A Vanilla Victory with the Rotosolver

A Vanilla Victory with the Rotosolver

In the world of food production, staying ahead of the curve is essential. For companies dedicated to creating the finest products, innovation isn’t just an option—it’s a necessity. For one flavoring company, staying in front of taste trends allows them to lead the
market in designing and producing flavoring emulsions, extracts and powders for beverages, baked goods, confections and dairy.
Making their French Vanilla flavoring was an all-day mixing marathon! The process for making the flavor mix had been the same for years. All the ingredients were added into a vat. The production team would turn on a mixer and let the mixer run overnight. They would come in the next morning and test to see if completely mixed. The flavor mix started as a hallowed orange initially but would turn to a French vanilla, creamy dark yellow color when well mixed. Our sales rep Jacklyn took the Admix Rotosolver® demo unit to the plant. The demo unit has a transparent tank which enabled the production team to watch the color change during the demonstration. Once the ingredients were added, the Rotosolver was turned on. After 7 minutes, the operators’ mouths were hanging open; the flavor mix had already changed color to the creamy, dark yellow they wanted.

The following week, the customer placed an order for a Rotosolver unit on a portable stand and changed their mixing process. Efficiency isn’t just about speed—it’s also about costeffectiveness. The Rotosolver has significantly cut down on production costs. Reduced mixing times mean lower energy consumption, and the consistent results minimize waste due to off-spec batches. These savings are not only beneficial to the company’s bottom line but also align with their commitment to sustainable practices. Here’s to the perfect blend of tradition and innovation, and to many more delicious creations to come! We turned an 8-hour vanilla mix marathon into a 7-minute flavor sprint – that’s how We Make It Work Better!

 

If you want more information, contact us by phone or email. 

Electric vs Pneumatic Actuators

Electric vs Pneumatic Actuators 

While electrical and pneumatic actuators have several unique benefits and are preferred in different applications, using
the wrong one for your application can have serious consequences. It’s important to understand the principles and
differences between pneumatic and electric actuators before comparatively analyzing their features to help you choose
the right one for your application.

Valve actuators are automation devices that are used to remotely control valves without human intervention. These devices generate motion to control valves based on signals received. Actuators are mounted on the valves to be controlled, replacing manual levers. The mounting features that connect a valve to an actuator vary in
different actuator models. Valve actuators are broadly classified based on how they generate the torque – or force – required to open a valve. Based on this classification, the two most prevalent types of actuators are electric and pneumatic actuators. Electric valve actuators utilize electricity to produce the required motion, while their pneumatic counterparts utilize compressed air systems.

Electric actuators
Electric actuators convert electrical energy into the force that opens or closes the valve. These devices may run on AC or DC power. Electric valve actuators may feature an electric motor that produces the rotary motion that turns the valve. This type of actuator is used for quarter-turn valves, which require a 90° turn to open or close, and are known as quarter turn actuators. Examples of quarter-turn actuators are ball and butterfly valve actuators. Another widely used type of electric actuator in piping and fluid control systems is the solenoid actuator. These devices are typically available integrated with the valves, forming a single unit.

On the other hand, in double-acting actuators, the air is
supplied to both sides of the piston. The difference in pressure
between the two sides keeps the valve in the desired position.
Pneumatic actuators typically produce linear motion. However,
in actuators such as butterfly valve actuators (which are
required to generate rotary motion), motion conversion
mechanisms – such as rack and pinion, and scotch yoke
mechanisms – are used.

Pneumatic actuators
Pneumatic actuator utilizes pneumatics – controlled compressed air systems – to produce the force required to operate a valve. These actuators may feature a piston, or diaphragm, that is controlled via compressed air. Pneumatic actuators may be single-acting or double-acting. Single-acting actuators, more commonly known as spring return actuators, feature a loaded spring on one side of the piston that keeps the valve in its natural position. To open or close the valve, pressurized air is supplied on the other side of the piston, and the air pressure overcomes the force of the spring.

Seven considerations to choose between an electric and a pneumatic actuator

Both electric and pneumatic valve actuators have specific advantages in different applications. To choose the right one for your application, certain factors and characteristics of these actuators must be analyzed. Some of these factors and characteristics are explored below.

1. Precision
Precision is considered for valves that need to operate in partially open or closed positions to allow an exact amount of media to flow through. Both electric and pneumatic actuators provide precise control. However, when relying on
pneumatic actuation, the inclusion of an electro-pneumatic positioner may be required as an accessory on a pneumatically operated device such as a control valve to achieve the high precision control necessary in applications.
2. Force range
Pneumatic actuators provide a significantly higher force/torque per unit side than their electric counterparts. For applications that involve a large valve or a valve with high operating pressure, pneumatic actuators are the better option.
3. Speed
Speed of actuation is a crucial consideration in specific applications. Like with precision, both electric and pneumatic actuators can be fast. However, a pneumatic actuator reacts faster and has high duty cycles. Furthermore, the operating
speeds of pneumatic actuators are adjustable.
4. Lifespan
Pneumatic actuators have fewer components. Therefore, they are easier to maintain and have a longer lifespan than electrical actuators, which have several parts that may require regular maintenance. However, while the actuator unit
may not require maintenance, other components such as the air compressor and the FRL (Filter, Regulator, and lubricator) may require more frequent maintenance
5. Cost
The design of pneumatic valve actuators is more straightforward than that of their electric counterparts, and so these actuators cost less than electric counterparts. However, when the cost of the accompanying pneumatic system is
considered, the overall cost of a pneumatic actuation system increases. This cost can be significantly reduced by setting up numerous actuators with the same pressurized air supply system.

6. Fail safe
In applications where a failure in the actuator can have severe consequences, the actuator needs to have a fail-safe mechanism. A fail-safe is easier and cheaper to install in pneumatic actuators. Spring return pneumatic valve actuators feature a natural fail-safe mechanism, as the force of the spring will automatically return the valve to its natural position in the case of a failure.

7. Hazardous conditions
Electric actuators often feature delicate components that may not function correctly in hazardous conditions. Furthermore, these actuators require numerous certifications to be deemed suitable in certain environments. Electric actuators need a high level of protection against high temperatures and pressures, dust, and moisture. On the other hand, pneumatic actuators are quite rugged and can withstand higher pressures and temperatures than their electric counterparts.

If you want more information, contact us by phone or email. 

Sanitary Check Valves Overview

An Overview of Sanitary Check Valves  

A check valve – also called a one-way valve or non-return valve – allows for fluids to flow in one direction only, hence the “check”. The valves have two ports – one for entry and another for exit. Check valves are used in a wide range of
applications, both sanitary and industrial, including condensate lines, pump discharge lines, steam lines and more. The purpose of a check valve is simple – they prevent back flow in your process. As a manual valve, they work automatically and are typically not controlled by any external control. In sanitary processing, check valves are typically 316L stainless and are CIP’able when installed properly. In other applications, check valves may be made of plastic or some other composite material. The two basic types of sanitary check valves are the disk type and the ball type.

Ball Check Valves 
Ball check valves have a Y body configuration. The closing portion of the valve is a ball, either spring-loaded or gravity operated. During product flow, the ball is pushed up into the Y branch of the valve out of the product stream; allowing full flow through the valve. The combination of gravity and back pressure pushes the ball back against the valve seat in the main run of the valve when flow is stopped. Ball valves can be installed vertically or horizontally. In a vertical installation, product must flow from bottom to top in order for
gravity to seat the ball. In a horizontal installation, the curved portion of the valve should be upright and perpendicular to the pipe to ensure that it is free-draining and that the ball seats properly. 

When selecting a ball check valve, make sure to pick the correct elastomer ball for your application. Balls are normally available in Buna, Viton®, and EPDM. Choose the material that is compatible with your product. 

Disk Check Valves
Disk check valves have a straight through body with a valve seat machined into the valve. An insert holds a metal disc that is normally spring loaded to push against the valve seat. During product flow, the disk is pushed away from the seat. When the flow stops, a spring returns the disk and holds it closed against the seat. Back flow pressure also pushes the disk into the closed position. These valves are available with either a straight metal seat or a metal seat with an O-ring seal. The O ring seal option is used to ensure proper sealing as metal seats alone do not always create a perfect seal. They can be used in either horizontal or vertical applications, however if free-draining is required, the horizontal mount is recommended.

Disk check valves typically cost less than other standard valves and are smaller and lighter. However, they are not recommended for applications where there is heavy, pulsating flow.

Thick, sticky products can also be problematic with ball check valves. In these cases, the ball can sometime stick in the Y branch and not properly reseat itself when flow stops. You can PIG your line through a ball check valve. Ball check valves have virtually no pressure drop. Some ball valves have an optional air blow check. This feature is used to isolate upstream equipment so that lines can be evacuated of product or CIP solution using air. These valves may also be used when passivating process lines.

Disk check valves are available with a wide range of springs to provide greater precision on the pressure needed to “crack” or open the valve during operation. Disk check valves will have a higher pressure drop since the disk is in the flow path.

If you want more information, contact us by phone or email. 

WIrelessHART Instrumentation

Wireless HART Instrumentation 

Wireless security is critical to the successful deployment of both field instrument
networks and plant application solutions.

Wireless HART is a wireless mesh network communications protocol for process automation applications.

It adds wireless capabilities to the HART protocol while maintaining compatibility with existing HART devices, commands and tools.

Each Wireless HART network includes three main elements:

  1. Wireless field devices connected to process or plant equipment
  2. Gateways that enable communication between these devices and host applications connected to a high-speed backbone or other existing plant communications network
  3. A network manager responsible for:
    – Configuring the network
    – Scheduling communications between devices
    – Managing message routes
    – Monitoring network health

Each of the wireless network devices, PDAs, laptops, RFID tags, or field instrument wireless Gateways, has its traffic routed from the device to one of the plant network mesh access points. From there the communication travels back through the mesh network until it reaches the root access point. The communication passes directly to the managed switch where the virtual LANs are split in the different physical LANs. The communication is finally routed through a firewall at each network level that serves as “belt and suspenders” to ensure only traffic meant for each network level is routed through. Finally, the communication is routed to the appropriate final network device.

It extends wired HART technology by using 2.4 GHz radio, connecting field instruments to a central gateway for diagnostics and monitoring. It provides high reliability through self-healing, self-organizing networks; making it ideal for monitoring without expensive wiring.

Key aspects of Wireless HART 

  • Technology: Operates on IEEE 802.15.4, utilizing mesh networking where devices act as routers, allowing data to bypass obstructions.
  • Reliability & Security: Features channel hopping to avoid interference, alongside 128-bit AES encryption and secure device authentication.
  • Benefits: Reduces installation costs, allows for easier production expansion, and enables predictive maintenance by transmitting diagnostics.
  • Flexibility: Battery-powered, with devices typically lasting 3–8 years.
  • Integration: Easily integrates with existing SCADA or DCS systems.

For more information, visit our website:  www.mgnewell.com and www.newellautomation.com.

Maintaining Hygienic Valves

Maintaining Hygienic Diaphragm Valves 

A process-specific preventative maintenance program improves productivity and reliability.

The biopharmaceutical industry relies on hygienic diaphragm valves for its demanding process applications due to a
unique need for cleaning and draining and for pressure and temperature capabilities. Over the past 40 years, the basic
design of such valves has remained the same: body, diaphragm, topworks, and four fasteners (see Figure 1). Properly
installing and maintaining these valves requires experienced personnel and stringent maintenance practices to assure
consistent and reliable valve performance.

Preventative Maintenance Benefits
Facilities can cut costs and decrease downtime through preventative maintenance, which involves a schedule and process for maintaining equipment; preventative maintenance is particularly important when it comes to valves. Although it can take hundreds of hours a year to
properly maintain hygienic diaphragm valves, resulting in thousands of dollars of maintenance cost and lost hours of production, the primary function of a maintenance program is maximized production up-time, reduced planned and unplanned man-hours of labor, and early detection of diaphragm failure. Many plants fail to have a maintenance schedule for their hygienic diaphragm valves and may even wait until a piece of equipment fails before performing any maintenance at all– resulting in a costly and lengthy plant shutdown. Failure of the diaphragm, which will occur if it is not replaced on a
routine basis, will most likely contaminate the process somewhere along the process lines. In many cases, the three major types of failures include valve leakage (fluid leaks between diaphragm and valve body to atmosphere), complete diaphragm rupture (diaphragm tears allowing process fluids to escape through the valve bonnet), and diaphragm tears (diaphragm tears allowing process fluids to escape through the valve bonnet). The result of these failures can be loss of product. In addition to the product that leaks out, a leak can put the entire batch at risk because of possible contamination entering the system. A diaphragm rupture can introduce contamination from the non-sterilized internals of the valve topworks, allowing the product to come into contact with greases and other contaminating liquids. Diaphragm tears can cause contamination from fluids that get entrapped in the diaphragm tears.

How to maintain hygienic diaphragm valves 

Hygienic valves act as both the static seal (shell seal) and a dynamic seal (weir shutoff). They are often exposed to harsh chemicals, high temperatures, and high pressures, resulting in high amounts of wear and tear and an increased need for routine maintenance. Proper valve maintenance requires several steps by the maintenance team to ensure that the valve will function to its full potential.

 

Diaphragm tears can be especially insidious; because the pressure boundary of the diaphragm is not breached, the in-line instrumentation does not detect a system problem. Many times, all of the process fluids produced from the time of
detection of the problem may be recalled or put on hold for testing. Valve leakage can also result in lost production time and an additional need for maintenance and time to clean up the equipment and repair the leaking valve. Additionally, valve leakage can cause potential safety risk, including employee exposure to dangerous process fluids, steam leaks, clean-in-place fluids, and dangerous organisms. Preventative maintenance can help maintain these seals and decrease the risk of leakage. Ultimately, detecting failures before they occur can result in improved sterility and minimized risk of contamination, and therefore, reduced maintenance hours and commissioning. Additionally, going through the process of preventative maintenance reduces the need for managers to unnecessarily replace valves or react to potential problems that can occur, resulting in greater efficiency, reliability, and ease of use. The keys to proper valve maintenance are knowing the steps involved in maintaining valves and implementing a preventative maintenance plan that works for a particular facility and application.

Valve assembly/installation. One of the most important parts of maintenance is proper assembly during the diaphragm change-out process. If the valve is not assembled properly, it can leave room for batch contamination, poor valve performance, and short lifecycle. Proper diaphragm installation per manufacturer’s instructions is essential. If installed improperly, excessive force during operation can result in diaphragm damage. Fluids can then pass through the closed valve or, in the worst case, cause catastrophic failure that results in process fluid contamination and leaks. Torqueing and retorqueing are also important steps in the assembly process that can often lead to seal failure, by either making the seal too tight or too loose for proper performance.

Replacing the diaphragm. Another aspect of valve maintenance is knowing when a replacement diaphragm is needed. To make sure valves do not fail, some companies change out their diaphragms on a regular basis (e.g., every six months), regardless of whether or not it is needed. Facilities that use diaphragms with a shorter life expectancy, such as rubber-type diaphragms, may be more likely to perform require more regular changes. However, consistently replacing diaphragms with no signs of failure can cost plants unnecessary expenses and time. Knowing the signs of valve failure is also essential to maintaining a facility’s valves. Physical signs that a valve or diaphragm needs to be replaced are excessive wear, corrosion, or fluid leakage.

Improved valve designs
In recent years, the design of the hygienic diaphragm valve has been optimized to increase productivity, ultimately advancing maintenance practices in biopharmaceutical facilities. New valve technology, for example, can reduce average diaphragm replacement time from 23 minutes to three minutes and total maintenance time from hundreds of man hours to just a few hours, hence reducing maintenance cost by more than 90% (2). Preventative maintenance practices and more innovative technology, such as valves that do not require tools or re-torqueing, are preventing the potential of human error and making processes safer and more efficient. Improved designs can help meet the biopharmaceutical industry’s growing demand for increased productivity, extended maintenance intervals, and reduced operating costs, in conjunction with an effective preventative maintenance program.

Factors to consider
Because of the wide range of applications and conditions within the pharmaceutical processing industry, preventative maintenance programs should be built up over time and should be specific to the application. Programs can vary widely from one plant to another. There are many factors to consider when facilitating a preventative maintenance program. The biopharmaceutical industry is fairly unique in that valves are used in many different applications with different exposures to temperatures and harsh fluids. Different applications for valves can include steam-in-place (SIP) or high-temperature sterilization; cleaning in place (CIP) where caustics and acids act as detergents; cold processing where purification is usually below ambient conditions (2-8 °C typically); and purification processes, such as chromatography and filtration. Many of these processes run in sequence or through the same pipes, which means the valves are exposed to a wide range of application temperatures and conditions. Other factors that affect valve performance and maintenance include the amount of exposure time to liquids and steams, the type of diaphragm (one-piece vs. two piece diaphragm), and the thermal cycle (the swings between minimum and maximum temperature). Diaphragms and other soft parts, such as gaskets and O-rings, often face fluctuations between
steam sterilization and cold-processing temperatures in the biopharmaceutical industry. A typical valve undergoes hundreds of thermal cycles in its maintenance lifecycle, which can affect the valve seal and ultimately the product. As
thermal cycles increase, the valve diaphragm is continually being compressed and relaxed, resulting in thinning of the diaphragm. These dimensional changes create less seal contact and will eventually result in valve leakage to the
atmosphere. Although some leaks can be addressed with re-torqueing, most end-user procedures do not allow valves to be re-torqued after the process has been released to production.
Thermal cycle performance has been a significant topic for the biopharm industry for some time. The American Society of Mechanical Engineers Bioprocessing Equipment Committee, which drives many of the industry best practices, has developed a test procedure that will help the end user determine the potential performance of a given seal/diaphragm in these varying conditions. This “Appendix J” test (1) allows seal/diaphragm manufacturers to rate the performance of their
elastomers based on a standard test protocol. This testing is currently non-mandatory and is in its infancy of adoption by the end users in the industry. Eventually these Appendix J ratings will provide end users a consistent basis to assess
expected life expectancy with regards to thermal cycle performance. Many of the forward-thinking pharmaceutical companies are now partnering with valve manufacturers to assess maintenance frequencies. With proper application data, including temperature, pressure, process fluid data, and exposure times, valve manufacturers can help develop a maintenance program that aligns with the risk profile of the end user. In this way, the end user can save unnecessary maintenance costs and production down time, ultimately reducing their total cost of ownership of the process system.

If you want more information, contact us by phone or email. 

Homogenization Overview

Homogenization Overview

Homogenization is the process of emulsifying two immiscible liquids (i.e. liquids that are not soluble in one another) or
uniformly dispersing solid particles throughout a liquid. The benefits include improved product stability, uniformity, consistency, viscosity, shelf life, improved flavor and color. It has become a standard industrial process in food and beverage, chemical, pharmaceutical and personal care industries. The process of homogenization was invented and patented by Auguste Gaulin in 1899 when he described a process for homogenizing milk. Gaulin’s machine, a three-piston thruster outfitted with tiny filtration tubes, was shown at the World Fair in Paris in 1900. Since then, his name has become synonymous with homogenization. Basic emulsion formation involves adding both a surfactant and mechanical energy to join the two phases. The first step or primary homogenization involves adding surfactants or emulsifiers. Emulsions, by nature, are inherently unstable. Over time, all emulsions will eventually coalesce or “break”. Surfactants work by facilitating the creation of the emulsion and help slow down its eventual break. The resulting particle size of the globules can range in size from 0.1 to 10 microns. Emulsions change their size distribution over time, shifting to larger sizes.

The stability of an emulsion is determined by several factors including the choice of emulsifier, the phase-volume ratio, the method of manufacturing the emulsion and the temperature in both processing and storage. The order of addition, the rate of addition and the energy of the system can have a large impact on the final properties of the emulsion. Ideally, the lipophilic (oil-loving) surfactant should be dispersed in the oil phase. Finer emulsions result when the hydrophilic (water-loving) surfactant is also dispersed in the oil phase. When combining oil and water, the addition of water to the oil phase produces the finest emulsions. If the oil is added to the water phase, more energy is required to produce small droplets. A significant improvement in the emulsion can usually be seen by adding the water phase at a slower rate. Most emulsions are sensitive to the temperature of the system. Generally heat is added to the system since warm oil/fat molecules disintegrate more easily than cold ones. Micro-emulsions are a dispersion of water, oil and surfactant with particle sizes ranging from 1-100 nm. They are typically characterized as a more stable emulsion and are generally clear in appearance. They tend to have a higher concentration of surfactant relative to the oil content. These are commonly used in the pharmaceutical and personal care industries.

The Homogenizer
In today’s environment, homogenizers are used to produce more consistent emulsions in a high efficiency process. A wide variety of homogenizers have been developed to run at different pressures and capacities depending on the product mixture. In addition to product improvements, today’s homogenizers also feature reduced noise and vibration and reduced maintenance.

So how do homogenizers work?
a. The non-homogenized product enters the valve seat at
high pressure and low velocity.
b. As the product enters the close (and adjustable) clearance
between the valve and the seat, there is a rapid increase in velocity
and decrease in pressure.
c. The intense energy release causes turbulence and localized
pressure differences which tear apart the particles.
d. The homogenized product impinges on the impact ring and
exits at a pressure sufficient for movement to the next step.

Homogenizers may be equipped with a single valve assembly (single-stage) or two valves connected in a series (two-stage). For most products, a single-stage valve is sufficient. A two-stage assembly, where ~10% of the total pressure is applied to the 2nd stage, controls back pressure and minimizes clumping. This improves the droplet size reduction and narrows the particle size distribution. Generally, two-stage
homogenization is used for products with a high fat content or products where high homogenization efficiency is required.

The valve technology is one of the most critical components of the homogenizer. Poppet valves are typically used for low-viscosity, moderately abrasive products such as ice cream, dairy, vegetable oils or silicone emulsions. Ball valves are
used for high-viscosity, abrasive products such as peanut butter, evaporated milk or wax emulsion.

Potential Problems

To minimize potential problems with your homogenizer, one should realize that not all products are conducive to
produce in a homogenizer. If you are running one of these types of products or process conditions, you should review
the product, process and equipment with one of our technical representatives. Alternatives such as high-speed blending
or colloid mills may be recommended.

 Air in the product
 Heavy particles in the product
 Wearing or abrasive products
 High viscosity products
 Aggressive products (i.e. chlorine ions)
 High temperatures (max 105°C)
 Low flash point products
 Products with high solids content

Selecting a homogenizer

When purchasing or replacing a homogenizer, discuss the following parameters with one of our representatives.

1. Define the desired product characteristics

  • What particle size and size distribution is desired?
  • What is the product viscosity?

2. Define the desire production conditions

  • Batch vs continuous
  • Volume desired
  • Temperature

3. Identify and test homogenizers

  •  Should I use a high-speed blender vs a high-pressure homogenizer vs a colloid mill
  •  Rent a homogenizer for a trial period

4. Optimize homogenization conditions

  • Pressure
  • Flow rate
  • Time and temperature
  • Emulsifier type and concentration
If you want more information, contact us by phone or email. 

Flowmeters 101 – Magnetic and Coriolis

Flowmeters 101 – Magnetic and Coriolis Flowmeter

Flowmeters play a vital role in sanitary processing. They are used to measure incoming raw materials, incoming water supply, CIP solutions, ingredients in your formulation, final product production and even waste water leaving the plant. Considering their use in critical applications, ensuring that you are using the right type of meter with the correct level of accuracy for your application can be the difference in the quality of your product and save you thousands of dollars in lost revenue or profit.

In sanitary processing, one will typically find mechanical flowmeters (Positive Displacement, Turbine), electromagnetic
and Coriolis flowmeters.

Magnetic Flowmeters 

Magnetic flowmeters use Faraday’s Law of Electromagnetic Induction to determine the
flow of liquid through a pipe. This type of flowmeter works by generating a magnetic
field and channeling that through the liquid in the pipe. Faraday’s Law states that flow of
a conductive liquid through the magnetic field will cause a voltage signal that can be
sensed by electrodes on the tube walls. When the fluid moves faster, more voltage is
generated. The voltage generated is proportional to the movement of the liquid.
Transmitters process the voltage signal to determine liquid flow.
The signals produced by the voltage are linear with the flow. With this, the turndown
ratio is very good without sacrificing accuracy.

Pros and Cons 

Since these flowmeters measure conductivity, obviously the fluids measured need to be conductive – water, acids and
bases. Low conductive liquids, such as deionized water or gases, can cause the flowmeter to turn off and/or measure
zero flow. There is no obstruction in the path of the liquid, therefore no induced pressure drop across the meter. One
other benefit of mag meters is that they can be used on gravity-fed liquids. With gravity-fed liquids, make sure the
orientation of the flowmeter is vertical so that the flowmeter is completely filled with liquid. These flow meters are
sensitive to air bubbles because the meter cannot distinguish entrapped air from the liquid. Air bubbles will cause the
meter to read high.
Mag meters are typically chosen because they have no obstructions, are cost-effective and provide highly accurate
volumetric flow. Additionally, they can handle flow in either direction and are effective at low and high volume rates.

Coriolis Mass Flowmeters 

A Coriolis mass flowmeter operation is based on the principles of motion mechanics. This flowmeter contains a vibrating
tube in which a fluid flow changes in frequency and amplitude. As fluid moves through this tube, it is forced to
accelerate toward the point of peak amplitude vibration. Conversely, a decelerating fluid moves away from the point of
peak amplitude as it exits the tube. The result is a twisting reaction of the tube as flow moves through it. The amount
of twist is proportional to the real mass flow of fluid passing through the tube.

This effect can be experienced when
riding a merry-go-round – when moving
toward the center, a person will “lean
into” the rotation to maintain balance.
Most flowmeters have a split coil design.
During operation, a drive coil stimulates
the tubes to oscillate in opposition (sine
waves). A sensor measures the time
delay between the two sine waves
(Delta T) which is directly proportional to
mass flow rate.

 

Pros and Cons 

These flowmeters are used in a wide range of critical and challenging applications. They can handle low to high flow
rates with very high accuracy. They are highly reliable and have minimal calibration requirements and low maintenance
costs. In addition, fluid density has basically no impact on flow measurement which makes Coriolis meters ideal where
the physical properties are unknown. They have a higher initial cost than other flowmeters. Pressure drop must also be
considered, especially if running high viscosity fluids.

If you want more information, contact us by phone or email. 

Flowmeters 101 – Turbine and PD meters

Flowmeters 101 – Turbine and PD meters

Flowmeters play a vital role in sanitary processing. They are used to measure incoming raw materials, incoming water
supply, CIP solutions, ingredients in your formulation, final product production and even waste water leaving the plant.
Considering their use in critical applications, ensuring that you are using the right type of meter with the correct level of
accuracy for your application can be the difference in the quality of your product and save you thousands of dollars in
lost revenue or profit.
Before we begin, let’s cover a few basics of flow. Both gas and liquid flow can be measured in volumetric or mass flow
rates such as gallons per minute or pounds per minute, respectively. These measurements are related to each other by
the density of the product. In engineering terms, the volumetric flow rate is usually given the symbol 𝑸 and the mass
flow rate is given the symbol ṁ. For a fluid having a density 𝝆, mass and volumetric flow rates are related by ṁ = 𝝆 ∗ 𝑸.
In sanitary processing, one will typically find mechanical flowmeters (Positive Displacement, Turbine), electromagnetic
and Coriolis flowmeters.

Turbine Flowmeters 

Turbine flowmeters use the mechanical energy of the fluid to rotate a “pinwheel” (rotor) in the flow stream. Blades on the rotor are angled to transform energy from the flow stream into rotational energy. The rotor shaft spins on bearings. When the fluid moves faster, the rotor spins proportionally faster. Shaft rotation can be sensed mechanically or by detecting the movement of the blades. Blade movement is often detected magnetically, with each blade or embedded piece of metal generating a pulse. Turbine flowmeter sensors are typically located external to the flowing stream to avoid material of construction constraints that would result if wetted sensors were used. When the fluid moves faster, more pulses are generated. The transmitter processes the pulse signal to determine the flow of the fluid. Transmitters and sensing systems are available to sense flow in both the forward and reverse flow directions.

Pros and Cons 

Turbine flowmeters have a moderate cost and work well in clean, low viscosity fluids at a moderate, steady velocity. They do create some pressure drop. Bearings do wear out over time and accuracy will diminish and eventually fail as the bearings wear. Turbine flowmeters also typically work best in a limited temperature ranges. These meters are less accurate at low flow rates due to bearing/rotor drag.

 

Positive Displacement Flowmeters 

Positive displacement flowmeter technology is the only flow measurement technology that directly measures the volume of the fluid passing through the flowmeter. Positive displacement flowmeters achieve this by repeatedly entrapping fluid in order to measure its flow. This process can be thought of as repeatedly filling a bucket with fluid before dumping the contents downstream. The number of times that the bucket is filled and emptied is indicative of the flow through the flowmeter. Many positive displacement flowmeter geometries are available.


PD flowmeters have the same basic mechanism as a PD pump. Rotors turn to move a fixed amount of liquid through the body of the flowmeter. In most designs, the rotating parts have tight tolerances so these seals can prevent fluid from going through the flowmeter without being measured (slippage). Rotation can be sensed mechanically or by detecting the movement of a rotating part. When more fluid is flowing, the rotating parts turn proportionally faster. The transmitter processes the signal generated by the rotation to determine the flow of the fluid.

Pros and Cons 

One of the main benefits of using a PD flow meter is the high level of accuracy that they offer, the high precision of internal components means that clearances between sealing faces is kept to a minimum. The smaller these clearances are, relates to how high the accuracy will be. Another benefit is the flow meters ability to process a huge range of viscosities and it is not uncommon to experience higher levels of accuracy while processing high viscosity fluids, simply due to the reduction of slippage. When considering and comparing flow meter accuracy, it is important to be aware of both ‘linearity’ i.e. the flow meters ability to accurately measure over the complete turndown ratio, and ‘repeatability’, the ability to remain accurate over a number to cycles. This is another area where PD flow meters excel, repeatability of 0.02% and 0.5% linearity are standard. Similar to a PD pump, PD flowmeters are considered to have low maintenance requirements. The moving parts will wear over time and require maintenance and calibration. They should not be used for products that contain large particles. Another factor to consider is the pressure drop caused by the PD flow meter; although these are minimal, they should also be allowed for in system calculations.

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The Case of the Locking Rotors

The Case of the Locking Rotors 

When the Pumps Went Silent, the Pressure Told the Truth 

Detective Newell hated getting calls before coffee. This one came from one of the outside saleswomen.  “Newell,” she said, voice tight. “My customers got a problem. Ten U2-006 PD pumps that are all locked up.”

Locked up pumps were never just locked up pumps. They were always a symptom—never the disease.  Newell grabbed his jacket and motioned to Inspector Gauge. “Let’s go see what the pumps are trying to tell us.”

They found the pumps mounted on their sides, perched above a piece of equipment installed by another contractor. Newell didn’t like that already. Pumps, like people, don’t appreciate being put in awkward positions.

They cracked them open one by one. Same story every time.

“Notice this?” Inspector Gauge said, pointing.

Newell nodded. “One side locks up first. Always the same side.”

Back at the shop, they tore down four of the suspects. The evidence didn’t lie: rotors had kissed the cover—hard—and seized.    “Running dry,” Newell muttered. “Starved.”

They told the customer as much, but the customer pushed back. “No way. That’s not it. Let’s try hot clearance rotors.”

Newell didn’t argue. He’d learned long ago that sometimes people need to walk into the truth on their own.

Before the fixes even started, the phone rang again.

More pumps.

Locked up.

Same equipment.

All twenty U2-006 PD pumps were now suspects—and victims.  Newell and Gauge went back to the plant. Déjà vu. Same damage. Same story.

“You’re running them dry,” Newell said again, slower this time.  The customer still wasn’t convinced.  So Newell made his move. “Then let us watch them run.”

They met with an engineer and walked the process line end to end. Newell asked questions. He listened. He watched. He always watched…

“How much pressure are you seeing?” he asked.

“About 8 PSI,” the engineer replied.  Newell stopped walking.  “8?” He looked at Gauge. Gauge didn’t have to say anything.  “That’s not just low,” Newell said. “That’s a confession.”

He told them to install temporary pressure gauges. No theories. No opinions. Just facts.

They ran the system again.  Three minutes in, Newell spotted it – the centrifugal pump feeding the PD pumps wasn’t running.

“There it is,” he said quietly. “That’s the culprit.”

Newell laid it out clean and simple.  “The centrifugal pump must always run first. Always.”   PD pumps can’t be started without feed pressure.  If a PD pump runs dry, the rotors expand, touch the cover and lock up.   An improper start sequence and low PSI in the feed lines will always lead to problems.

They changed the sequence.  Ran the test again.  The pumps didn’t lock – didn’t squeal – didn’t complain.  They just ran.

Another mystery solved.  Another reminder that the correct start-up sequence is never optional.  Another case where the culprit wasn’t a broken part— but bad timing, low pressure, and the truth hiding in plain sight.

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