Optimizing Manufacturing Processes Through Expert Sales Engineers

Industrial process control instrumentation and valves are essential for maintaining the efficiency, safety, and smooth operation of various manufacturing processes. Experienced industrial Sales Engineers play a critical role in this context, bringing unique and indispensable benefits to specifying, selecting, and applying these vital components.

Sales Engineers possess comprehensive knowledge of the latest technologies, product offerings, and industry best practices. Through extensive training and hands-on experience, they provide valuable insights and tailored recommendations for specific applications. Their expertise enables engineers and project managers to make informed decisions, ensuring the selection of the most suitable and cost-effective components for their projects.

More than just intermediaries, Sales Engineers proactively delve into understanding customer needs, challenges, and objectives. They don't just listen, they act. They translate these insights into actionable solutions, guiding customers through the complexities of industrial instrumentation and valves. This close collaboration helps optimize processes, enhance efficiency, and achieve desired outcomes by offering product specifications, compatibility, and system integration advice.

Sales Engineers support projects throughout their lifecycle, from initial design and specification to technical support and troubleshooting. They assist in instrument and valve sizing, material selection, and performance evaluation, ensuring seamless integration with other system components. Their commitment to customer success often extends to ongoing support and after-sales service.

Effective communication and coordination among various stakeholders are not just facilitated, but championed by Sales Engineers, who act as central points of contact in industrial projects. They bridge the gap between technical and non-technical stakeholders, fostering collaboration and ensuring alignment toward common goals. By translating complex concepts into understandable terms, they enable productive discussions and smooth project execution.

Sales Engineers stay updated on industry standards, regulations, and compliance requirements, guiding the selection of instrumentation and valves that meet stringent safety, environmental, and performance standards. This proactive approach helps avoid costly rework, delays, and potential legal issues, ensuring that projects adhere to necessary standards and best practices.

The partnership with Sales Engineers is not just a transaction, it's a journey that often leads to long-term benefits and strategic alliances. As trusted advisors, they gain a deep understanding of their customers' businesses, processes, and future goals. This knowledge enables them to identify opportunities for improvement, propose innovative solutions, and align offerings with evolving needs. Strong relationships built on trust and mutual success make Sales Engineers valuable assets, contributing to the overall growth and competitiveness of their customers' operations.

In summary, industrial Sales Engineers' involvement in specifying, selecting, and applying process control instrumentation and valves is highly beneficial. Their technical expertise, industry knowledge, and commitment to customer success make them invaluable partners in optimizing processes, improving efficiency, and achieving project objectives. By leveraging the skills and support of Sales Engineers, engineers, and project managers can confidently navigate the complexities of industrial instrumentation and valves, ultimately driving the success of their projects and organizations.

CTi Controltech
https://cti-ct.com
925-208-4250

Process Measurement, Valve, and Combustion Experts Serving Northern California and Nevada

CTi Controltech contributes a wealth of knowledge, experience, and skill in their customer engagements. The items we carry come from globally recognized manufacturers and are used in conjunction with our contracting and engineering resources to provide complete solutions to our customers' problems. A leading provider of valves, valve actuation, emissions control, and monitoring systems for industrial burners and boilers. CTi Controltech also provides custom SCR systems as well as steam management solutions. CTi Controltech, headquartered in San Ramon, California, serves Northern California and Nevada. We design solutions to the problems that our customers experience daily in process control.

Combustion, Emission and Steam Solutions 

• Low and ultra low NOx burners and burner retrofits 
• BMS and CMS system design and hardware 
• Custom design SCR Systems 
• Burner air fuel mix recalibration 
• Pre-emission test and boiler tune-ups 
• Heat rate, efficiency studies and plant improvement 
• Vapor recovery 
• Particulate and CO2 control 

Process Control and Combustion Services 

• Factory trained service personnel 
• Commissioning and startup technical support 
• Technical seminars and training 
• Valve and actuator calibration and startup 
• Instrument calibration and startup 
• Complete turnkey project capabilities 
• U.L. 508 custom design 
• Project CAD drawings 
• PLC Programming 
• CFD and modeling 

Process Control Instrumentation Solutions 

• Flow, level, pressure, density and temperature

Valve, Actuation, and Automation Solutions 

• Severe service valve sizing and selection 
• Valve and actuation packages, pneumatic, hydraulic and electric 
• Noise and cavitation control 
• Total valve management programs 
• Turbine by-pass 
• Desuperheating and attemperation 
• Damper drives 
• Check valves 
• Vent to atmosphere and silencers 
• Best fit for purpose replacement recommendations 
• Ease of operation and life cycle cost considerations 

Pressure Relief and Flame Mitigation Technology

• Pressure/Vacuum Relief Valves 
• Pressure Relief Valves 
• Vacuum Relief Valves 
• Pilot Operated Valves 
• Flame and Detonation Arresters 
• Emergency Relief Valves 
• Waste Gas Burners 
• Pressure Regulators  

https://cti-ct.com
925-208-4250

Linear and Quarter-turn Industrial Valves

Various valves are designed and used for multiple roles in process control. Linear and quarter-turn valves are two types of valves used to regulate and control fluid flow in the industry. Their design and construction reflect the intended use of the valves, with each suited to a different class of service. 

All valves work by controlling the position of an internal structure that obstructs fluid passage to some extent. In general, fluid flow at the valve classifies as unrestricted (valve fully open), stopped (valve fully closed), or throttled (valve partially open). The operational requirements of the process will determine whether only two of those conditions (fully open and fully closed) or all three are required. When choosing an appropriate valve, the fluid, the process, and the surrounding environment must be considered. It is not always a simple task. 

Linear valves distinguish themselves using straight-line motion to position the valve plug, disc, diaphragm, or other flow controlling elements. The linear valve trim's shape, size, and arrangement provide the operator with a flow range through the valve. The linear valve's positioning allows it to regulate fluid flow slower but more accurately. Linear motion valves include gate and fixed cone valves—linear valves best suit flow control.

Quarter turn valves move from fully open to closed by rotating a shaft connected to the controlling element 90 degrees. Their relatively simple operation allows for a rugged and compact design. The ability of quarter-turn valves to quickly reposition from open to closed positions is one of their distinguishing features. The torque required to operate the valves is typically low to moderate. Quarter turn valves include ball and butterfly valves. 

Depending on the situation, linear valves and quarter-turn valves are the best choices for specific process environments. The linear valve's accuracy and ability to move in a linear fashion rather than a quarter-turn come with easy maintenance and a lower likelihood of cavitation. Both valve types are widely used and are not competing for the same application. Each excels in a specific set of applications.

https://cti-ct.com
925-208-4250

Upcoming Yokogawa Process Control Webinar Schedule

Yokogawa's "Back to Basics" webinar series provides you a great resource to learn and review different measurement technologies. These online webinars discuss recommended practices, application selection and sizing, and how to avoid common pitfalls. Gain insight directly from the Yokogawa experts!

WEBINAR SCHEDULE

Fundamentals of Fabulous Flow Measurement

Online Webinar

Thursday, April 16, 2020

11:00 AM Eastern / 8:00 AM Pacific

This webinar will explore the fundamentals of flow measurement technologies and how they stack up in different applications.

In this webinar we:

• Review the theory behind flow measurement technologies
• Discuss common flow application challenges
• Evaluate the different technologies when selecting a flow meter
• Illustrate installation practices for successful measurements

Register Here

Magical Mystery Tour of High Purity pH Measurement

Online Webinar

Thursday, April 23rd, 2020

8:00 AM Pacific / 11:00 AM Eastern

The presentation will explore the theory of pH and how it can be successfully applied in high purity applications, discuss both standard and solution temperature compensation, review installation requirements, and illustrate good calibration and maintenance procedures to facilitate satisfactory measurements.

In this webinar we:

• Review the theory behind the measurement of pH
• Discuss the issues surrounding high purity pH measurements
• Illustrate the difference between standard and solution temperature compensation
• Assess installation requirements for successful measurements
• Clarify good calibration and maintenance procedures

Register Here

Vibrating Element Technology for Gas Density, Specific Gravity, and Hydrogen

Online Webinar

Thursday, April 30, 2020

8:00 AM Pacific / 11:00 AM Eastern

This presentation goes over the theory behind vibrating element technology and explores some of the applications in which it can be used.

In this webinar we will review:

• The theory behind density and vibrating element technology
• The importance of using compensated density
• How to clean the detector

Register Here

Digitally Transform your Plant with Field Wireless and IIOT

Online Webinar

Thursday, May 7, 2020

11:00 AM Eastern / 8:00 AM Pacific

Wireless sensor networks can provide reliable and secure communications for applications including control, monitoring, safety, and reliability. Regardless of the application, wireless technology has opened the door for companies to pursue improvements that may have been impossible or uneconomical in the past. However, adopting a wireless strategy is more than just throwing a few radios out into the plant. A little planning can go a long way to ensure your future success.

Topics covered include:

• Where you would use Field Wireless vs IIoT
• The fundamentals of wireless sensor networks
• Applications that illustrate how a wireless strategy can transform your operations, improve reliability, and increase safety

Register Here

CTi Controltech Service and Support: Improving Our Customer's Safety and Profitability

With engineering, design, and support resources available in Northern California and Western Nevada, CTi Controltech delivers value-added solutions that improve operations and increase profitability for our customers in the power generation, alternative energy, municipal water, wastewater treatment, gas & oil, chemical, refining, mining, agricultural, food service, pharmaceutical, and aerospace industries.

CTi Controltech offers our customers a group of services designed to provide outstanding value and cost savings throughout your equipment's life span. By integrating access to best-in-breed equipment manufacturers, decades of application experience, and state-of-the-art tools, CTi Controltech helps customers:

• Improve plant and personnel safety
• Optimize asset uptime and performance 
• Lower total cost of operation and maintenance
• Increase equipment reliability

PARTS, REPAIRS, UPGRADES AND FIELD SERVICES

CTi Controltech mobile service personnel and advanced diagnostic technologies, along with the unparalleled expertise of their technicians, is equipped to address virtually any process equipment service requirement, regardless of the manufacturer.

Repair and Upgrades — CTi Controltech repairs and/or upgrades equipment, providing new life to existing process instrumentation, valves, and control systems.

Replacement Parts and Components — Using its broad network of manufacturer's service facilities, and our own local stocking centers, CTi Controltech provides timely delivery of quality parts that keep your operations running smoothly and profitably .

Field Service Personnel — From maintenance to management, highly qualified CTi Controltech project managers, engineers and technicians will assist you in keeping your plant running smoothly .

ENGINEERING AND TECHNICAL SERVICES

Technical Analysis — CTi Controltech can perform system audits to identify operational issues that may be constraining output or elevating operating costs, and then recommended laser-focused solutions.

Reliability and Efficiency Services — CTi Controltech lends their decades of hands-on experience to offer practical solutions that improve the performance, efficiency, and reliability of your process control equipment - all while lowering your total cost of ownership.

Loop Design, Integration and Engineering Support — CTi Controltech engineers engage with our customers, providing on-site support for grassroots project planning, system design, or project management requirements.

ASSET MANAGEMENT AND OPTIMIZATION

CTi Controltech continues to invest in its capabilities and technologies to help our customers realize more payback from their plant assets.

Equipment Life Cycle Optimization — Through a combination of on-site assessments and technology, CTi experts help customers benchmark operational performance, define key metrics, and implement precise solutions to achieve long-term operational goals.

Intelligent Product Solutions — By employing an array of sophisticated products, services, and software that collects, examines and understands data, CTi Controltech helps customers use predictive analytics to take action and improve asset reliability and reduce downtime.

EDUCATION AND TRAINING

CTi Controltech offers a wide range of innovative training programs to help plant operators, managers, reliability specialists, engineers and maintenance staff further develop their understanding of critical equipment and processes.

Training at CTi — At our state-of-the-art facility in San Ramon, California, highly trained instructors provide hands-on training and instruction in the principles of process control, instrumentation maintenance, control valve operation, and equipment reliability.

Customer On-site Training — CTi Controltech will design, develop, and deliver training programs tailored specifically around the people, equipment and processes at a customer’s facility.

CTi Controltech

925-208-4250

https://cti-ct.com

Control Valves by CTi Controltech

CTi Controltech handles a complete portfolio of control valves. From linear control valves to rotary control valves, CTi can handle the most severe services, including cryogenic, superheated steam, volatile, erosive, and corrosive fluids, high pressure drops, vibration, cavitation, flashing, and high noise levels. CTi's applications engineers can select and size the best choice for your application, and counsel you on the best practices for safety, accuracy, and long operating life.

https://cti-ct.com

925-208-4250

Industrial In-line, Spring-loaded Check Valves

Check-All Check Valve

Check-All Valve manufactures in-line spring-loaded poppet-type check valves, vacuum breakers, and low pressure relief devices. All valves are available with metal to metal or soft seats. Sizes range from 1/8” NPT to 20 inch flanged connections. Pressure ratings are available from full vacuum to 10,000 psi. Special materials available are Titanium, Alloy C-276, alloy 20 and many others. Fluoropolymer (FEP) encapsulated springs are available for special corrosion applications.

Certifications & Compliances

• ISO 9001
• 3-A Sanitary Standards
• B16.34 Certification
• Canadian Registration Number
• CE (PED 2014/68/EU) Conformance
• NACE Standards

For more information, download the Check-All Valve Product Catalog from this link, or view the embedded document below.

CTi Controltech
https://cti-ct.com
925-208-4250

Check-All Valve Product Catalog from CTi Controltech

Welcome to CTi Controltech

Since 1976 CTi Controltech has represented the leading process control and combustion manufacturers.  These products, together with our engineering capabilities, give CTi customers high quality solutions to the most difficult industrial applications.

CTi is focused on the top quality manufacturers in process control, valves, instrumentation, and combustion. Over the past three decades CTi has continually added and upgraded the quality of companies it represents.

Our staff of engineers and technicians is well versed with all our products and are ready to help you with your most demanding applications.

Fluid Processing - Plug Valves

Plug valve cutaway view
Image courtesy Flowserve - Durco

Fluid process control operations commonly employ pumps, piping, tanks and valves as the means of transporting, containing and controlling the fluid movement through a system.

Valves, of which there are many types, provide control over the flow rate, direction and routing of fluids in a processing operation. Flow can be started, stopped or modulated between zero and full rate using a properly sized and configured valve. Some valves enable media flow to be diverted to a selection of outlets, in lieu of a single inlet and outlet pair. Specialized valves regulate inlet or outlet pressure, or prevent fluid flow from going in an undesirable direction. All of these capabilities are packaged into differing valve product offerings that present a very large selection array to a process designer or engineer.

Industrial flow control valve types are generally classified according to the structure or arrangement contained within the valve body that provides obstruction to fluid flow. Some of the common types are ball, butterfly, gate, globe, and plug. Surely, there are more valve types, and this article is not intended to list them all. Some of our previous blogs have discussed selection considerations for gate, ball and butterfly valves. This article will focus on one of the oldest valve types, the plug valve.

Plug valves, like ball and butterfly valves, span from fully open to fully closed positions with a shaft rotation of 90 degrees. The “plug” in a plug valve is installed in the flow path within the valve body and rotated by means of a stem or shaft extending to the exterior of the body. Plugs are often tapered toward the bottom and are fitted to a seating surface in the valve body cavity that prevents fluid from bypassing the plug. An opening through the plug, the port, can be shaped to provide particular flow characteristics. There are numerous variants of the basic plug valve which may make it suitable for particular applications. One common variant is the lined or sleeved plug valve, with an insert or interior lining of material that creates an isolating barrier between the valve body and the media. This allows use of less expensive materials for the body construction that may be otherwise subject to corrosion by exposure to aggressive media.

Plug valves can be selected for a number of attributes.

• 90 degree rotation from open to closed provides fast operation.
• With proper configuration, can be well suited for frequent operation.
• Availability of corrosion resistant liner may provide comparative cost savings because valve body can be constructed of less expensive material.
• Design is simple and employs a low parts count.
• Valve can be serviced in place.
• Generally, low resistance to flow when fully open.
• Reliable leak-tight service due to tapered plug wedging action, replaceable sleeve, and injection of lubricant in some variants.

Potential issues of concern for plug valve application include a short list of items.

• Higher friction in the plug closure mechanism may require comparatively higher operating torque than other valve types.
• Without a specially designed plug, generally not well suited for throttling applications.
• Rapid shutoff delivered by plug design may not be suitable for some applications where hammering may occur.

Share your fluid control application challenges with a valve and automation specialist. Leverage your own knowledge and experience with their product application expertise to develop an effective solution.

High Performance Butterfly Valves for Challenging Process Fluid Conditions

High performance butterfly valves handle challenging
 media and process conditions.
Image courtesy Flowserve - Valtek Control Products

Industrial process control applications can present stringent and challenging performance requirements for the physical equipment and components that comprise the process chain. The valves employed in fluid based operations need to be resistant to the impact of extreme fluid conditions, requiring careful design and selection consideration to assure proper performance and safety levels are maintained in a predictable way.

Industrial valves intended for extreme applications are generally referred to as severe service or high performance valves. While there are plenty of published and accepted standards for industrial valves, one does not exist to precisely define what constitutes a severe service valve.

So, how do you know when to focus valve selection activities on severe service or high performance valves, as opposed to those rated for general purpose? There are a number of basic criteria that might point you in that direction:

• Extreme media or environmental temperature or pressure
• High pressure drop operation that may cause cavitation
• Rapid or extreme changes to inlet pressure
• Certain types or amounts of solids contained in the fluid
• Corrosive media

Certainly, any of these criteria might be found in an application serviceable by a general purpose valve, but their presence should be an indicator that a closer assessment of the fluid conditions and commensurate valve requirements is in order. The key element for a process stakeholder is to recognize when conditions are contemplated that can exceed the capabilities of a general purpose valve, leading to premature failure in control performance or catastrophic failure that produces an unsafe condition. Once the possibility of an extreme or challenging condition is identified, a careful analysis of the range of operating conditions will reveal the valve performance requirements.

There are numerous manufacturers of severe service or high performance valves, each with specialized product offerings focusing on a particular performance niche. Flowserve, under their Valtek brand, manufactures the Valdisk high performance butterfly valves ranging from NPS 2-52 and ASME class 150, 300, 600, 900, 1500 pressure ranges. The valve design is ideal for manual or automated actuation, installed with a manual hand gear, electric actuator, or a pneumatic actuator. Seats are available as soft or metal on this double offset butterfly valve that provides tight closure for bi-directional flow. Construction materials include carbon steel and stainless steel. A range of options and variants are available to customize the valve build to suit a replacement or new installation.

There is more information available about the Valtek high performance valve offering. Share and discuss your special requirements with a valve specialist. They have application experience and access to technical resources that can leverage your own process knowledge and experience into an effective solution.

Combustion, Emission, Steam, Valve, Automation and Instrumentation Solutions

Cti Controltech delivers process measurement and control
solutions across many industries.

CTi Controltech brings knowledge, experience and expertise to their customer relationships. We carry a broad range of process control, combustion and steam related products manufactured by globally recognized companies, along with the contracting and engineering resources to deliver complete solutions to customer challenges. CTi Controltech, located in Northern California, is a top flight provider of valves, valve actuation, emissions control and monitoring, industrial burners and boilers, pressure, temperature, level and flow instrumentation, custom SCR sytems, and steam management products. We craft solutions to the challenges our customers face everyday in process control.

Combustion, Emission and Steam Solutions

• Low and ultra low NOx burners and burner retrofits 
• BMS and CMS system design and hardware 
• Custom design SCR Systems 
• Burner air fuel mix recalibration 
• Pre-emission test and boiler tune-ups 
• Heat rate, efficiency studies and plant improvement 
• Vapor recovery 
• Particulate and CO2 control 

Valve and Automation Solutions

• Severe service valve sizing and selection 
• Valve and actuation packages, pneumatic, hydraulic and electric 
• Noise and cavitation control 
• Total valve management programs 
• Turbine by-pass 
• Desuperheating and attemperation 
• Damper drives 
• Check valves 
• Vent to atmosphere and silencers 
• Best fit for purpose replacement recommendations 
• Ease of operation and life cycle cost considerations 

Pressure Relief

• Rupture disc 
• Pressure/Vacuum Relief Valves 
• Pressure Relief Valves 
• Vacuum Relief Valves 
• Pilot Operated Valves 
• Flame and Detonation Arresters 
• Emergency Relief Valves 
• Waste Gas Burners 
• Pressure Regulators 

Instrumentation Solutions

• Flow, level, pressure, density and temperature 

Services

• Factory trained service personnel 
• Commissioning and startup technical support 
• Technical seminars and training 
• Valve and actuator calibration and startup 
• Instrument calibration and startup 
• Complete turnkey project capabilities 
• U.L. 508 custom design 
• Project CAD drawings 
• PLC Programming 
• CFD and modeling 

Lined Ball Valves

Lining of ball valves extends their application to a range
of corrosive fluids.
Image courtesy Flowserve - Atomac

Lined valves of all types have an isolating layer of material that keeps the media from contacting the valve body, maybe even the valve trim itself. The purpose of the lining is generally to extend the useful life of the valve by eliminating the corrosive effect that may be imparted by media on the valve construction. Lined valves, with no exception I can think of, will have metal bodies. The lining can be any of a number of materials that will be selected based upon resistance to degradation by the process media under consideration.

Lined ball valves deliver the performance of conventional ball valves, coupled with the corrosion protection afforded by an appropriate lining material.

• Low pressure loss
• Quarter turn operation
• Simple automation
• Positive shutoff
• Low to moderate operating torque
• Compact

Options for the ball configuration are available to meet throttling or other requirements. Automation can be accomplished via a range of means. For more information, share your valve and automation challenges with application specialists and leverage your own knowledge and experience with their product application expertise.

Atomac Lined Ball Valves from CTi Controltech

Differential Pressure Transmitter Inferential Applications

Differential pressure transmitter for industrial
process control applications.
Image Courtesy Azbil North America

Differential pressure transmitters are utilized in the process control industry to represent the difference between two pressure measurements. One of the ways in which differential pressure (DP) transmitters accomplish this goal of evaluating and communicating differential pressure is by a process called inferential measurement. Inferential measurement calculates the value of a particular process variable through measurement of other variables which may be easier to evaluate. Pressure itself is technically measured inferentially. Thanks to the fact numerous variables can be related to pressure measurements, there are multiple ways for DP transmitters to be useful in processes not solely related to pressure and vacuum.

An example of inferential measurement via DP transmitter is the way in which the height of a vertical liquid column will be proportional to the pressure generated by gravitational force on the vertical column. The differential pressure transmitter measures the pressure exerted by the contained liquid. That pressure is related to the height of the liquid in the vessel and can be used to calculate the liquid depth, mass, and volume. The gravitational constant allows the pressure transmitter to serve as a liquid level sensor for liquids with a known density. A true differential pressure transmitter also enables liquid level calculations in vessels that may be pressurized.

Gas and liquid flow are two common elements maintained and measured in process control. Fluid flow rate through a pipe can be measured with a differential pressure transmitter and the inclusion of a restricting device that creates a change in fluid static pressure. In this case, the pressure in the pipe is directly related to the flow rate when fluid density is constant. A carefully machined metal plate called an orifice plate serves as the restricting device in the pipe. The fluid in the pipe flows through the opening in the orifice plate and experiences an increase in velocity and decrease in pressure. The two input ports of the DP transmitter measure static pressure upstream and downstream of the orifice plate. The change in pressure across the orifice plate, combined with other fluid characteristics, can be used to calculate the flow rate.

Process environments use pressure measurement to inferentially determine level, volume, mass, and flow rate. Using one measurable element as a surrogate for another is a useful application, so long as the relationship between the measured property (differential pressure) and the inferred measurement (flow rate, liquid level) is not disrupted by changes in process conditions or by unmeasured disturbances. Industries with suitably stable processes – food and beverage, chemical, water treatment – are able to apply inferential measurement related to pressure and a variable such as flow rate with no detectable impact on the ability to measure important process variables.

Share your process measurement challenges with instrumentation specialists, leveraging your own process knowledge and experience with their product application expertise to develop an effective solution.

Industrial Transmitters for Pressure and Differential Pressure from CTi Controltech

The Application of Heat in Industrial Settings

Heat exchangers are found throughout industrial and
commercial settings in many sizes and types.

The measurement and control of heat related to fluid processing is a vital industrial function, and relies on regulating the heat content of a fluid to achieve a desired temperature and outcome.

The manipulation of a substance's heat content is based on the central principle of specific heat, which is a measure of heat energy content per unit of mass. Heat is a quantified expression of a systems internal energy. Though heat is not considered a fluid, it behaves, and can be manipulated, in some similar respects. Heat flows from points of higher temperature to those of lower temperature, just as a fluid will flow from a point of higher pressure to one of lower pressure.

A heat exchanger provides an example of how the temperature of two fluids can be manipulated to regulate the flow or transfer of heat. Despite the design differences in heat exchanger types, the basic rules and objectives are the same. Heat energy from one fluid is passed to another across a barrier that prevents contact and mixing of the two fluids. By regulating temperature and flow of one stream, an operator can exert control over the heat content, or temperature, of another. These flows can either be gases or liquids. Heat exchangers raise or lower the temperature of these streams by transferring heat between them.

Recognizing the heat content of a fluid as a representation of energy helps with understanding how the moderation of energy content can be vital to process control. Controlling temperature in a process can also provide control of reactions among process components, or physical properties of fluids that can lead to desired or improved outcomes.

Heat can be added to a system in a number of familiar ways. Heat exchangers enable the use of steam, gas, hot water, oil, and other fluids to deliver heat energy. Other methods may employ direct contact between a heated object (such as an electric heating element) or medium and the process fluid. While these means sound different, they all achieve heat transfer by applying at least one of three core transfer mechanisms: conduction, convection, and radiation. Conduction involves the transfer of heat energy through physical contact among materials. Shell and tube heat exchangers rely on the conduction of heat by the tube walls to transfer energy between the fluid inside the tube and the fluid contained within the shell. Convection relates to heat transfer due to the movement of fluids, the mixing of fluids with differing temperature. Radiant heat transfer relies on electromagnetic waves and does not require a transfer medium, such as air or liquid. These central explanations are the foundation for the various processes used to regulate systems in industrial control environments.

The manner in which heat is to be applied or removed is an important consideration in the design of a process system. The ability to control temperature and rate at which heat is transferred in a process depends in large part on the methods, materials, and media used to accomplish the task. Share your process control challenges with application specialists, combining your own knowledge and experience with their product application expertise to develop effective solutions.

Wireless Transmitters In Process Measurement and Control

Industrial process instrumentation connectivity can present
substantial challenges.

In process control, various devices produce signals which represent flow, temperature, pressure, and other measurable elements of the process. In delivering the process value from the measurement point to the point of decision, also known as the controller, systems have traditionally relied on wires. More recently, industrial wireless networks have evolved, though point-to-point wireless systems are still available and in use. A common operating protocol today is known as WirelessHART™ , which features the same hallmarks of control and diagnostics featured in wired systems without any accompanying cables.

Wireless devices and wired devices can co-exist on the same network. The installation costs of wireless networks are decidedly lower than wired networks due to the reduction in labor and materials for the wireless arrangement. Wireless networks are also more efficient than their wired peers in regards to auxiliary measurements, involving measurement of substances at several points. Adding robustness to wireless, self-organizing networks is easy, because when new wireless components are introduced to a network, they can link to the existing network without needing to be reconfigured manually. Gateways can accommodate a large number of devices, allowing a very elastic range for expansion.

In a coal fired plant, plant operators walk a tightrope in monitoring multiple elements of the process. They calibrate limestone feed rates in conjunction with desulfurization systems, using target values determined experientially. A difficult process environment results from elevated slurry temperature, and the associated pH sensors can only last for a limited time under such conditions. Thanks to the expandability of wireless transmitters, the incremental cost is reduced thanks to the flexibility of installing new measurement loops. In regards to maintenance, the status of wireless devices is consistently transmitted alongside the process variable. Fewer manual checks are needed, and preventative measures may be reduced compared to wired networks.

Time Synchronized Mesh Protocol (TSMP) ensures correct timing for individual transmissions, which lets every transmitter’s radio and processor ‘rest’ between either sending or receiving a transmission. To compensate for the lack of a physical wire, in terms of security, wireless networks are equipped with a combination of authentication, encryption, verification, and key management. The amalgamation of these security practices delivers wireless network security equal to that of a wired system. The multilayered approach, anchored by gateway key-management, presents a defense sequence. Thanks to the advancements in modern field networking technology, interference due to noise from other networks has been minimized to the point of being a rare concern. Even with the rarity, fail-safes are included in WirelessHART™.

All security functions are handled by the network autonomously, meaning manual configuration is unnecessary. In addition to process control environments, power plants will typically use two simultaneous wireless networks. Transmitters allow both safety showers and eyewash stations to trigger an alarm at the point of control when activated. Thanks to reduced cost, and their ease of applicability in environments challenging to wired systems, along with their developed performance and security, wireless industrial connectivity will continue to expand.

Share your process measurement requirements and challenges with application specialists, combining your own process knowledge and experience with their product application expertise to develop effective solutions.

Dual Input Industrial Temperature Transmitter - What You Can Do

Dual input advanced industrial transmitter
has many built in functions
Courtesy Azbil

You will likely find temperature measurement to be a part of almost every industrial process. It is a mainstay of commercial and industrial processes and operations globally. Accurate measure of process, equipment, or product temperature provides operators with useful information that is utilized in countless ways. The range of available instruments and equipment for measuring temperature in industrial process settings is extensive, with devices or varied types, performance, and form factor to accommodate every application.

There are a variety of instruments and methodologies for measuring temperature, the most common of which is probably direct contact between the target substance and an appropriate temperature sensor. Industrial process applications are commonly served by thermocouples or resistance temperature detectors (RTD), chosen for their cost, accuracy, and flexibility of installation.

Every operating process is "critical" to some group of stakeholders. The process may be of great importance for a number of reasons:

• The process output may serve as an input to another process with great value.
• The process output may be of great direct value to the stakeholders.
• The process may have significant levels of hazard associated with improper or out of control operation.
• Out of control operation may result in substantial financial loss to the stakeholders.

When temperature is an important indicator of process function, whether for financial or safety reasons, the operator cannot tolerate a loss of the temperature signal. One manufacturer has an advanced solution in the form of a dual input temperature transmitter with built in functions that:

• Switch to the backup sensor if the primary has a failure indication.
• Alert the operator if the deviation between the two sensor readings indicates sensor drift. 
• In wide range temperature applications, switch between sensors with differing measurement ranges for better accuracy.

Along with HART communications and other useful features, these advanced temperature transmitters can help reduce risk and increase performance and safety. Assess how these advanced devices can enhance your process performance. A product data sheet is included below. Product specialists can help with product configuration and selection, along with any application concerns you may have.

Advanced Industrial Temperature Transmitter from CTi Controltech

Rack and Pinion Style Pneumatic Valve Actuator

One example of a pneumatic rack and pinion valve actuator
Courtesy Rotork

Three primary kinds of valve actuators are commonly used: pneumatic, hydraulic, and electric.
Pneumatic actuators can be further categorized as scotch yoke design, vane design, and the subject of this post - rack and pinion actuators.

Rack and pinion actuators convert linear movement of a driving mechanism to provide a rotational movement designed to open and close quarter-turn valves such as ball, butterfly, or plug valves and also for operating industrial or commercial dampers. The rotational movement of a rack and pinion actuator is accomplished via linear motion and two gears. A circular gear, known as a “pinion” engages the teeth of one or two linear gears, referred to as the “rack”. Pneumatic actuators use pistons that are attached to the rack. As air or spring power is applied the to pistons, the rack changes position. This linear movement is transferred to the rotary pinion gear (in both directions) providing bi-directional rotation to open and close the connected valve.

Rack and pinion gear
Courtesy Wikipedia

The actuator pistons can be pressurized with air, gas, or oil to provide the linear the movement that drives the pinion gear. To rotate the pinion gear in the opposite direction, the air, gas, or oil must be redirected to the other side of the pistons, or use coil springs as the energy source for rotation. Rack and pinion actuators using springs are referred to as "spring-return actuators". Actuators that rely on opposite side pressurization of the rack are referred to as "direct acting".

Most actuators are designed for 100-degree travel with clockwise and counterclockwise travel adjustment for open and closed positions. World standard ISO mounting pad are commonly available to provide ease and flexibility in direct valve installation. NAMUR mounting dimensions on actuator pneumatic port connections and on actuator accessory holes and drive shaft are also common design features to make adding pilot valves and accessories more convenient.

Pneumatic rack and pinion actuators are compact and effective. They are reliable, durable and provide good service life. There are many brands of rack and pinion actuators on the market, all with subtle differences in piston seals, shaft seals, spring design and body designs. Some variants are specially designed for very specific operational environments or circumstances.

Share your process valve control and automation challenges with application experts, and combine your process experience and knowledge with their product application expertise to develop effective solutions.

Electric Control Valve Actuators

CVQ Electric Valve Actuator
For quarter turn valves
Courtesy Rotork

Many process control valve installations present the option of selecting either electric or pneumatic actuators as part of the control component train. Pneumatic actuators have been in use for many years, but advances in electric motor design that delivered greater torque and more precise operation have brought electric valve actuators into a prominent market position.

Electric actuators are compact and comparatively self contained, requiring only cable connections and none of the additional devices sometimes needed for a pneumatic installation. There are some points of advantage to consider with electric actuators. Rotork introduced their CVA line of electric actuators almost ten years ago, making it something of a mature product now. Here are some advantageous points about the CVA actuators that likely apply generically as well.

• Setup is accomplished with a Bluetooth enabled device which provides quick calibration of open and closed positions, as well as establishment of valve setup parameters.
• A separately sealed electrical connection compartment keeps motor and mechanical compartment isolated from the environment while electrical connection section cover is removed.
• An on board datalogger records thrust and position data over time for use in asset management and service functions. Data can be downloaded by Bluetooth or transmitted by common protocol to another station.
• Change in setpoint produces a rapid and precise change in valve position with high resolution accuracy and repeatability.
• Actuator can be programmed to move to a preset condition in the event of a loss of electric power. The energy to achieve the failsafe position is stored in the actuator.
• Force balance positioning used in pneumatic valves, with spring force vs. air pressure, has resilience that can result in a change in position of the valve trim in response to a bump in system pressure. Resistance from the gear train on electric drives prevents this movement.
• Static friction of the valve packing and other parts increases the amount of force to intially get the valve moving toward a new position. The additional time required to build air pressure and force to overcome static friction results in delayed valve response, then overshoot of the new setpoint. A combination of a sensor system and the mechanical drive section of an electric actuator eliminates overshoot and delayed response.

Electric actuators can be had in quarter turn and linear versions, with torque ranges suitable for a broad range of process control applications. The datasheet below, from Rotork, provides useful illustrations of the actuator interior, along with additional detail about electric actuators. Share your process control valve requirements and challenges with product application specialists, combining your own process knowledge and experience with their product application expertise to develop the best solutions.

Electric Control Valve Actuators for Industrial Process Applications from CTi Controltech

Lined Ball Valves Provide Corrosion Protection Without Exotic Alloys

Cutaway view of lined ball valve
Flowserve Atomac

Ball valves are a staple of fluid process control, delivering a host of design and performance attributes making them the valve of choice for many applications. When the process involves corrosive fluids, steps must be taken to accommodate the aggressive nature of the media, so that valve trim and body are not prematurely degraded by the intended use.

A good solution for valves exposed to aggressive media is an interior lining of fluoropolymer or other material resistant to the corrosive effect of the fluid. Employing a lining protects the valve metal parts from contact with the fluid, allowing the use of less expensive metals in the construction of valve body and other valve components. In extreme cases, ball valves can be delivered with fluid paths fabricated of ceramic material for superior corrosion and erosion resistance.

Flowserve Atomac is a globally recognized leader in the manufacture of lined ball valves, as well as lined strainers, sight glasses, sampling valves, and check valves. Lined ball valves are available in essentially all the configurations expected of more conventional ball valves, including diverter and control service versions.

An overview of the Atomac line is included below. Share your corrosive fluid processing challenges with a product specialist, combining your process expertise with their product application knowledge to deliver effective solutions.

Lined Ball Valves Provide Corrosion Protection from CTi Controltech

New Introductory Video From CTi Controltech

CTi Controltech has released a new welcome video illustrating the company's capabilities. CTi’s expertise includes burner management and combustion control, as well as other areas of process control in the refining, power (including renewable such as geothermal and solar), food, specialty chemicals, mining, and semi-conductor industries. The company's personnel resources include engineers, technicians, and sales/support staff. CTi Controltech is strategically based in San Ramon, CA.