
percent to 268,000 tons, compared to a 7.1 percent growth in imports,
which came in at 660,000 tons. In addition, the total value of foreignmade plastics reached $3.39 billion, a 20 percent rise on the previous
year, compared to a 2.7 percent increase in export value, which came
in at $1.51 billion. As a result of this market development, Brazils trade
deficit for processed plastics soared by 37 percent to $1.88 billion.
The outlook for 2012 does not foresee more optimistic results for the
domestic industry, PlastEurope says. Between March and September
2012, exports of processed plastics shrank 13 percent to 137,000 tons,
whereas imports rose by 8.2 percent and reached 392,000 tons. Similarly,
the total value of imports continued to grow over the period and
reached $2.03 billion, a 7.6 percent increase, while the export value fell
by 9.3 percent to $792 million.
The processing industry in Brazil depends on feedstock coming from
China and Asia in general, which accounted for a third of the total
imports up to September. The second most important supplier of plastics
was the European Union, accounting for 23 percent of the imports, followed by Latin American countries and the United States, which provided
19 percent and 16 percent of the imported plastics, respectively.
Roriz Coelho singled out several factors that contributed to the poor
performance of the local plastics industry. One of the reasons is the

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10

Industry Briefs
slowdown in Brazils GDP growth, with readings dropping sharply from
7.53 percent in 2010 to 2.73 percent in 2011. The International Monetary
Fund expects this to fall further to 1.47 percent this year. Other purely
internal factors, such as high operating costs, poor infrastructure, bureaucracy and corruption also have a negative impact on the industry, the
Abiplast president noted.
US to surpass Saudi Arabia as global oil production leader
LONDON The United States is likely to emerge as the worlds biggest oil producer by 2020, following a shale oil production surge that will
allow it to surpass Saudi Arabia, the International Energy Agency (IEA)
said in its just released annual World Energy Outlook publication.
The IEA said that the global oil market is going through significant
changes in terms of energy supplies and geopolitics. The U.S. is set to
lead the way in oil and gas production over the coming years, the IEA
added, contrasting with its own prediction from last year, which saw
Saudi Arabia and Russia as the top contestants for the trophy.
The U.S. has reduced the volume of oil imported over recent years
and it now accounts for about one-fifth of the nations needs. Over the
next 10 years imports will drop by more than half, from the current 10
million bpd to about 4 million bpd. At the same time U.S. oil exports are
expected to increase, as domestic production booms, the IEA claims.
The main factor that has contributed to the recent boost in oil production is the unexpected rapid development of hydrocarbon resources
from tight rock formations like shale, which are currently being extracted
through a combination of hydraulic fracturing and horizontal drilling.

The IEA prediction chimes in with the recent acknowledgement from


the Organization of the Petroleum Exporting Countries (OPEC) that its
exports to the United States are likely to decline due to the development in shale oil production. By 2035 OPECs exports to the U.S. are
predicted to drop by nearly two-thirds, to less than 2 million bpd, the
organization has estimated.
Furthermore, the IEA says that the U.S. will effectively need no oil
imports from the Middle East and this might have an impact on military
alliances. As Asia is expected to account for 90% of the Middle East oil
exports, OPEC will increase its global share from 42% to 50% by 2035
and Asian countries will have the primary interest in maintaining political and economic stability in the region, explains Richard Jones, deputy
executive director at the IEA.
Nevertheless, the IEA notes that the U.S. is not likely to remain the
worlds largest oil producer in the long run. According to Fatih Birol, the
IEAs chief economist, Saudi Arabia is likely to return to the top if no new
U.S. resources are found over the next few years and global oil prices fall
from their current levels.
Correction: In Processings December 2012 coverage of the
Breakthrough Products award winners, we wrongly identified the headquarters of Camfil Farr APC. The company is actually headquartered in
Jonesboro, Ark., and it is the team there that was responsible for development of the Integrated Safety Monitor Filter (iSMF).

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US chemicals industry again


globally competitive
Natural gas as fuel and feedstock; demand growth from emerging economies
By Kevin Parker
Its all a matter of vocabulary. First the word shale entered the daily
water-cooler discourse, along with horizontal drilling and fracturing.
It wasnt long before large swaths of the American public realized the
natural-gas energy revolution was on.
In the next phase, growing numbers will become aware that shale gas,

used as both feedstock and fuel, gives the North American petrochemical industry a big advantage. Cable news and business sections will point
out that new found quantities of ethane, which comes out of the ground
along with the natural gas, are causing corporations and local governments to engage together in groundbreaking and ribbon-cutting ceremonies.
Large volumes of ethane obtained as a by-product in
shale gas production have changed the cost position of
North American cracker operators from an inferior rank to the
second best, topped only by operators in the Middle East,
says Prof. Rainer Dierks, president of the petrochemicals division of industry giant BASF, in an online interview conducted
at ACHEMA 2012.
Energy has always been a volatile commodity. Put in
motion by this dramatic shift in natural gas supply, idled
plants are being restarted in North America, and units are
being converted from naphtha to ethane use as cracker feedstock. Expanded capacity for production of ethylene, based
on ethane and a core petrochemical feedstock, has been
announced, as well as considerable expansion in downstream
capacity for products like polyethylene and ethylene glycol.
Further, this shift to lighter feedstocks causes a different product output pattern in steam crackers, Dierks says.
Using a large portion of ethane as cracker feedstock allows
production of nearly exclusively ethylene. Typical by-products
of naphtha crackers, like propylene or butadiene, are
Shale gas, used as both feedstock and fuel, gives the North American petrochemical industry a big advantage.

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14

Chemical Industry
produced in only small amounts in these ethane-based crackers.
The result, Dierks goes on to say, is a significant increase in propylene
and butadiene prices, leading to investments in on-purpose propylene
production.
Unfolding implications
But why is natural gas proving such a big advantage for North
America? After all, there are huge shale deposits outside the U.S. While
global companies and overseas governments are eager to drill, a Dec. 3
article in The Wall Street Journal suggests, significant delays are being
caused by governmental ownership of mineral rights, environmental
concerns and a lack of infrastructure to drill and transport gas and oil.

Marcellus Shale gas well site in northern Pennsylvania.

Its also the case that less is known about the geology in most foreign
countries than in the U.S. North Americas infrastructure includes a transportation pipeline network already in place and the ready availability of
drilling rigs. What it all means, experts say, is that significant overseas
shale energy production could be a decade away.

The U.S. has a top-notch supply base, one well accustomed to delivering world-class quality levels on time and
at agreed-upon prices.
Other reasons why a more general U.S. manufacturing renaissance,
encompassing both process and discrete manufacturing industries, may
be imminent, are evoked in a June report by Accenture consultants Paul
Bjachek and Larry Oglesby, which notes, The U.S. has a top-notch supply base, one well accustomed to delivering world-class quality levels on
time and at agreed-upon prices.
The consultants say U.S. ethylene production could increase by as
much as 30% by 2017, and categorically state, Based on the current
trajectory of low and stable gas prices, the U.S. chemical industry is once
again globally competitive.
Widening ramifications
Natural gas accounts for between 24% and 30% of total energy consumption in North America. In India and China it is only 7% and 3%
respectively.
Of course, besides being a feedstock, natural gas is also a fuel and it

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Chemical Industry
makes up about three-quarters of the energy used by the chemical industry in the U.S., excluding pharmaceuticals, Accenture says. Overall, aside
from the energy industry itself, chemical production has by far the highest
energy intensity of all other industries.
Natural gas prices used to rise and fall with those for oil and naphtha,
but the last several years their prices have diverged. One reason is difficulties in transporting natural gas, making it less expensive the closer to
the source the buyer is. A similar split is occurring downstream as chemical companies that make greatest use of natural gas find a competitive

Overall, aside from the energy industry itself, chemical


production has by far the highest energy intensity of all
other industries.
advantage, while other chemical industries still dependent on high-priced
oil struggle with high energy costs and lumpy demand.
Still further downstream, the chemical industry is said to touch 90%
of manufactured goods, making goods makers the largest consumers
of chemical products. The result, say
Accentures Bjacek and Oglesby, is that
executives in a number of high-valueadded industries, such as chemicals
and automobile production, are seeing
compelling reasons to make products in
[North America] again that trump trying
to capture low labor costs.
Coins other side
The chemical industry has been growing for the last five decades, according
to Zacks Equity Research, most especially
production of synthetic polymers used as
plastics, fibers and elastomers. The industry also had a strong recovery from the
2008 recession.
As this issue of Processing magazine
goes to press, the Dow Chemical Co.,
which has announced its own $4 billion
investment plan in petrochemical plants
in Texas and Louisiana, has calculated
the total value of announcements in shale
related investments at $90-billion plus,
says the Financial Times.
Reports indicate that the price of ethane has fallen in the U.S. from about 80
cents per gallon at the start of the year to
less than 23 cents a day.
Further, since the start of 2010, industrial production is up 12% in the U.S., while
it has fallen 2% in China.
Yet apart from the high hopes and
significant investment engendered by
the natural gas boom, and the potential
for North America to take market share
away from other global regions, the U.S.
chemicals industry is projected to experience only moderate growth the next
several years, according to the American
Chemistry Council (ACC).
It is a $720 billion industry that contributes 26% of U.S. gross domestic product,
with output expected to rise about 2% in
2013. Earlier this year, the ACC said the
immediate prospect is for slow growth
with improvements in investment spending and residential investment as bright
spots. Capital spending in the business of
chemistry will reach $35.5 billion in 2012,
rising to $51.5 billion in 2017, while longer
term the industry will continue to grow
faster than U.S. GDP, based on increasing
exports.

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Plastic connectors: Many


factors weigh in when
choosing the right ones
Metal connectors continue to be supplanted in many industrial and laboratory applications
By Riley Phipps
Diverse challenges confront industrial and laboratory original equipment manufacturers (OEMs) in developing versatile, user-friendly, lightweight and cost-effective equipment and instrument solutions. One
important, but not always fully appreciated, task is selecting tubing connectors for transfer and management of fluids and gases, particularly for
mission-critical applications.
For many applications, plastic tubing connectors continue to supplant
those made of metal, not only for design flexibility, improved ergonomics,
reduced weight and lower cost, but also for their ability to meet stringent
industry standards in diverse and harsh environments. Many plastic connector features, long proven in critical medical equipment applications,
are being integrated into a broad spectrum of industrial equipment and
laboratory instruments.
Choosing the right plastic connector can be a challenge, with more
options for material selection, user interface and custom design than
metal connectors. A basic understanding of the options available can
support specification of the most optimized
features, leading to peak equipment or instrument performance.
Plastic conical or taper seal
connectors, called luers,
can link various industrial
and laboratory system
components.

Application driven
While plastic connectors fill many roles,
they arent suitable for all laboratory and
industrial uses. Brass, aluminum, die-cast zinc
and stainless steel connectors are right for

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January 2013www.ProcessingMagazine.com

extreme durability and high-performance fluid handling, particularly when


influenced by high pressures and temperatures. Choosing the ideal connector calls for a careful application assessment. Prime factors to consider
include the following:
Temperature range minimum and maximum temperature tolerances
within which the connectors need to function. Depending on connector material, temperature tolerances can range from -40 F to 200 F and
above;
Pressure range determining minimum, maximum and working pressures the connectors are expected to tolerate;
Flow rate required volume per minute, and the effect of fluid pulsation and modulations from connect and disconnect forces;
Media the viscosity, sensitivity and corrosiveness of the fluid or gas
moving through the connection;
Exposure degree of impact from external
or internal conditions, such as UV, wind, dust,
vibration, radiation, gases, water submersion,
chemicals, cleaning agents or mechanical stress;
Specialized environments for food and
pharmaceutical grade manufacturing, including
The MQC Series plastic quick wash-down, clean room, aseptic environments
connect from Value Plastics
and vacuums;
provides a wide selection
User interface level of human contact
of color-coding options for
expected
with the system and connectors; and
ease of maintenance and to
prevent misconnections.
Cycle life anticipated maintenance and

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19
changeability required for the system, and
expected operational longevity.
Once identified, the application requirements
then determine what materials are best suited
for the connectors.

In addition, PTFE is fluoropolymer-resistant


to most chemicals and solvents, with stability at
high temperatures. Once the connector material is determined, the type of connection best
suited to the need can be picked.

Plastic connector materials


Plastic connector material is chosen based on
mechanical requirements and the media type
moving through the system. Significant pros
and cons need to be weighed. Properties such
as toughness, ductility, impact strength, transparency, lubricity, temperature capability, ozone
resistance and UV compatibility may all come
into play.
The media is critically important, given that
fluid or gas flowing through a connection can
affect its strength, surface appearance, color
and performance. And, conversely, the wrong
connector material can adversely impact the
media. Chemical compatibility need be considered and the most appropriate plastic resin
chosen.
When made
from high-purity
resin materials for
use with aggressive
chemicals, plastic
connectors offer
Plastic tube to tube connec- broad compatibiltors are a popular choice
ity. Many are manufor applications that do not factured from virgin
require the disconnection
resins, with accomof equipment or parts at
any point during production panying certification
of lot traceability.
or use.
Plastic resins across
a broad spectrum are used for connectors, each
with characteristics to match specific application
needs. Some thermoplastic resins commonly
used for connectors include:
Polyethylene chemically resistant, translucent or opaque, with low-temperature impact,
to withstand a variety of application environments;
Polycarbonate hard, transparent and with
moderate chemical resistance, provides good
impact resistance and superior dimensional
stability;
Polypropylene soft, highly resistant to
chemical attack from solvents and chemicals in
harsh environments;
Polyamide (Nylon) versatile, with good
wear and chemical resistance, low permeability
to gases and performs well at elevated temperatures;
ABS tough, with good stiffness and impact
resistance even at lower temperatures, as well
as good dimensional stability and high temperature resistance;
Acetal strong, lightweight and provides
high strength and rigidity over a wide range of
temperatures; and
PVDF strong, with good ductility over a
broad temperature range, as well as excellent
chemical resistance.

Connection options
Connectors are meant to accommodate tubing of varying hardness, as would be measured
by a durometer, from soft and flexible like PVC,
silicone and C-flex, to semi-rigid types like polypropylene, polyethylene, polyurethane and ethylene vinyl acetate (EVA).
To facilitate these
varying styles of tubing, different connector types include
barbed connectors,
The selection of the barb
check valves, luer
style on both plastic and
connectors, quick
metal connectors is very
connects, threaded important to the connectors
luers and tube-totube holding capability.
tube connectors.
Of these, the most
commonly used tubing connectors are tubeto-tube, luers and quick connects. These basic
styles cover a wide range of liquid and air applications in laboratories and plants.
Tube-to-tube connectors are popular for
applications that dont require equipment
or parts disconnection at any point during
use. Tubing connectors are available in many
different configurations, sizes and material
options to adapt to different tube sizes or
styles, reroute the flow direction without kinking
and act as a manifold.
Delivery systems can employ conical or taper
seal connectors, called luers, to link various sys-

tem components. The male and female components of luer connectors join together to create
secure, yet detachable, leak-proof connections
with no O-ring or gasket required.
Luer connectors
come in a variety of
configurations, including for tube conPlastic connector technology
nections, threaded
affords designers and manufacturers a wide latitude of
connections (UNF,
NPT and metric) and flexibility, such as with this
latest generation of check
other luer or quick
valves.
connect terminations. Some of those incorporate a tapered
UNF thread, similar to a pipe thread, which can
also seal on the thread due to interference on
the pitch diameter, facilitating directional alignment with tees and elbows.
So-called quick connects allow flexible
tubing and equipment to be quickly and safely
connected and disconnected. This may be preferred over general connectors for fluid control
because they can incorporate built-in shut-off
valves that prevent spillage, allow multiple disconnections and faster servicing.
One of the newest and most versatile plastic
quick-connect solutions available for laboratory
and industrial applications, the MQC Series
manufactured by Value Plastics, a Nordson
Company, provides an intuitive push-to-connect
design. With its large, ergonomic buttons providing an audible click on connection and grips
for easy handling with gloves, combined with
a wide selection of color-coding options, the
MQC is unique for ease of handling and the
prevention of misconnections.
Many of the latest quick connect designs
focus on the user interface and are equipped

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Piping

20

with simple thumb-latch and side-latch mechanisms to make for easy handling in laboratory and industrial fluid management applications. Quick
connects mitigate the prospect of accidental misconnections and create
quicker and safer device connections.

One barb, or two?


Plastic barb-style connectors accommodate the widest possible range of
tubing properties and application conditions, including a multitude of configurations such as tees, Ys, elbows and
manifolds. Barb designs are available for
The latest plastic quick connect
designs can be equipped with in- handling assembly forces, tensile resistuitively simplistic thumb latch and tance and blow-off resistance, without
side latch mechanisms to make
the need for clamps.
for easy handling in laboratory
Barbs derive their holding capability
and industrial fluid management
by
expanding tubing above its nomiapplications.
nal inside diameter (ID), creating some
amount of interference for a secure seal and good mechanical retention.
The tube expansion can vary dramatically, from lower profile, easier connections to much more aggressive interferences, depending on the pressure and tensile pull requirements.
The selection of the barb style is very important to the connectors
tube-holding capability. The cylindrical surface behind the barb should
allow the tubing to relax against the connector. In choosing a barb style,
users should be sure the barb has a sharp peak, allowing it to bite into
the tubing for optimal retention.
Many plastic connectors and almost all metal connectors use a multi-barb,
making for an inferior tube connection and seal. Multi-barbs cannot create
a sharp bite on the tube, inhibiting retention, and do not allow the tube a
chance to relax behind the barb, also resulting in poor tensile pull strength.
The multi-barb manufacturing process leaves a parting line on the sealing surface, creating a potential leak path. This is an inherent design flaw,
yet all multi-barb connector designs, including metal connectors, display
this liability. In fact, many inferiorly crafted single-barb plastic connectors
are also afflicted with a parting line, reducing connector efficacy. A good
injection-molded connector has a singular barb with no parting line, a
sharp bite and a clean sealing surface.
Design optimization
Many factors reduce tubings ability to perform under pressure
including temperature, chemical degradation, mechanical stress, fluid pulsation, selection of connector type and barb design. The latest generation
of plastic connector technology affords designers and manufacturers wide
flexibility to design and set-up applications to fit their specific needs.
Compared to metal, plastic connectors offer a considerable reduction in
weight and much improved flexibility with regard to the equipment they
serve. Plastic quick connects allow rapid and easy servicing and maintenance
of assembly-line equipment, filling systems and packaging systems. The cost
difference between metal and plastic connectors is a major motivating factor in the embrace of plants and laboratories of plastic connectors.
Given demanding project requirements and timelines, precision fluid
management solutions are critical to achieve a high efficiency ROI. Plastic
connectors, particularly when custom designed for the application, are
becoming the preferred solution in industrial and laboratory settings.
Value Plastics Inc., a Nordson Co., manufactures and markets fluid management components designed specifically for flexible tubing and instrumentation. Riley Phipps is technical and design services manager there.

Value Plastics
www.valueplastics.com
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Larger Coriolis mass flowmeters


takecenterstage
A brief discussion of measurement needs and practices in North Americas oil
and gas industry
By Andre Verdone
Accurate liquids measurement is important for the oil and gas industry.
But its essential for bulk-transfer devices where large product volumes
are moved and monitored, including crude oil depots, gasoline and jet
fuel tank farms, refineries and even cruise line terminals.
Mass transfer has been measured in batches with weigh scales or load
cells. But their use is not suitable for continuous flow measurement.
For continuous processes, orifice plate and magnetic flow tubes can
measure volumetric flow, but other instruments are needed to measure
temperature and pressure to compensate for fluid density changes.
Additional instruments also introduce errors, resulting in an overall measurement error rate as high as 3.0%.
Several measurement standards are moving toward use of Coriolis
mass flowmeters, which can measure mass flow directly and at the same
time measure temperature and density. Whats more, mass transfer mea-

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surement is independent of, and unaffected by, changing process fluid


characteristics, including pressure, temperature, viscosity, conductivity
and gravity.
Among Coriolis devices available, the straight-tube design is the most
accurate and easiest to install and maintain. Especially for measurement
skids, widely used in the oil and gas industry, the straight-tube Coriolis
meter can be a factor in minimizing skid size.
From mechanical to Coriolis
Petroleum fluid flow has been measured fairly reliably using a wide
range of mechanical meters. One significant drawback is that mechanical
meters experience serious wear and tear, which leads to high maintenance costs and need for frequent replacement parts.
Also, mechanical meters must be calibrated on a single grade, making
recalibration, also known as meter proving, necessary each time a different product is measured. Custody system operators often need to use a
prover for measuring one batch to another, reproving for every different
fluid transaction.
Advances in manufacturing technology have led to larger Coriolis
meter sizes, making them viable for oil and gas applications that have
heretofore been the domain of mechanical meters. Coriolis meters have
no moving parts. Unlike mechanical meter measurements used for custody transfer, Coriolis meters measure product mass directly, independent
of pressure and temperature.
Direct mass flow measurement with Coriolis flowmeters means that
one flowmeter with a single point of measurement can obtain multiple
measured values, including mass flow and mass total, density and concentration, volume flow, volume total and temperature. It also reduces

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24

Flowmeters
overall costs, because only a single instrument is bought and maintained. Cable laying and power consumption are reduced, and controls
simplified.
Reducing pressure drop
Pushing fluids past a mechanical meter always creates a pressure
drop, which is not recoverable. Every time pressure drop is imposed, it
must be overcome with pump use, which adds equipment, cabling and
energy costs.
No extra pressure drop is experienced across a Coriolis mass flowmeter. Most meters have twin tubes, and the
only pressure drop is caused by splitting
the flow into the two pipes. A straightpipe Coriolis meter creates less permanent pressure drop than the bent-tube
variety.
Almost all operators using mechanical flowmeters
also run separate
pressure and temperature meters.

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Say the mechanical flowmeter exhibits a 0.5% accuracy error; the pressure meter also poses a 0.5% accuracy error; and the temperature meter
a further 1.0%. Combined in a flow corrector or computer, the overall
calculated error rate could be 2.0% or higher. Plus, since each instrument
independently drifts over time, accuracy is further degraded, perhaps to
as high as 3.0%.
The Coriolis meters error rate is only 0.1% to 0.2% of rate, making it
nominally five to 10 times more accurate than mechanical measurement.
Its long-term drift is minimal compared to devices with moving parts.
The straight-tube Coriolis meter takes up little space with simple process piping. The straight-tube design is easier to clean than the benttube version, which tends to get deposit buildup on the tube, and much
simpler than equivalent mechanical meters, which also require strainers
and upstream filters.
With a typical Coriolis mass flowmeter, operators view all fluid-related
parameters, including volumetric flow, mass flow, density and temperature. Most have options for multiple outputs, including digital converters that allow for direct MODBUS to all parameters. Available controls
ensure the correct product is going through the meter; verify product
is drawn from the right tank; and tell operators if product is hotter or
cooler than expected.

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26

Flowmeters
Ontario refinery experience
At one Ontario petroleum refinery site that produces refined gasoline,
jet fuel and other petroleum products, operators ship and meter product
through a 5-kilometer long, 8-inch diameter pipeline that connects to a
major pipeline delivering product to the greater Toronto area. Product is
measured leaving the plant site and going to the shipping pipeline, and
a density reading was wanted at the same time. Different products are
shipped through one line and the site needs to confirm correct product
shipment.

Management did not want to do a large-scale modification to install


additional structural supports for meters. Pressure drop through the
meter needed to be minimal to avoid increasing the cost of running the
pipeline.
The facility looked at ultrasonic, vortex shedding and orifice plate
meters, but ultimately chose a Coriolis mass flowmeter.
The straight-tube design offered lower pressure drop and was less subject to plugging. Most importantly, it was simpler to install and took up
less space than other available options.
Managers initially had reservations
about using a straight-tube design. Bent
tube is the more traditional choice and
has a larger installed base. However, they
chose a straight-tube OPTIMASS 2000
Coriolis meter from KROHNE, based on
lower installation costs, combined with
high accuracy and linearity.
The refinery can monitor the meter
remotely from a laptop. The meter sensor
has its own smart-sensor interface and onboard memory, so the electronic converter/transmitter talks digitally and directly
to the sensor.
While sharing device configuration
data, the two installed devices are remote
and segregated, so if there is a problem with either sensor or transmitter,
technicians can replace one or the other
independently. Sensor calibration files or
converter parameters can be uploaded
from either device, adding to the meters
reliability.
Custody transfer has a significant
impact on the bottom line, so precision and reliability are key requirements.
Todays Coriolis mass flowmeters can
compete with traditional mechanical
meters. For the bulk measurement of any
fluid with a significant value, large diameter Coriolis mass flowmeters offer more
accurate and repeatable bulk fluid transfer measurement. Further, straight-tube
Coriolis meters offer the lowest pressure
drop and highest accuracy.
Andre Verdone is a vice president and
technical expert with Krohne, Inc., a global technology leader in the development,
manufacture and distribution of accurate,
reliable and cost-effective measuring
instruments for the process industries. He
has spent the last 35 years working in the
water industry and has written and presented several papers around the world
on key issues related to improving the
operation, conservation and management
of water systems.

Krohne, Inc.
www.krohne.com
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LNG: key to supplying Asia


Pacific energyneeds
Australia uses about half the natural gas it produces, and exports the rest
in the form of LNG
By Jesse Yoder, PhD
(Editors note: Dr. Yoder is just returned
from an 11-day research trip to Australia,
where he delivered the keynote speech at
the November Flow Measurement & Control
Forum held in Perth.)
China and India tend to grab the headlines when it comes to economic growth in
Asia. But when it comes to energy, the entire
Asia-Pacific region is of extreme interest and
encompasses much more than can be contained within those two countries borders.
In fact, given the distinct cultures and diverse
political systems of the countries involved, the
regions characteristics arent easy to classify.
One way to do it is as follows:
China,theKoreas,andthecountriesof
Southeast Asia mainland;
Japanstandsbyitself;
TheislandsofthePhilippines,Malaysiaand
Indonesia;
AustraliaandNewZealand;and
Othersmallerislandsintheregion.
Theprimaryenergysourcesintheregionare
coal, nuclear, oil, natural gas and renewables.
It will take 20 to 30 years before renewables
count as a substantial energy source for most
ofthesecountries.Thetechnologyisnotyet
sufficiently developed for it to be price com-

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petitivewithcoal,oilandnaturalgas.Nuclear
energy has its dangers and coal is a significant
source of pollution, so many countries are
turning to oil and natural gas as their primary
energy sources. Between the two, natural gas
iscleanerandmoreplentiful.Thus,naturalgas
is increasingly seen as a long-term bridge to
renewables.
Energy challenges
Manyofthecountriesintheregionarechallenged when it comes to energy resources.
Theymusteitherproduceenoughenergyto
be self-sufficient or import what they cannot
produce. China is rich in coal, and still relies
heavilyonitasanenergysource.Japanhas
little in the way of oil or natural gas, and has
reliedonnuclearpowerandcoal.Nearlyallof
the natural gas and oil it uses must be imported.Naturalgasisimportedintheformof
liqueiednaturalgas(LNG).Chinaalsoimports
signiicantamountsofLNG.
Other countries in the region, including
Australia, are rich in natural gas. Yet transporting natural gas can be challenging. Over long
distances, natural gas is transported either by
pipelinesoraboardshipsasLNG.Pipelines
work within a country or regionally, but

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30

Flowmeters
typically not across the oceans expanses. Of course, natural gas pipelines can be buried under the water, as demonstrated by the natural gas
pipeline that runs under the Persian Gulf from Qatar to Abu Dhabi in the
United Arab Emirates (UAE). This pipeline supplies much of the natural
gas used by both the UAE and Oman.
Australia, both a country and a continent, sees an opportunity to be
a major natural gas supplier to the region. It has proved natural gas
reserves roughly equal to those of China.
Australia already has undertaken a large number of natural gas projects. The largest by far is the Gorgon Project, located off the west coast

of Australia. Construction of the Gorgon Project began in 2010. It is on


schedule to produce its first natural gas late in 2014. Once the project is
operational, it is expected that about three LNG shipments a week will
be loaded for export to Asian markets via a 1.3 mile jetty.
The primary participants in the Gorgon Project are Chevron Australia,
Shell Development Australia, and Mobil Australia Resources. Its current
estimated cost is $54 billion. The Gorgon and Jansz fields are located
about 130 kilometers, or roughly 80 miles, off the coast of Western
Australia. An LNG plant is being built on Barrow Island, conveniently
located between the natural gas fields and the mainland. This plant is
expected to produce 15.6 million metric
tons of LNG per year.
Conventional and not so much
While the Gorgon project is devoted to
producing what is usually called conventional gas, Australia also has a significant
amount of technically recoverable shale
gas about the same amount as Canada.
Because Australia is so rich in conventional
gas, developing shale gas has not been
a priority. However, in October 2012, the
first shale gas in Australia was pumped
from a well in outback South Australia.
Now that Australia has begun producing shale gas, it will undoubtedly become
a growing resource for this vast continent.
Australia uses about half the natural gas it
produces, and exports the rest in the form
of LNG.
Australia has many other natural gas
projects besides the Gorgon Project,
though none larger. And there are many
other natural gas fields throughout the
region. What is common to many of these
projects is that they involve shipping natural gas in the form of LNG. While there
are some pipelines in the IndonesianMalaysian region, sheer distance dictates
that much of the natural gas shipped in
this region will be in the form of LNG. In
the Asia Pacific it is one of the most promising growth opportunities that has ever
existed in the field of energy.
Natural gas has to be measured, especially for custody-transfer applications,
whether it is in the form of LNG or goes
by pipeline. This presents a major opportunity for flowmeter manufacturers. Both
McCrometer and GE Measurement have
brought out flowmeters designed specifically for LNG measurement. Look for other
flowmeter manufacturers to take advantage of this unprecedented opportunity.

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Jesse Yoder, Ph.D., is president of Flow


Research, Inc. (www.flowresearch.com), a
company he founded in 1998. He has 24
years of experience as an analyst and writer in process control. Dr. Yoder specializes in flowmeters and other field devices,
including pressure, level and temperature
products. He has written over 100 market
research studies in industrial automation
and process control and has published
numerous journal articles.

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Valves & Actuators


Easy maintenance characteristic of two-piece, reduced-bore
split-body ball valve
As an alternative to one-piece ball valve body designs, a
new split-body valve series with a two-piece bolted-body
design meets ANSI take-out dimensions for either a long full
port or short reduced port pattern.
Engineers typically discard larger, one-piece body valves
when seat failures occur. In many cases the equipment
required to repair a one-piece body design is not available. One-piece
body designs can have very finely threaded seat retainers, which tend to
cause galling, a problem only amplified when it comes to stainless steel
valves. Upgrading and converting a valve to have a metal seat, when it has
a one-piece body design, is expensive and time-consuming.
On the other hand, the two-piece body design can accommodate a
variety of hard-seat materials, including Peek, UHMPFE and other exotic
materials.
A two-piece design offers:
Easeofmaintenanceandseatchangeout;

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Lowercostandlighterweightthanfullport;
Improvedlowcontrol;and
CustomV-Portoptions.
Given the ease of ball valve change-out in the two-piece body design,
full-portvalvesareeasilyconvertedtoV-Portcontrol.Areduced-portcontrolvalveoffersbetterperformancewithmoreoptions,tocustomizelow
at lower prices and torques.
It is now possible for a reduced port valve body to be provided with the
same ease of assembly and disassembly as a full-port version.
Flo-TitesEZseries,two-piecereduced-borelanged-endballvalves,are
availablein6-through14-inchANSIClass150.
Robert M. Donnelly is vice president of marketing with Flo-Tite Valves &
Controls.

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34

Valves & Actuators


Integrated Multi-port Valve Systems

Emergency Gas Shutoff

For 20 years, GEM has manufactured stainless steel, sterile multi-port valve blocks for the
pharmaceutical and biotechnology industry.
For customized block designs,
GEM integrates a
wide range of
functions: blending, splitting,
diverting, draining, feeding or
cleaning. Double
shutoffs, cross
connections,
safety and
control functions as well
as the integration of sensors, filters and check
valves are also possible. GEM can even integrate tanks, process containers and plant housing walls as well as mounting points.

Halogens Terminator emergency shutoff system


sequentially closes 150 lb. cylinder valves containing toxic gas in less than three seconds when
activated from remote sensors and switches. The
operator would then be
required to correct the
condition, check the
facility and manually
reset the valve before
restarting the gas system. The Gemini controller has a self-contained battery system
that guarantees the
operation of the motorized closing mechanism
even during a power failure. This dual-torque
microprocessor controlled system applies 40
foot-pounds of torque for emergency closures of
the cylinder valve.

GEM

Halogen Valve Systems

www.gemu.com
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www.halogenvalve.com
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Gate Valve
Modern sustainability demands require plants
to increase efficiency and reduce carbon dioxide emissions. KSBs ZTS Gate Valve has the
performance and reliability to provide this
efficiency, helping plants meet zero-emission
goals. With its hammer-forged steel body, the
valve can handle water, steam, gas,
oil, and other non-aggressive
fluids, even at temperatures in
excess of 1000 F. The valves
efficiency and durability
make it ideal for industrial
settings, power stations and
process-engineering systems.

KSB, Inc.
www.ksbusa.com
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36

Valves & Actuators


Solenoid Valves with Two Coil Types
Parker Fluid Control Division, manufacturer of the Skinner and Gold
Ring lines of solenoid valves and the Sinclair Collins line of process
control valves, offers the choice of a tab
or integrated coil as part of its Series 204
and 304 solenoid valve lines. The options
feature flexible production possibilities for
long-lasting valves that can operate under
maximized pressure ratings. The 204 and
304 Series is a family of direct-acting solenoid valves for air and liquid (including light oil) applications. These small
yet powerful valves meet virtually all of todays commercial, industrial,
mobile, instrumentation and medical market needs.
Parker Fluid Control Division
www.parker.com

Control Systems
Val-Matic Control Systems provide low maintenance and reliable control of butterfly, plug and ball valves equipped with cylinder actuators.
Hydraulic and electric panels operate pump control valves with air, oil or
water power and include solenoid and flow control valves for slow open/
close and emergency shutdown. Oil Accumulator Systems provide a clean
and reliable oil supply to operate pump control
valves even after power outages. Hand control
valves are also available to provide open-close
and manual position of a cylinder operated valve
without electrical power.

Val-Matic Valve & Mfg. Corp.


www.valmatic.com
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Slide Gate Valve for Heavy Duty and Abrasive Material


Handling

Rotary Airlock Valves

The Vortex Titan Series TSG Valve is designed to meet the most demanding applications when handling heavy-duty abrasive materials such as sand,
gravel, coal, whole grains, metal powders or minerals.
The TSG Valve handles dry material in gravity flow
applications where positive material shut-off and
dust tight sealing are required. This slide gate is
available in a wide variety of configurations with
rectangular sizes and customer specific hole patterns. The TSG Valve has live loaded nylon seals
that extend service life by compensating for wear
and provide an exceptional material seal across the gate and to atmosphere. The TSG Valve has replaceable liners that can be swapped while
the valve is still in-service vastly reducing downtime.

Ideal for sanitary applications such as food processing,


pharmaceutical processing and chemical or plastics applications, the Run-Clean Series of rotary airlock valves are
designed with multiple features that reduce the material
buildup inside the valve housing that can occur during
operation. These features include: angled surfaces and
rounded edges inside the housing to eliminate dead
zones and ensure optimal material flow; factory-applied
internal surface coatings, such as tungsten, to prevent
surface wear imperfections where material can buildup; glandless, sleeve-style shaft seals that prevent contaminant migration into the
housing; and stainless steel housings cast in North America to ensure
superior strength in the composition and solidification of the housings
metallurgy.

Vortex Valves

ACS Valves

www.vortexvalves.com

www.acsvalves.com

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Industrial-grade computer
peripherals: more than just a
NEMA enclosure
Rugged internals and components keep joysticks, mouse pointers and keyboards
from breakdown in harsh, messy environments
Industrial peripherals the joysticks, mouse pointers and keyboards
that act as the interface between humans and processing equipment
are under constant assault in harsh, messy industrial environments.
In processing plants, mines and mills across the country, these peripherals
are exposed to extremely high and low temperatures, moisture, high-pressure wash downs, dirt, grime and operator abuse often around the clock.
Unfortunately, many industrial peripherals built to last in these environments often fail or malfunction within months and are replaced or
repaired at considerable ongoing cost.
The problem isnt always the harsh, abusive environment. Instead, many
industrial peripheral manufacturers rely too heavily on ruggedized enclosures, while using commercial-grade components and internal designs
adopted from the PC market.
One technicians take on it
For Robert Johnson, a service technician for Bethlehem,
Pa.-based Minteq, a supplier
of refractory systems, the steel
foundry environment is, among
the harshest imaginable and the
choice of peripherals used in any
control system is critical to care-free
daily operation.
Minteqs LaCam laser profile measuring system for non-contact measurement
of refractory linings in metallurgical reac-

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tion and transport vessels operates in an environment where temperatures can vary from -10 F to more than 2,000 F at the furnace.
We were using an industrial keyboard/mouse combination unit,
Johnson says. But it wasnt reliable. It wasnt very industrial. It didnt
react to the temperature extremes like we needed. It would lock up from
time to time. We were constantly replacing them.
The keyboard/mouse combination came with a guide rail and roller
system, to pull the keyboard out during use. It wasnt designed to handle
dirt or extreme high and low temperatures. The mouse didnt respond
well when operators wore gloves, which in the steel industry is most of
the time. Finally, once the membrane that covered the mouse got dirty or
roughed up it didnt work at all. When the mouse began failing the entire
unit had to be replaced. Johnson estimates this occurred every couple of
months over the span of 10 years.
NEMA designations
Built strictly to meet established industry standards, many industrial
peripherals are protected by a NEMA 4X (IP66) enclosure. This designation indicates the enclosure protects internals from dust, dirt, water
(including pressure washing) and even external ice formation.
In addition to enclosures, the industry uses several other common techniques to keep peripherals sealed and watertight. Industrial keyboards, for
example, are commonly covered with a monolithic elastomer cover.
But like the old saying goes, you cant judge a peripheral by its cover
or enclosure. A deeper look into the internal components and design
separates the industrial peripheral from those truly ruggedized devices
that survive and thrive for many years.

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39
A true industrial-grade peripheral entails ruggedized components that
can stand a temperature range from -40 C to 80 C, are hardened against
wear caused by heavy or rough use and have few moving parts or potential failure points.
Johnson says he spent a considerable amount of time searching for an
alternative and tried six or seven different products before discovering the
Industrial Mouse from Stratford, Conn.-based CTI Electronics, which designs
and manufactures industrial-grade trackballs, joysticks, keyboards and intelligent switches for OEMs, system integrators and commercial end-users.
The joy of it
The Industrial Mouse is a rugged joystick used as a mouse pointingdevice, with an inductive effect patented by CTI Electronics to deliver the
desired control. Unlike most joystick-style devices, there are no physical contacts and only three moving parts, so there is little internal wear
despite potentially millions of operations.
Its the easiest thing to install, you basically plug it in and it works,
explains Johnson. Theres no fooling around with it no drivers, no settings, no nothing.
Today, the devices Johnson installed 18 months ago are still in service.
The most impressive thing is that its almost indestructible, says

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Johnson. It handles everything we throw at it from the extreme heat


down south to extreme cold up at the top of Lake Superior. Sometimes,
youve got to go from the furnace at 2,400 F back to -10 F in about a minute. It handles all that without skipping a beat.
The operators love it, adds Johnson. Its a joystick and they can use
it while wearing gloves. Its got a little button on top. Basically, its like a
video game to them. Its easy and fast. They can just move, click, move,
click, move, click.
The Industrial Mouse allowed Minteq to eliminate the keyboard component altogether. Now operators use the joystick along with touch screens.
Eliminating the keyboard also put an end to the difficulties with the
guide rail and roller mechanism. That delivered about 1.25 inches of additional room inside the machine for future design elements, says Johnson.
Its a complete win. Weve upgraded every keyboard/mouse unit that
failed or that we simply wanted to upgrade.

CTI Electronics Corp.


www.ctielectronics.com
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www.ProcessingMagazine.comJanuary 2013

40

Weighing & Feeders


Screw-style Feeder
Hapmans new screw-style U-Trough feeder is designed to efficiently measure ingredients and consistently deliver material to the
process. This versatile feeder is available with either volumetric or gravimetric controls. The range of measurement options makes
this feeder optimal for dry product integration for use in food, chemical or water treatment processing. Featuring an optional
integral agitator, the U-Trough Feeder is engineered to effectively operate as a dry material mixer.

Hapman
www.hapman.com
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Versatile Vibratory Feeder


Equipped with a drive that vibrates
a specially designed feed tray, the
SolidsFlow 2000 provides versatility
for a number of process applications.
A key feature of the SolidsFlow 2000
is its uniquely designed feed tray.
Each tray contains a number
of slats with a
gap and overlap
across the entire
width of the discharge opening.
All slat dimensions and angles
are designed to
suit the particular physical characteristics of each
material being fed. Therefore, when
the vibrations cease, material flow
stops instantaneously due to changes in the vibrated and static angle of
repose of the product.

Schenck AccuRate
www.accuratefeeders.com
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Wireless Scale System


Cardinals SnapStream allows a scale
to send weight data wirelessly to an
indicator and the indicator in turn to
send that data wirelessly to a host of
peripheral equipment such as remote
displays, printers, PCs and networks.
The digitally controlled weighing and
diagnostic system was designed utilizing 802.15.4 Zigbee protocol for reliable and accurate weight and data
transmission. SnapStream may be used
with Cardinals model 205, 210 and 225
digital weight indicators, where scale
diagnostics can be viewed directly on
the indicator without having to go to
the scale itself. SnapStream may be
configured using one to 16 load cells.

Cardinal Scale
www.cardinalscale.com
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January 2013www.ProcessingMagazine.com

41
Bulk Bag Discharging and Feeding System
Patented MATERIAL MASTER BULK BAG DISCHARGING SYSTEM lifts, loads, seals and discharges flexible intermediate bulk containers of dried bulk materials. Unit features an electric chain hoist with motorized trolley, monorail system and energy chain package. Unit
features a custom product discharge transition with integral Sure-Seal system for dust-tight discharge into a vibratory feeder with variable speed controls. Equipment includes a Flo-Lock discharge gate for partial bag discharging, allowing bag to be retied, removed
and reused.

Material Transfer & Storage, Inc.


www.materialtransfer.com
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Crane Scale with Wireless


Remote
The Alliance/CAS IE Series Crane Scale
is suitable for a wide range of material handling applications. It includes a
wireless remote control with a 32-foot
range and features a sturdy
aluminum die
cast case, an
easy-to-read
1.1-inch LED
or LCD display
and function keys for
power, zero,
tare and hold.
The portable
crane scale will operate for up to 50
hours on a fully charged battery and
includes a rugged hook and shackle for
hanging.

Alliance Scale, Inc.


www.alliancescale.com
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Multiple Screw Feeder Unloader


The Unloader from Sodimate, Inc. features a vertical spindle fitted with flexible blades to ensure the mechanical
discharge of dry powders from silos, rigid
bins and hoppers. The unloader rotates
within the container bottom to prevent
non-flowing materials
from jamming, bridging, compacting or
rat holing as often
seen with vibration
and fluidization systems. The system
can also integrate up
to four precise volumetric screw feeders.
Each feeder is totally
independent and can feed up to 15,000
lb/hr with different lengths and throughput variations. Sodimates discharger
was specifically designed for difficult dry
powders and chemicals such as lime and
soda ash.

Sodimate, Inc.
www.sodimate-inc.com
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www.ProcessingMagazine.comJanuary 2013

42

Filtration/Separation
Eddy Current Separator
The RevX-E Eccentric Eddy Current Separator is the newest offering
in Eriez extensive line up of state-of-the-art Eddy Current Separators.
Designed for separation of nonferrous metals, the RevX-E is ideally suited
for purifying cullet and plastics, and recovered valuable metal from secondary metals and incineration ash, especially the separation of small particles. The RevX-E features an eccentrically mounted magnetic rotor within
a non-conductive larger diameter shell. This eccentric rotor concentrates its
eddy current forces into a zone of separation at the end of the belt.

Eriez
www.eriez.com
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Universal Filter Frame


Camfil Farr has introduced a time-saving,
universal filter frame for built-up bank
HVAC systems. The FastFrame air filter
holding frame uses exclusive new Camfil
Farr compression tab technology. This
innovation allows rapid filter change-out
without the hassle of clips and fasteners, or the very common problem of finger cuts caused by the sharp
edges on conventional framing systems. FastFrame is constructed
of 16-gauge all-welded galvanized steel for long-term corrosion
protection. Its unique design allows for convenient, simple filter
replacement while preserving the integrity of the filter seal.

Camfil Farr
www.camfilfarr.us
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Downdraft Table
Airflow Systems DT-3000V2 downdraft table is designed to provide
high-efficiency, source-point collection and filtration of powder, dust,
fumes, smoke and other contaminants produced during industrial processing and production operations. The DT-3000V2
generates 195 FPM of downdraft air velocity
across the 19.25 sq. ft., grate-style work surface to
quickly draw contaminants down and away from the
workers breathing zone. Contaminants are then
collected and filtered from the airflow path using
high-efficiency filtration (MERV 17 after-filter). The
Airflow Systems DT-3000V2 prevents contaminants
from becoming airborne, migrating throughout the facility and presenting possible environmental health and safety concerns.

Airflow Systems, Inc.


www.airflowsystems.com
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January 2013www.ProcessingMagazine.com

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43
Filtration System with Real-time
Process Monitoring
The lack of specialized equipment for manufacturing-scale bioprocesses can increase the labor
and time required for normal flow filtration
operations. PendoTECHs
recently launched VirusDepth Filtration System
enables complete process control with
pre-programmed
functions for different steps during the
critical flow filtration
process. Equipped
with a real-time monitor
and built-in alarms that provide regulation, the systems use of PendoTECHs Single
Use Pressure Sensors, tubing pinch valves, single-use flow meter and non-invasive air detector permit a single use fluid path to increase the
process efficiency.

PendoTECH
www.pendotech.com

Multi-bag Filter Housing System for High


Volume Applications
Eaton Corporations PROLINE 100 Series filter
housings are 100 PSI rated, non-coded vessels for
use with standard #2 size filter bags. The new HE
Series vessel design offers a spring-assisted lifting
mechanism that balances the
cover perfectly. The SE Series
vessel offers the revolutionary
QIC-LOCK opening mechanism
for fast and easy access to the
filter chamber with minimal
downtime. Eatons development of the PROLINE 100
Series multi-bag vessel took
into consideration the total
life cycle costs as well as their
commitment to sustainability.
As a result, the housings are only
available in 304 stainless steel, which is 100 percent recyclable when service life is complete.

Eaton Corp.
www.eaton.com/filtration
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Low-maintenance Air Filtration


Solution
The patented Never Miss cleaning mechanism from Mac Process pulses the bags only
when the nozzles are
in direct position.
Exceptionally uniform
media cleaning is
achieved, which optimizes bag life and
pressure drop. The
result is better bag
cleaning, less energy
consumption, lower
emissions and longer
bag life. The MCF
PowerSaver requires
no integrated plant
compressed air to function, which generates
energy cost-savings of up to 50 percent over
conventional high pressure pulse jet or reverse
air cleaning systems.

Mac Process
www.macprocessinc.com/air-filtration
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www.ProcessingMagazine.comJanuary 2013

44

Powder & Bulk Solids


Precision Feed Systems
Adding the PosiPortion feeder to any Hapman conveyor or bulk bag unloader instantly transforms equipment into a precision delivery system that automatically supplies material to your process in premeasured batches, or continuously on a rate-controlled basis.
PosiPortions engineered design maintains the quality of your bulk material without degradation, segregation or agglomeration. Plus,
it easily starts under heavy loads, making the unit ideal for installing beneath silos and large surge hoppers. Hapman has extensive
experience in custom tailoring systems to meet unique application requirements, including necessary controls and process instrumentation.

Hapman
www.hapman.com
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Vacuum Conveying System


Volkmanns ATEX-approved INEX
vacuum conveying system takes
vacuum transfer of dry or wet powder
and granules into
potentially hazardous conditions to a
new level. By using a
sophisticated, patentpending nitrogen
purging function,
INEX reduces oxygen
content within the
unloaded batch to
below 7% (or lower when required),
maintaining the materials inert safety
while providing dust-free transport.
The INEX features a closed station that
can be flushed from within by sucking
in the washing liquid or through WIP/
CIP. Standard lightweight and pressure-rated systems are available with
INEX functionality.

Volkmann, Inc.
www.volkmannUSA.com
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Powder Induction, Wetting,


Dispersion in One Process
The Ystral Conti-TDS, now certified by
3-A Sanitary Standards, brings major
efficiencies to the production process by
offering powder induction, wetting and
then dispersing of an agglomerate-free
liquid all with one machine. Powder
Technologies, Inc., (PTI), exclusive distributor of Ystral powder and liquid processing systems throughout North America,
offers the Conti-TDS as one of its solutions for processing applications in the
food, cosmetics, pharmaceutical, chemical and coatings industries.

Powder Technologies, Inc.


www.powdertechusa.com
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January 2013www.ProcessingMagazine.com

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46

Info Center
New Rotork CMA
Actuators

Automated Tank Cleaning


Machines

Heavy Duty Butterfly


Valve

New Rotork CMA, continuous


modulation actuators, are available in several sizes and are
suitable for linear, quarter-turn,
and rotary control valve and
pump applications. They offer
precise position control, easy
set-up, and can be powered by
single-phase or DC supplies.

Gamajet manufactures costeffective, time-efficient rotary


impingement machines for
all types of tanks and vessels.
Gamajet machines provide the
best clean by preventing crosscontamination and eliminating
the need for confined space
entry.

The Posi-flate Series 585/586


inflatable seated butterfly
valves are designed for the
most the most severe applications. The new heavy duty seat
has been designed for higher
operating pressures and temperatures.

ROTORK, Inc.

Gamajet, part of the Alfa Laval Group

Posi-flate

675 Mile Crossing Blvd., Rochester, NY 14624


585-247-2304Fax:585-247-2308
www.rotork.comEmail:info@rotork.com

604JeffersCircle,Exton,PA19341
1-877-GAMAJET610-408-9940Fax610-408-9945
Email:sales@gamajet.comwww.gamajet.com

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High Accuracy Digital


Pressure Gauges

Automated Bulk Bag


Conditioner

OmegasnewDPG409seriesof
high accuracy digital pressure
gages features a large backlit
display that makes it possible
for users to read digits from
over 10.7m (35 ft). The Stainless
Steel enclosure is designed specifically for wash-down, sanitary
and marine applications.

BLOCK-BUSTERBulkBag
Conditioner loosens bulk
materials that have solidified
during storage and shipment. Hydraulically actuated,
variable-height turntable allows
automated bag rotation and
conditioning at varying heights.

OMEGA ENGINEERING, INC

Flexicon Corporation

OneOmegaDrive,Stamford,CT06907
203-359-1660Fax:203-359-7700
www.omega.com

1-888-353-9426
Email:sales@lexicon.comwww.lexicon.com

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Rota-Cone Vacuum
Dryers

St. Paul, MN
651-484-5800
Email:info@posilate.comwww.posilate.com
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Dry Run Protection


New PMP-25 Pump Load
Control guards against dry running, cavitation and overload.
It monitors true pump power
formaximumsensitivitywhile
displaying power, trip points and
delays. The 4X-enclosure is small
enough to fit on size 1 starters
and can be door-, panel- or wallmounted.Free30-daytrial!

Load Controls, Inc.


www.loadcontrols.com
888-600-3247

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Stainless Steel Hose


Reel Offers Maximum
Protection

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Metal Detectors for


Severe Duty

Hannay Reels SS1500 Series


stainless steel hose reel is
engineered to withstand contaminates and corrosion in
industrial, chemical and food
processing settings or any
harsh environment.

TheEriezMetalarmMA3600
Eagle/HawkSeriesdetects
metal as small as , using
pulseinductionversuscoils.For
harsh conditions in quarries and
mines, and highly-conductive
products like iron ore and steel
corded belts. Download a free
Metalarm brochure.

Paul O. Abbe

Hannay Reels

ERIEZ

Bensenville, IL
800-524-2188Email:sales@pauloabbe.com
www.pauloabbe.com

877-467-3357
www.hannay.com

Rota-Cone Vacuum Dryers


provide an efficient and economical method of drying solids. The slow tumbling action
of the double-cone is gentle
on friable solids. Vacuum drying lowers the evaporation
temperature of liquids, which
improves heat.

888-300-ERIEZ
www.eriez.com

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Krytox Fluorinated
Lubricants
DuPontKrytoxGreases
andOilsare:Chemicallyinert.
Nonflammable. Thermally
stable-103to800F.Oxygen
Compatible. No migration. Low
outgassing.OffersExtreme
Pressure, Anticorrosion,
Antiwear properties. Mil-spec,
Aerospace,FoodGrades!

MILLER-STEPHENSON
CHEMICAL CO., INC.
California Illinois Connecticut Canada
203-743-4447
email: support@miller-stephenson.com
www.miller-stephenson.com

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Loss-in-Weight Feeders

January 2013www.ProcessingMagazine.com

Efficient Plastic
Diaphragm Valve Solution

TheMECHATRONLossin-WeightFeedersprovide
processing industries precise
material feeding accuracies of
1/4 to 1 percent of feed rate
setpoint at 2 sigma. Complete
disassembly from the non-processsideofthefeeder.Feed
rates from .002 to 1,100 ft per
hour are achievable.

Schenck AccuRate

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746E.MilwaukeeStreet,Whitewater,WI53190
800-558-0184
www.accuratefeeders.com/mechatronfeeders.html
Email:mktg@sarinc.com
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ThenewR677andR690
DiaphragmvalvesfromGEMU
have been designed to be
a highly efficient plastic diaphragm valve solution. The
optimized internal geometry provides higher Cvs and
improved flow characteristics.

Gem Valves
www.gemu.com

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47
Jefferson Stocks Stainless
Steel Valves

Size Reduction Equipment

Wobble Pump Shop!

Same day shipping on all


valves we have in stock including stainless steel and brass
solenoid valves. Jefferson
stocks ALL seat materials such
as EPMD, FKM, PTFE AND
BUNA N. Cost-effective crossover done on all valves.

Atlantic Coast Crushers


manufactures and sells
innovative size reduction
machinery for use in the
chemical process industries.
Company specializes in designing machinery that uses impact
to shatter chunks, lumps and
agglomerations formed from
friable materials.

Wobble Pumps are very easy


to handle and economical.
Only one joint saves costs
and reduces downtime when
replacing spare parts. The
wobble-stator pump saves
space because the lantern has
been dispensed with the
drive flanged onto the pump
directly.

Jefferson Valves

Atlantic Coast Crushers

seepex

20225 NE 15th Ct., Miami, Fl 33179


www.jeffersonvalves.com
305-249-8120

www.gocrushers.com
Email: info@gocrushers.com
908-259-9292Fax:908-259-9280

shop.seepex.com

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Classifieds

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The Processing Blog features commentary


and insights from some of the top minds in
the process industries.
Visit www.ProcessingMagazine.com/Blogs
to ask questions and interact with
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Processings expert bloggers.


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We can picture your ad here!


For more information, contact Liz Zane at Liz@grandviewmedia.com
www.ProcessingMagazine.comJanuary 2013

48

Index

Find featured products' company websites and get free product information at www.ProcessingMagazine.com/freeinfo.

Advertiser Index
Argonide ....................................................... 38

Greyline Instruments ..................................... 38

Plast-O-Matic Valves, Inc. .............. Back Cover

Assured Automation ..................................... 40

GEM ............................................................ 24

Posi-flate........................................................ 36

A-T Controls, Inc. .......................................... 35

Halogen Valve Systems................................. 18

Process Flow Direct ...................................... 45

Automatic Filters, Inc. ..................................... 6

Hannay Reels................................................. 20

Rice Lake Weighing Systems ........................ 17

Benko Products ............................................. 28

Hapman Conveyors ........................................ 7

Rosemount Analytical, Inc. ........................... 13

Blue-White Industries .................................... 39

H-P Products ................................................. 15

Rotork Controls, Inc. ..................................... 23

Cashco............................................................. 4

Inline Industries ............................................. 32

Schenck AccuRate......................................... 26

CheckAll Valve .............................................. 18

Jefferson Solenoid Valves USA .................... 34

seepex, Inc. ................................................... 12

CME............................................................... 12

K-Tron America, Inc. ..................................... 14

Sierra Instruments, Inc. ................................. 29

Collins Instrument Co. ................................ 43

Kuriyama of America, Inc. ............................. 39

SmootCo, Div. of Magnum Systems ............ 10

CPV Manufacturing ....................................... 28

Load Controls Inc. ........................................... 6

Specialty Equipment ....................................... 3

Dynamic Air ..................................................... 1

Lutz Pumps .................................................... 22

SPX Flow Technology ..........Inside Back Cover

Eldridge Products ......................................... 22

Magnatrol ...................................................... 28

Triple S Dynamics ......................................... 41

Eriez Manufacturing Co. ................................. 8

Material Transfer & Storage, Inc. ................. 11

Tuf-Lock International ................................... 38

Federal Equipment ....................................... 40

Micro Motion ................................................ 31

Vac-U-Max ..................................................... 16

Flexicon ........................................................... 5

Midwestern Industries................................... 27

VEGA Americas, Inc. ....................................... 9

FLEXIM Americas Corp. ............................... 44

Morris Coupling Co. ..................................... 21

Viega, LLC ..................................................... 33

Flo-Tite Valves & Controls ............................ 32

Nanmac Corp. ............................................... 19

Vortex Valves ................................................ 25

Fox Thermal Instruments, Inc. ...................... 24

New Age Industries ...................................... 42

Water/Waste Processing .............................. 42

GEA Process Engineering ............................. 30

Omega Engineering ...........Inside Front Cover

GEMCO Valve Co. ........................................ 37

Paul O. Abbe ................................................ 36

Product Index
Filtration/Separation

GEM 34

Airflow Systems, Inc. 42

Halogen Valve Systems 34

Camfil Farr 42

KSB, Inc. 34

Eaton Corp. 43

Parker Fluid Control Division 36

Eriez 42

Rotork Controls, Inc. Front Cover

Mac Process 43

Val-Matic Valve & Mfg. Corp. 36

PendoTECH 43

Vortex Valves 36

Powder & Bulk Solids

Weighing & Feeders

Hapman 44

Alliance Scale, Inc. 41

Material Transfer & Storage Front Cover

Cardinal Scale 40

Powder Technologies, Inc. 44

Hapman 40

Volkmann 44

Material Transfer & Storage, Inc. 41


Rice Lake Weighing Systems Front Cover

Valves & Actuators

Schenck AccuRate 40

ACS Valves 36

Sodimate, Inc. 41

January 2013www.ProcessingMagazine.com

Advertising Representation
M
ikeWasson,Publisher
Ph: 973-539-7715
Fax: 205-408-3797
Email: mikew@grandviewmedia.com

J ayHaas,District Manager
Ph: 205-572-1058
Fax: 205-408-3797
Email: jay@grandviewmedia.com

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lizabethZane,Account Manager
Ph: 205-408-3736
Fax: 205-408-3797
Email: liz@grandviewmedia.com

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