INDUSTRIAL BOILER

April 2019 • Volume 26, Number 4

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Buying Advice

INDUSTRIAL BOILER

PH0419 Cover-v3.indd 1 3/18/19 10:31 PM

5 PPM NOx WITHOUT SCR?THAT’S SMART.Our new SOLEX™ burner can

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PH0219-John Zink..indd 1 1/22/19 10:10 AM

www.process-heating.com APRIL 2019 3

APRIL 2019 Volume 26 • Number 4APRIL 2019 Volume 26 • Number 4

38

Columns & Departments 4 Commentary 6 Inner Workings 11 Calendar41 Product Highlights44 Photo Gallery

45 Advertiser Index45 Classified Directory46 Places & Faces46 Contact Us

PROCESS HEATING (ISSN: Print 1077-5870 and Digital 2328-9996) is published 12 times annually, monthly, by BNP Media, Inc., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualifi ed individuals. Annual rate for subscriptions to nonqualifi ed individuals in the U.S.A.: $149.00 USD. Annual rate for subscriptions to nonqualifi ed individuals in Canada: $184.00 USD (includes GST & postage); all other countries: $209.00 (int’l mail) payable in U.S. funds.Printed in the U.S.A. Copyright 2019, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations.Periodicals Postage Paid at Troy, MI and at additional mailing offi ces.POSTMASTER: Send address changes to: PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076.Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to IMEX Global Solutions, P.O. Box 25542, London, ON, N6C 6B2.Change of address: Send old address label along with new address to PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. For subscription information or service, please contact Customer Service at: Phone: (800) 952-6643 Fax: (847) 763-9538.

About the CoverA deaerator unit and boiler makeup feedwater tank from Hurst Boiler (www.hurstboiler.com), Coolidge, Ga., are installed as part of the steam system in a pharmaceutical manufacturing plant. Process Heating’s annual Equipment Overview on Boilers serves as an effective tool to help you to find suppliers. To use our annual boilers guide, turn to page 20.

April 2019 • Volume 26, Number 4

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process-heating.com

Buying Advice

INDUSTRIAL BOILER

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3/18/19 10:31 PM

Online Exclusives Web -Exclusive Podcasts from Process HeatingVisit www.process-heating.com/podcasts to catch recent episodes on fluid-bed drying, combustion controls for fired heaters and controlling NOx and other emissions from industrial processes.

Video Demonstrates RTD FunctionalityVisit SOR’s YouTube channel to view an overview of RTD technology and how it works.

Quick links point the way:www.process-heating.com/connect

Go MobileUse your smart phone to read Process Heating, wherever you are! Point your phone or tablet’s camera at the image at right to scan the QR code with your mobile phone or tablet. Your device will display the mobile version of the current issue of Process Heating instantly!Your mobile service provide may charge for data transmission usage. Contact your mobile provider for details on your data plan and limits.

12 Combustion ControlsControlling Combustion for Fired HeatersAn evaluation of measurements and control philosophies utilized in fired heater systems identifies opportunities to leverage available technology to improve heater performance.

16 Improving Efficiency in Fluid-Bed DryingDryer design changes can help boost thermal, energy and operational efficiencies.

20 Equipment OverviewIndustrial BoilersUsed for generating steam for power, processing or space heating, or for producing hot water to heat products or a hot water supply, a boiler delivers steam or hot fluid to the end use point at the desired pressure and temperature. But once you know that you need a boiler, how do you find a supplier? One source is Process Heating’s annual Equipment Overview on Boilers.

24 Valves Desuperheater Application Best PracticesProper specification, installation and maintenance of desuperheaters and associated control valves will increase efficiency and uptime.

29 Temperature MeasurementHow to Select Temperature-Measurement ComponentsSome applications use a modular approach to temperature sensing while others must be built from scratch. Fortunately, there is no shortage of temperature sensor options to solve even the most complex problems.

34 Temperature MeasurementWireless RTDs: The Modernization of Temperature Measurement Wireless RTDs have bridged the gap from decades of hardware to remotely connected devices.

38 Additive ManufacturingPerfecting Diffusion BondingSpecialized furnaces with integrated presses provide superior control of pressure and temperature to create better diffusion bonds when joining similar or dissimilar metals.

Features

Always Online� Archives � Energy Notes column � Digital Editions� Calendar of Events � Equipment Overviews � Buyers Guide� Drying Files columns � Heating Highlights � Archived Webinars� New Products � Industry News

Check out our redesigned site with more frequent updates and web exclusives!

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PH0419 TOC.indd 3 3/19/19 2:07 PM

It’s a point of pride that I have every issue of Process Heating ever published cataloged in a small library in my home office. Admittedly, it’s not as tidy as you might find at your local library. I tend to stack issues that I “check out” on the floor in front of the library until it’s time to clean my office. And, while my lazy filing means a career as a bibliophilic cataloger is doubtful, it also provides opportunities for rediscovery.

Such was the case as I paged through the September 2014 issue and came across my own column, “Life Lessons from Process Heating.” Though you can read the complete column online, one life lesson that bears repeating is, “Innovation is essential to manufacturing success. Keeping your products in line with and even ahead of your competitors’ — and more importantly, your customers’ wants and needs — is a challenge, and not one that can be ignored.”

Certainly, some principal concepts — heat transfer fluids should be tested at least annually, or product loading within an oven must influence airflow design if you hope to achieve effective and consistent product heating, for instance — are virtually truisms, typically because they reflect immutable laws of physics, chemistry and heat transfer. Those same immutable laws also can drive innovation and ingenuity. As Larry Stoma notes in his article, while the drilled-hole deck in fluid-bed dryers has been used as the conveying surface for decades, innovations in deck design may improve heat transfer and temperature uniformity. The wedge-wire deck design Stoma describes also addresses other limitations of the drilled-hole design such as clogging, hot spots and dead spaces. Stoma will be joining me for a Process Heating podcast in April, so visit www.process-heating.com/podcasts to hear more about fluid-bed drying.

Innovation and ingenuity are also the drivers behind a burner with a mixed-air combustion zone that serves as the focus of an article from Tom Korb, Chad Carroll and Jose Córcega of John Zink Hamworthy Combustion. The article looks at factors that can lead to sub-stoichiometric

combustion in fired heaters, and how burner-level insights allow the operator to optimize heater operation without sacrificing safety.

Additive manufacturing in the form of diffusion bonding, a solid-state welding technique used to join similar and dissimilar metals with heat and pressure, is a modern innovation that is being

exploited to make new technologies for process heating and cooling. Conformal cooling channels can be formed directly into the bonded materials, allowing the heat transfer paths to closely follow the dimensions and contours of items such as plastic injection molds. The diffusion bonding process also is suitable for joining refractory and other high strength alloyed materials together without brazing, says the engineering team at PVA TePla America. It’s certainly a technology that bears watching.

Temperature-sensing technologies have evolved from simple two-wire thermocouples to wireless protocol based remote-sensing devices. One article in this issue high lights how innovation can augment existing solutions to create a seamless networked solution. Stephen Drake, Ph.D., of heat tracing system maker Thermon, and Ted Johnson of measurement and control devices manufacturer SOR Controls Group, teamed up to offer insights on wireless RTDs and the modernization of industrial process temperature measurement. As Drake and Johnson note, wireless RTDs are not a new concept. For legacy plants and systems, however, their adoption likely depends on when controls upgrades are planned or when a spot-specific solution is required.

How have your process heating technologies evolved?

Commentary

More Life Lessons from Process Heating

By Linda Becker

Chemicals/Petrochemicals

Food Processing

Finishing

Plastics/Rubber

Pharmaceuticals

Pulp/Paper/Wood/Converting

Ethanol/Biodiesel

Packaging/Printing

Electronics

HeatProcessing

Technologies for these

9 Industries

Visit www.process-heating.com to read industry-focused content as well as thousands of articles covering industrial heat processing equipment.

Linda Becker, Associate Publisher and Editor, [email protected]

4 APRIL 2019 Process Heating

Listen to the Process Heating Podcast atwww.process-heating.com/podcasts

Have something to say? Send your idea to Linda Becker at [email protected] Commentary.indd 4 3/19/19 4:31 PM

GO DIGITAL IN 2019

PROCESS HEATING’s Digital Edition is an engaging format that is viewable from any device. Our simple keyword research tool makes ÿ nding and saving articles relevant to you just a click away. Get your FREE subscription in your email inbox each month by requesting your digital edition today.

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Inner Workings

Lucifer Furnaces supplied several convection ovens to a manufacturer of small medical parts in the southern United States. The units, which heat to 1200°F, are insulated with 4.5” of multilayered firebrick and 2” insulat-ing cold-face block with overlapped seams for reduced thermal loss. Tem-perature uniformity is achieved with recirculating airflow.

Onboard controls include a Honeywell UDC3500 digital time-proportioning temperature controller with four 20-segment setpoint programs. A high limit controller from Honeywell is used to prevent temperature excursions.

The side-wall heating element banks consist of coil-wound resis-tance wire in ceramic holders to ease replacement. A horizontal-swing door with adjustable latch provides a firm brick-to-brick seal, according to Luci-fer. A safety switch powers off both fan and heating elements when the door is opened to protect the user.

Brewery Utilizes Boiler to Expand OutputAn East Coast Brewery implemented a low pressure steam heating system and energy-efficient boiler to help

increase its production.Cypress Brewing, Edison, N.J., want-

ed to go from a two-barrel system to a 20-barrel system. (Each barrel pro-duces approximately 31 gallons.) After a review, the three-year-old company installed low pressure steam, cast-iron boiler manufactured by Weil-McLain.

In a low pressure steam brewery operation, the boiler converts the

water into steam. This steam enters the steam main and travels to the boil ket-tle and the hot liquor tank, a tank that just holds water, and heats the water. The steam then enters jackets inside the boil kettles, where it releases its latent heat. Once the kettle condenses the steam, it releases the condensate via float and thermostatic steam drip traps to a condensate receiver and pump that moves the condensate to a boiler feed pump, which returns the condensate to the boiler when the water level falls low enough.

Following the boiler change, the production process at the brewery averages 28 days, according to the boiler manufacturer. More impor-tantly, says the maker, Cypress Brew-ing is seeing less charring of the beer, and the overall steam process heating energy cost is less expensive than it had been with its previous system, an all-electric heating method.

Brazing School Set for Early MayA spring session of a furnace brazing school will be held May 7-9 at Wall Colmonoy’s Aerobraze Brazing Engineering Center in Cincinnati.

Manufacturer of Medical Parts Orders Convection Ovens


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Inner Workings

Engineers, technicians, quality managers and production managers can participate in hands-on practical exercises while learning about brazing technology. The three-day seminar will include sessions on:

• Brazing design.• Metallurgical aspects and brazing

operation.• Brazing atmosphere and furnace

equipment.• Brazing material selection and ap-

plications.• Quality control.

Attendees will be able to tour the facility and see an actual brazing application on the shop floor. They also will have the opportunity to apply different forms of filler metal to supplied samples, have them vacuum brazed and discuss the outcomes.

Visit www.wallcolmonoy.com for seminar details or to register.

U.S. Government Funds Curing Oven for Airplane PartsEpcon Industrial Systems was selected to build an industrial oven with two combustion chambers located on top and three guillotine doors. The large unit, which will cure airplane parts, was funded by the United States government with a comprehensive site factory acceptance test (FAT) and on-site commissioning.

Each 20’ section of the oven can operate independently or as a single unit, providing flexibility in the line.

Refinery Selects Program for Valve Actuation ManagementHengyuan Refining Company Berhad chose the Rotork client-support pro-gram (CSP) for the asset management of Rotork valve actuation equipment

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Inner Workings

at its Port Dickson refinery in Malaysia. The CSP encompasses 157 Rotork electric actuators, a Rotork master sta-tion and Pakscan control-loop testing facility.

The client-support program is designed to increase valve actuator

and control product reliability and availability via planned maintenance, predictive maintenance and asset management. The primary goal is to identify and eliminate any potential issues before they occur. This includes equipment checks, replacement of

worn components and partial or com-plete overhauls at specific periods. The refinery will have continuous access to Rotork support centers with prioritized technical assistance.

Emergency at Pulp-and-Paper Facility Calls for Watertube Boilers

A pulp-and-paper facility in the Pacific Northwest was forced to take down its large power boiler for repairs. The company called on Nationwide Boiler Inc. to provide two 70,000 lb/hr package watertube boilers on a fast-track emergency basis.

Each trailer-mounted boiler trav-eled nearly 1,000 miles to the site and was delivered, installed and put into service in just seven days. The boilers are currently operating and support-ing production at the pulp-and-paper facility. According to Nationwide, they will continue providing steam to the plant through the duration of the repairs.

Endress+Hauser Breaks Ground on Texas FacilityAutomation company Endress+Hauser broke ground at its new site in Pearland, Texas, just outside of the Houston area. The $38.5 million, 112,000 ft2 facility will include areas for calibration, repair and training, as well as a new process training unit (PTU).

The facility also will house teams to support the company’s products and services for process automation; SpectraSensors’ gas analysis systems; and Analytik Jena’s product lines for laboratory instrumentation.

The campus will include a building and warehouse location for

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Inner Workings

Endress+Hauser’s partner for sales and service in the Gulf, Vector Controls and Automation Group. In all, 110 employees are expected to be on-site once the facility is complete. Completion is scheduled by the end of 2020.

Calibration Center Opens in ChinaBriskHeat, a provider of flexible heating, insulating, temperature-control and composite-curing solutions, opened a calibration center in Shenzhen, China. It joins the company’s ACR hot bonder calibration and repair centers in Columbus, Ohio, and AeroNed B.V. in Rotterdam Netherlands. The centers are manned by technical product specialists and sales engineers to provide field training and phone support. Locating the centers internationally allows BriskHeat to reduce transportation costs and turnaround time for customers.

Columbus, Ohio-based BriskHeat manufactures electric process heaters, a UL- and cUL-recognized hot bonder system and composite curing equipment.

Magnatrol Valve Corporation67 Fifth Avenue • Hawthorne, NJ 07507

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Specifying SolenoidValves for Process

Heating Applications?

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3359_H Magnatrol 3.25x9.7_Layout 1 2/13/18 3:11 PM Page 1



Inner Workings

Catalytic Oxidizer Aids Sterilization Process at ManufacturerAn electrically heated catalytic oxidizer will be used by a Midwest medical products manufacturing company for the abatement of

ethylene oxide (EtO) emissions. EtO, a volatile organic compound (VOC), is a flammable, colorless gas used as an agent to sterilize equipment and plastic devices that cannot be sterilized by steam. Catalytic oxidizers are an effective technology for

controlling VOC emissions from the EtO sterilization processes.

The 400 SCFM catalytic oxidizer, manufactured and supplied by Cata-lytic Products International, will control five small, batch-style EtO-based labo-ratory sterilizers. It will destroy the VOC emissions at a minimum 99 percent VOC destruction-rate efficiency at vari-able and cyclic EtO emission loadings.

Thermal Deoiler Eliminates Toxic WastewaterA provider of stamping oil cleaning services utilized a thermal deoiler to eliminate toxic wastewater and reduce water consumption. The unit has a built-in secondary heat recovery system that uses a shell-and-tube heat exchanger design to recycle the heat from the oxidizer back into the burner-less oven.

Supplied by Epcon Industrial Sys-tems, the thermal deoiler reduced cost by more than 30 percent when com-pared to the old method of aqueous cleaning. It includes a cooling zone and multiple conveyors and platforms.



Calendar Events


April

1-4 — Powder Coating Technical Conference, Renaissance Orlando at SeaWorld, Orlando. Produced by Powder Coating Institute (PCI). Call 859-525-9988 or visit www.powdercoating.org.

2-4 — International Pharmaceutical Expo (INTERPHEX) 2019, Javits Center, New York. Call 888-334-8704 or visit www.interphex.com.

2-4 — Power Boiler Burners Course, Tulsa, Okla. Presented by John Zink Institute. Call 918-234-5710 or visit www.johnzinkinstitute.edu.

3-5 — National Insulation Association Convention, Grand Hyatt Baha Mar Nassau, Bahamas. Produced by NIA. Call 703-464-6422 or visit www.insulation.org.

7-9 — Seafood Expo Global/Seafood Processing Global, Brussels Expo, Brussels, Belgium. Call 207-842-5538 or visit www.seafoodexpo.com.

9-11 — International Converting Expo (ICE USA) 2019, Louisville, Ky. Call 312-809-9260 or visit www.ice-x-usa.com.

15-18 —Boiler Training Course (Level 1), Garden City, Kansas. Presented by Garden City Ammonia Program (GCAP), Steam Boiler Div. Call 620-271-0037 or visit www.boilerlicense.com.

16-18 — Vapor Controls Systems Course, Tulsa, Okla. Presented by John Zink Institute. Call 918-234-5710 or visit www.johnzinkinstitute.edu.

23-25 —Aquatech Annual Convention and Exposition, Las Vegas. Produced by Water

Quality Association (WQA).Call 630-505-0160 or visit www.wqa.org/convention.

24-26 — Process Flares Course, Tulsa, Okla. Presented by John Zink Institute. Call 918-234-5710 or visit www.johnzinkinstitute.edu.

29-30 — Process Burners Fundamentals Course, Tulsa, Okla. Presented by John Zink Institute. Call 918-234-5710 or visit www.johnzinkinstitute.edu.

29-May 1 — Industrial Heating Equipment Association Annual Meeting, Lido Beach Resort, Sarasota, Fla. Call 859-356-1575 or visit www.ihea.org.

29-May 1 — Process Burners Operators Training Course, Tulsa, Okla. Presented by John Zink Institute. Call 918-234-5710 or visit www.johnzinkinstitute.edu.

April 30-May 1 — Ceramics Expo, International Exposition Center (I-X Center), Cleveland. Call 855-436-8683 or visit www.ceramicsexpousa.com.

May

5-7 — Fundamentals of Industrial Automation, Instrumentation and Control Course, ISA, KBR Engineering, Hoover, Ala. Produced by the International Society of Automation (ISA). Call 919-549-8411 or visit http://bit.ly/2Gi1STp.

5-10 — ASME Boiler and Pressure Vessel Code Week, Grand America and Little America Hotels, Salt Lake City, Utah. E-Mail [email protected] or visit www.asme.org/events/boiler-pressure-vessel-code-week.

6-10 — General Meeting of the National Board of Boiler and Pressure Vessel Inspectors, The Grand American Hotel, Salt Lake

City, Utah. Call 614-888-8320 or visit www.nationalboard.org.

7-9 — Fabtech Mexico, Cintermex International Convention and Exhibition Center, Monterrey. Produced by the Society of Manufacturing Engineers. Call 508-743-8544 or visit mexico.fabtechexpo.com.

13-16 —Boiler Training Course (Level 1), Garden City, Kansas. Presented by Garden City Ammonia Program (GCAP), Steam Boiler Div. Call 620-271-0037 or visit www.boilerlicense.com.

1-2 — Advanced Process Burners Course, Tulsa, Okla. Presented by John Zink Institute. Call 918-234-5710 or visit www.johnzinkinstitute.edu.

3 — Fired Heater Reliability Course, Tulsa, Okla. Presented by John Zink Institute. Call 918-234-5710 or visit www.johnzinkinstitute.edu.

7-8 — Powder Coating 202: Optimizing Your Powder Coating Operation Workshop, Amherst, Ohio. Produced by Powder Coating Institute (PCI). Call 859-525-9988 or visit www.powdercoating.org.

13-16 — Hands-On Boiler Training Course (Level 1), Garden City, Kansas. Presented by Garden City Ammonia Program (GCAP), Steam Boiler Div. Call 620-271-0037 or visit www.boilerlicense.com or www.ammoniatraining.com.

14-16 — Eastec 2019 Manufacturing Show, Eastern States Exposition, West Springfield, Mass. Produced by the Society of Manufacturing Engineers. Call 508-743-8544 or visit easteconline.com.

PH0419 Calendar.indd 11 3/18/19 4:15 PM

for Fired HeatersAn evaluation of measurements and control philosophies utilized in fired heater systems identifies opportunities to leverage available technology to improve heater performance.

Combustion Controls


Atypical control approach for an industrial fi red heater uses global measurements to keep the system effi cient and

within safe operating limits. Differences in combustion stoichiometry between indi-vidual burners, however, can cause global measurements to produce an incomplete picture of the combustion taking place within the heater.

While global measurement and controls have been employed for decades, the im-plementation of new control philosophies

can enable signifi cant improvements in fi red heater performance. These solutions — created by combining combustion ex-pertise, new measurement technologies and advanced data analytics — provide better insight into key areas of combustion health, resulting in safer operation.

In a fi red heater, the transition from the radiant section to the convection section — often referred to as the bridgewall — is a common place for measurement of excess O2, combustible gas concentration, fl ue-gas temperature and draft (negative pressure within the fi rebox). Additionally, some fur-nace stacks are equipped with continuous emissions monitoring systems (CEMS) to measure excess O2, NOX and CO emissions for regulatory reporting purposes.

Global O2 measurements are a cost-ef-fective way to ensure there is enough com-bustion air within the fi rebox to achieve safe, complete fuel combustion. Minimiz-ing excess air improves fuel effi ciency by reducing the energy consumed to heat the additional air. Operating the heater with-out enough air to complete combustion, however, can result in unsafe conditions and should be avoided. (Common terms for this latter operating condition are heat-er bogging, sub-stoichiometric combustion and fuel-rich combustion, amongst others.)

As already mentioned, industry typically utilizes the bridgewall instead of the stack as the primary O2 measurement location for combustion control. This mitigates the risk of errors in the excess O2 measurement.

By Tom Korb, Chad Carroll and Jose Córcega, John Zink Hamworthy Combustion

CONTROLLING COMBUSTION

PH0419 John Zink.indd 12 3/18/19 4:17 PM

Process heating furnaces operate under negative pressure. As a result, “tramp,” or ambient, air can enter the heater through tube penetrations and sight ports if not sealed properly. Tramp air from the convec-tion section will skew stack O2 measure-ments to an artificially high value relative to the bridgewall section measurement.

Even though most global flue-gas mea-surements are taken at bridgewall level within the radiant box, there are still some instances where operational challenges prevent them from accurately representing the stoichiometry of each individual burn-er within the firebox. Some often-observed operational challenges include:

• Tramp-air ingress in the radiant section.• Unequal air-register settings per burner.• Gas tip plugging.

These challenges can compound as the fired heater designs become more complex. Heater features that can affect the ability to get accurate readings at the bridgewall include:

• Multiple burner-firing zones.• Different burner types, sizes and tech-

nologies• Adverse combustion flue-gas patterns.• Instrumentation drift • Mechanical burner failures.

Tramp air in the radiant section com-monly is entrained through viewing doors and radiant-tube penetrations. When air leakage enters the system, the measured ex-cess O2 will increase, which could result in a response by operations to reduce excess O2. This trimming of global excess O2 can inad-vertently result in sub-stoichiometric burner operation. Because the amount of tramp air is proportional to the heater draft, heaters that operate with significant negative pres-sure are at increased risk for air leakage and sub-stoichiometric burner operation.

In natural-draft and forced-draft heat-ers, excess O2 is most commonly tuned with stack damper or fan adjustments. Typically,

FIGURE 1. In a typical heater, a common control approach uses global measurements to keep the system efficient and within safe operating limits. Differences in combustion stoichiometry between individual burners, however, can cause global measurements to produce an incomplete picture of the combustion taking place within the heater.

Combustion Controls



the burner air register is manipulated when the stack damper or fan are outside their controllable range. Additional reasons for burner air-register adjustment include:

• Attempts to resolve undesirable flame shape.

• Localized high tube-metal temperatures measurement.

• Observations of flame impingement.

Yet, because these issues are gener-ally addressed in an isolated manner, the uniformity of burner air-register settings tends to decay with time.

While the combustion system is at nor-mal operating conditions with relatively hot flue-gas environments, sub-stoichio-metric operation of one or more burners may not be easily detectable. Generally,

burner stability and burner-flame anchor-ing are much more sensitive to burner-stoichiometry variations at low furnace temperatures. As a result, the safety con-cerns associated with varying burner-stoi-chiometric ratios are more likely to occur when the heater firing rate is reduced to turndown operating conditions or when performing cold startup operation.

To complicate matters, the distribution of fuel may vary from burner to burner. This is frequently observed when tip plug-ging or fouling takes place. Even if all burner air registers are at the same set-ting, the maldistribution of fuel can result in considerable differences in individual burner combustion stoichiometry. Because the bridgewall excess O2 measurement is an average of the stoichiometry of all burn-ers in operation, the extremes of individual

burner stoichiometry are simply unknown. Given the potentially severe consequences of sub-stoichiometric combustion, great caution should be exercised to ensure each individual burner stoichiometric ratio is acceptable and safe.

With such challenges affecting the abil-ity to accurately measure excess O2, the need for solutions to address the chal-lenges associated with global measurement and control become apparent. The abil-ity to provide the operator with operating data for each individual burner and opti-mize heater operation without sacrificing safety has contributed to the development of control technologies that combine novel measurement techniques and advanced data analytics.

These burner-level insights also can be leveraged to improve the emissions per-

FIGURE 2. Within the new burner design, two independent combustion zones are dynamically adjusted using proprietary control philosophies (left). This approach enables single-digit NOx and near-zero CO emissions throughout the operating range of the heater. The modern burner is shown firing refinery fuel gas at 8 MM BTU/hr (right).

Process Burner

Cool-Mix Zone

Mixed-Air

Combustion Controls



formance of combustion systems. Modern burner technology employing the control technologies demonstrate how the ad-vanced control philosophies can enable a level of emissions performance that was not previously possible from a burner-only solution utilizing the typical global control approach.

The key to improved emissions per-formance is the utilization of two inde-pendent combustion zones (figure 1) that are dynamically adjusted using the novel control philosophies. This approach en-ables single-digit NOX and near-zero CO emissions throughout the entire operating range of the heater, regardless of process demand, flue-gas temperature, fuel com-position and combustion air temperature.

One modern burner has a mixed-air combustion zone that utilizes a propri-etary, lean-premix arrangement to reduce NOX emissions (figure 2). The burner also

achieves shorter flames compared to tra-ditional ultra-low NOX burners. A cool-mix combustion zone utilizes proprietary remote fuel-staging techniques that per-mits global excess O2 trim while enabling single-digit NOX emission performance levels. Additionally, the decoupled nature of the cool-mix zone of combustion allows customized heat flux profiles, which can help increase process throughput.

The low NOX emissions are achieved by a reduction of localized flame temperature driven by the application of significantly high excess air within the mixed-air combustion zone. With a global control philosophy, typi-cal operational swings such as changing fuel compositions would cause the NOX from the mixed-air combustion zone to vary signifi-cantly. By contrast, the burner technology directly controls the fuel and combustion air to each burner, and to the discrete combus-tion zones within each burner.

While control philosophies that lever-age global measurements are widely ac-cepted in the process heating industry, the continual desire for improved safety, reduced emissions and optimized process performance drive the development of transformative solutions for fired heater measurement and controls. New control strategies, equipped with burner-level in-sights, are certainly a way to satisfy the industry’s growing demand for improved combustion performance.

Tom Korb is vice president of smart combustion, Chad Carroll is the process burner manager of engineering and technology development, and Jose Córcega is a process burners engineer with John Zink Hamworthy Combustion. The Tulsa, Okla.-based company can be reached at 918-234-1800 or visit www.johnzinkhamworthy.com.

The computational fluid dynamics (CFD) simulation shows multiple burners inside a heater. Smart combustion directly controls the fuel and combustion air to each burner, and to the discrete combustion zones within each burner.

Combustion Controls



in Fluid-Bed DryingDryer design changes can help boost thermal, energy and operational efficiencies.

IMPROVING EFFICIENCY

Fluid-bed dryers like this vibrating model offer an inherently efficient method of moisture removal.

Dryers


Fluid-bed dryers offer an inher-ently efficient method of mois-ture removal that has not changed since the systems were developed

in the 1950s. The introduction of ever-im-proving control technologies — personal computer-based and PLC control systems, smart sensors and other technological ad-vances — in the last 40 years, however, has changed how process engineers operate their fluid-bed drying systems. With ac-cess to accurate, real-time data, and the ability to adjust the dryer on the fly with

precision, process engineers have been able to optimize the process and improve the system efficiency.

Heat TransferFluid-bed drying offers highly effi cient heat transfer because the particles being dried are suspended in the heated process air for intimate contact with the entire sur-face area. Adding vibration provides a gen-tle force that helps liberate and allow the product to fl uidize. But, to fully capitalize on these capabilities, the airfl ow needs to be uniform throughout the entire area of the fl uid bed. A uniform airfl ow optimizes the area required for drying.

Dryer Conveying SurfaceTo introduce the fl uidizing airfl ow, many dryer manufacturers use the same type of drilled-hole deck conveying surface — a design that has been used for decades. This approach has a repeating pattern of drilled holes in a fabricated metal sheet. The heated air is directed upward through the holes, and the material is conveyed over the deck from the infeed to discharge.

Though inexpensive, the drilled-hole deck conveying surface has drawbacks. For example, the diameter of the holes needs to be small to prevent the particles from falling through or clogging the holes. This type of deck also can create hot spots and

By Larry Stoma, Witte Co.

PH0419 Witte.indd 16 3/19/19 11:26 AM

dead spaces. The hot spots have excessive heat that can cause product charring while the dead spaces lack heat and cannot ad-equately dry the product. The dead spaces also can lead to stalled material, product layering and inefficiencies, all resulting in off-specifications product. In addition, dead spaces invite clogging, which further contributes to hotter and cooler areas and requires manual unclogging to resume the airflow. Finally, the drilled-hole deck conveying surfaces can make it difficult to maintain the static pressure needed to provide the high jet velocity that keeps the particles suspended in the air.

Another fluid-bed deck approach that supports process efficiency uses a wedge-wire deck design. Instead of using round holes, this design sets the metal decking in narrow slots with a triangular, tapered pro-file running the entire dryer length. With these wires spaced 0.1875” apart, this con-cept provides a high velocity jet of air run-ning the entire length of the dryer.

In a fluid-bed dryer, a drilled-hole deck has a repeating pattern of drilled holes in a fabricated metal sheet. The heated air is directed upward through the holes, and the material is conveyed over the deck from the infeed to discharge. Dryer decks with drilled holes may have trouble maintaining the static pressure required to keep the particles suspended in the airflow.

STEAM CONTROL PRODUCTSSTEAM CONTROL PRODUCTS

Dryers


PH0419 Witte.indd 17 3/19/19 11:26 AM

The high, vertical jet of air flowing at a 90° angle perpendicular to the deck creates even air distribution for the entire drying area. Such an airflow and deck design al-lows particles as small as one micron to be processed without concern for clogged holes. In terms of air volume, the wedge-wire deck provides more open area for airflow than decks drilled with holes. This improvement in airflow efficiency also al-lows lower airflow volumes and velocities to be used for cost savings in energy and a reduced burden on the fan system.

PC/PLC ControlsOften, the most common source of inef-ficiency in a process is human error. Fortu-

nately, whether by modifying the dryer de-sign or by changing the process conditions, technological improvements are driving these inefficiencies out of the process.

Modern wireless sensors and transduc-ers relay process air temperature and prod-uct temperature data — both entering and leaving the dryer — to the operator. In addition, such controls are used to verify product moisture levels before the prod-uct enters the dryer infeed and as it exits the discharge. This level of insight allows process variables such as retention time and process air temperature to be adjusted quickly via a centralized personal com-puter or PLC. Such control systems ensure accurate, repeatable control over:

• The air temperature and volume.• Startup and shutdown sequence as well

as other parameters.

Computer or PLC-based controls also:

• Allow precise adjustments to be made via a touchscreen control panel.

• Log a history of any changes made.• Help eliminate the potential for human

error, or for human involvement that may run counter to the dryer’s design.

These systems automatically monitor the process continuously for proper operation, and they are constantly verifying the system is running at peak efficiency. In the event

Touchscreen controls on drying systems help eliminate the potential for human error. Personal computer or PLC-based control systems help ensure accurate, repeatable process management.

Dryers


PH0419 Witte.indd 18 3/19/19 11:26 AM

the system detects an unplanned change in the process or the product, an alarm may be sent instantly to quality control, produc-tion, manufacturing and other departments to rectify the situation before major product losses or line downtime is incurred.

Uniformity of FeedThe dryer itself may be optimized for ef-ficiency based on a given set of process parameters, but what if the process param-eters change without notice?

To fully capitalize on a dryer’s design, the equipment upstream must deliver a uniform product to the dryer infeed at a uniform feed rate. A surge in the feed rate would overload the dryer’s capacity for moisture removal and lead to discharging product that fails to meet the moisture requirements. Conversely, a shortage of product entering the dryer infeed may re-sult in overdrying.

For example, suppose a dryer is designed to efficiently reduce the moisture content of a product from 50 percent at the infeed to 10 percent at discharge. Due to a change in the upstream conditions, suppose the product at the infeed actually contains 75 percent moisture. (As an example, suppose the dewaterer is not operating as intend-ed.) In such a case, the dryer will not be able to meet the moisture requirements.

When faced with fluctuating process conditions, one way to improve drying efficiency is to adjust the time allotted to the material in the drying zone — a vari-able called retention time. The longer the retention time, the more moisture removal that can occur. For example, the retention time can be adjusted is by adding pneu-matically operated radius gates called au-toweirs. These automated gates rotate 60° upward and above the decks on a cycle timer to periodically slow, block or acceler-ate the rate of product advance toward dis-charge. These adjustments can be made in real time to quickly accommodate changes upstream conditions or equipment without compromising drying efficiency.

Heat SourceThe primary factor in determining wheth-er the process air is heated by natural gas, propane, steam or electricity often is avail-

ability. If the facility already has a steam plant in place, steam offers the lowest installation costs. Natural gas offers the least costly operation followed closely by propane. Electricity, with its electric coils and controls and relatively high ongoing costs, is typically cost-prohibitive for ap-plications requiring more than 1 million BTU/hr; however, electricity is a cost-efficient option in less energy-intensive applications such as drying seeds, cereals, some plastics and other delicate products at temperatures below 150°F (66°C). For slurries and products with a high moisture content such as sand and salt — which require drying temperatures above 300°F (149°C) — heating the air with natural gas may improve cost efficiency. The cost efficiency of steam typically peaks when heating the air up to 300°F.

Once the air has been raised to sev-eral hundred degrees, it becomes an asset. Rather than allow it to escape the process as exhaust, clever process engineers em-ploying heat recovery to put it to work elsewhere in the process. One method cap-tures 50 percent of the heated process air,

cleans it via a dust collector and returns it to the process. For instance, by raising the 250°F air to 500°F (121°C air to 260°C), rather than constantly raising ambient (65°F (18°C]) air to 500°F, the burden on the air heaters is reduced and energy ef-ficiency is improved. Further, the volume of air exhausted to the atmosphere may be cut in half, along with any particulates, to aid in compliance with the many environ-mental requirements.

In conclusion, implementing improve-ments in fluid-bed drying technology can improve efficiency, help reduce or eliminate waste, convert more material to saleable product, and yield direct savings in costs. As the tangible returns become visible and understood, these improve-ments at the dryer help promote a culture of efficiency that can be applied to the entire processing line — for even greater returns.

Larry Stoma is a senior sales and design engineer with the Witte Co., Washington, N.J. For more information from Witte, call 908-689-6500 or visit www.witte.com.

Wedge-wire decks use narrow slots with a triangular, tapered profile running the entire length of the dryer. A high velocity jet of air flows perpendicular to the deck for even air distribution.

Dryers


PH0419 Witte.indd 19 3/19/19 11:26 AM


Equipment Overview Boilers

image?

Type Design/Construction Fabrication Method Fuel / Energy Source Rating

(Provided in BHP | BTU/hr | lb/hr of Steam) Kilowatt Rating Design Pressure Auxiliary Systems O˜ ered Industries Served

We

man

ufac

ture

aft

erm

arke

t par

ts/s

uppl

ies

for o

ur b

oile

rs.

Fire

Tu

be, H

orizo

ntal

Ret

urn

Tubu

lar

Fire

Tub

e, S

cotc

h/Sc

otch

Mar

ine/

Shel

lFi

rebo

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ater

Tu

be Oth

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st Ir

onCo

il-Ty

peFi

re B

oxSt

eam

Gen

erat

orRa

dian

tTu

bele

ssO

ther

Pack

aged

/Ski

d-M

ount

edFa

ctor

y As

sem

bled

Fiel

d Er

ecte

dO

ther

Biom

ass/

Biod

iese

lDu

al F

uel (

Com

bina

tion

Oil a

nd G

as)

Elec

trici

tyHe

avy

Oil

Ligh

t Oil

Natu

ral G

asPr

opan

eO

ther

<100

| 3,

347,

500

| 3,4

5010

1 | 3

,380

,975

| 3,

485

200

| 6,6

95,0

00 |

6,90

020

1 | 6

,728

,475

| 6,

935

300

| 10,

042,

500

| 10,

350

301

| 10,

075,

975

| 10,

385

500

| 16,

737,

500

| 17,

250

501

| 16,

770,

975

| 17,

285

600

| 20,

085,

000

| 20,

700

601+

Up

To 1

0 kW

11 T

o 25

kW

26 T

o 50

kW

51 T

o 10

0 kW

101

To 2

00 k

W20

0 To

300

kW

301

To 5

00 k

W50

1 To

1,0

00 k

WG

reat

er T

han

1,00

0 kW

Less

Tha

n 15

psi

g16

To

150

psig

151

To 2

00 p

sig

201

To 3

00 p

sig

301

To 5

00 p

sig

501

To 1

,000

psi

gG

reat

er T

han

1,00

0 ps

igA

tmos

pher

ic F

eedw

ater

Rec

eive

rCo

nden

sate

Ret

urn

Syst

emD

eaer

ator

Econ

omiz

er/H

eat R

ecov

ery

Syst

emEx

tern

al H

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r Uni

t (To

Pre

-Hea

t Wat

er)

Low

NO

X Bur

ners

Wat

er C

ondi

tione

r/Tr

eate

rO

ther

Chem

ical

s/Pe

troc

hem

ical

sEl

ectr

onic

sO

il &

Gas

/Eth

anol

/Bio

dies

el F

uels

Fini

shin

gFo

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ssin

gPa

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Prin

ting

Phar

mac

eutic

alPl

astic

s/Ru

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Pulp

/Pap

er/F

ores

t Pro

duct

s/Co

nver

ting

Clayton Industries626-435-1200, www.claytonindustries.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes

Hurst Boiler & Welding Co. Inc.229-346-3545, www.hurstboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes

Miura America Co. Ltd.678-685-0929, www.miuraboiler.com • • • • • • • • • • • • • • • • • • • • • • • Yes

Parker Boiler Co.323-727-9800, www.parkerboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes

Acme Engineering Products Inc. • 518-236-5659, www.acmeprod.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesA� liated Steam Equipment Co. • 800-424-5392, www.a� liatedsteam.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *Babcock & Wilcox Co. • 704-625-4900, www.babcock.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesBryan Boilers • 765-473-6651, www.bryansteam.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesCleaver-Brooks Inc. • 800-250-5883, www.cleaverbrooks.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesComStar International Inc. • 718-445-7900, www.comstarproducts.com • • • • • • • • • • • • • • • • • • YesFin Tube Products Inc. • 330-334-3736, www.� ntube.com • • • • YesFives North American Combustion Inc. • 216-373-8162, www.combustion.� vesgroup.com • • • • • • • • • • • YesFulton Companies • 315-298-7182, www.fulton.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesGasmaster Industries • 604-523-0600, www.gasmaster.ca • • • • • • • • • • • • • • • • • • • YesHalgo Power Inc. • 469-368-8900, www.halgopower.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesHamilton Engineering Co. Inc. • 734-419-0200, www.hamiltonengineering.com • • *Indeck Power Equipment • 847-541-8300, www.indeck.com • • • • • • • • • • • • • • • • • • • • • • • • • • • YesJohnston Boiler Co., Hines Corp. • 616-842-5050, www.johnstonboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesLattner Boiler Co. and Unical/Lattner • 319-366-0778, www.lattnerboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes

Used for generating steam for power, processing or space heat-ing, or for producing hot water to heat products or a hot

water supply, a boiler delivers steam or hot fluid to the end-use point at the desired pressure and temperature. But, once you know that you need a boiler, how do you find a supplier? One source is Process Heating’s annual Equipment Overview on Boilers.

Complete listings are shown below. To view the matrix of

industrial boiler manufacturers online and automatically widen or narrow your search results based on the criteria you select, visit www.process-heating.com/directories. On that page, click on Equipment Overviews, then on Boilers in the upper left. Online, you can view an overview of each manufacturer’s capabilities, see all manufacturers that offer certain features, or search by keyword. Also online, some manufacturers have upgraded listings that


Companies with an in front of their names have an advertisement in this issue.

SAFER BY DESIGN▶ Low-water content design means less stored potential energy.▶ Unique technology and boiler geometry ensures greater safety.▶ Advanced, numerous safeguards maximize safer operation.▶ A better watertube boiler built around safety, reliability, e� iciency.

miuraboiler.com Manufactured in Rockmart, GAManufactured in Manufactured in Rockmart, GA

Miura_Process Heating Boiler Listing Ad.indd 1 3/19/18 4:55 PM

Search online at www.process-heating.com/boilers-chart

PH0419 EO Boilers.indd 20 3/19/19 11:59 AM


image?


(Provided in BHP | BTU/hr | lb/hr of Steam) Kilowatt Rating Design Pressure Auxiliary Systems Offere Industries Served

We

man

ufac

ture

aft

erm

arke

t par

ts/s

uppl

ies

fo

r our

boi

lers

.

Fire

Tu

be, H

orizo

ntal

Ret

urn

Tubu

lar

Fire

Tub

e, S

cotc

h/Sc

otch

Mar

ine/

Shel

lFi

rebo

xW

ater

Tu

be Oth

erCa

st Ir

onCo

il-Ty

peFi

re B

oxSt

eam

Gen

erat

orRa

dian

tTu

bele

ssO

ther

Pack

aged

/Ski

d-M

ount

edFa

ctor

y As

sem

bled

Fiel

d Er

ecte

dO

ther

Biom

ass/

Biod

iese

lDu

al F

uel (

Com

bina

tion

Oil a

nd G

as)

Elec

trici

tyHe

avy

Oil

Ligh

t Oil

Natu

ral G

asPr

opan

eO

ther

<100

| 3,

347,

500

| 3,4

5010

1 | 3

,380

,975

| 3,

485

200

| 6,6

95,0

00 |

6,90

020

1 | 6

,728

,475

| 6,

935

300

| 10,

042,

500

| 10,

350

301

| 10,

075,

975

| 10,

385

500

| 16,

737,

500

| 17,

250

501

| 16,

770,

975

| 17,

285

600

| 20,

085,

000

| 20,

700

601+

Up

To 1

0 kW

11 T

o 25

kW

26 T

o 50

kW

51 T

o 10

0 kW

101

To 2

00 k

W20

0 To

300

kW

301

To 5

00 k

W50

1 To

1,0

00 k

WG

reat

er T

han

1,00

0 kW

Less

Tha

n 15

psi

g16

To

150

psig

151

To 2

00 p

sig

201

To 3

00 p

sig

301

To 5

00 p

sig

501

To 1

,000

psi

gG

reat

er T

han

1,00

0 ps

igA

tmos

pher

ic F

eedw

ater

Rec

eive

rCo

nden

sate

Ret

urn

Syst

emD

eaer

ator

Econ

omiz

er/H

eat R

ecov

ery

Syst

emEx

tern

al H

eate

r Uni

t (To

Pre

-Hea

t Wat

er)

Low

NO

X Bur

ners

Wat

er C

ondi

tione

r/Tr

eate

rO

ther

Chem

ical

s/Pe

troc

hem

ical

sEl

ectr

onic

sO

il &

Gas

/Eth

anol

/Bio

dies

el F

uels

Fini

shin

gFo

od P

roce

ssin

gPa

ckag

ing/

Prin

ting

Phar

mac

eutic

alPl

astic

s/Ru

bber

Pulp

/Pap

er/F

ores

t Pro

duct

s/Co

nver

ting

Clayton Industries626-435-1200, www.claytonindustries.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes

Hurst Boiler & Welding Co. Inc.229-346-3545, www.hurstboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes

Miura America Co. Ltd.678-685-0929, www.miuraboiler.com • • • • • • • • • • • • • • • • • • • • • • • Yes

Parker Boiler Co.323-727-9800, www.parkerboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes

Acme Engineering Products Inc. • 518-236-5659, www.acmeprod.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesAffiliated Steam Equipment Co. • 800-424-5392, www.affiliatedsteam.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *Babcock & Wilcox Co. • 704-625-4900, www.babcock.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesBryan Boilers • 765-473-6651, www.bryansteam.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesCleaver-Brooks Inc. • 800-250-5883, www.cleaverbrooks.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesComStar International Inc. • 718-445-7900, www.comstarproducts.com • • • • • • • • • • • • • • • • • • YesFin Tube Products Inc. • 330-334-3736, www.fintube.com • • • • YesFives North American Combustion Inc. • 216-373-8162, www.combustion.fivesgroup.com • • • • • • • • • • • YesFulton Companies • 315-298-7182, www.fulton.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesGasmaster Industries • 604-523-0600, www.gasmaster.ca • • • • • • • • • • • • • • • • • • • YesHalgo Power Inc. • 469-368-8900, www.halgopower.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesHamilton Engineering Co. Inc. • 734-419-0200, www.hamiltonengineering.com • • *Indeck Power Equipment • 847-541-8300, www.indeck.com • • • • • • • • • • • • • • • • • • • • • • • • • • • YesJohnston Boiler Co., Hines Corp. • 616-842-5050, www.johnstonboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesLattner Boiler Co. and Unical/Lattner • 319-366-0778, www.lattnerboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes

include a link to the company website as well as datasheets and other product information.

If you need more information, visit the Equipment Overview on Boilers online and click on a company name. Complete contact information is included for each manufacturer. Or, use our RFP Builder to collect information from multiple suppliers. To do so, go to any Equipment Overview page and click the plus sign next to

those boiler manufacturers you wish to add to your list. You also can click the Add an Info Request button on any manufacturer’s list-ing. Continue adding companies until you’re ready to submit your list. Once you’ve selected those you are interested in, click on the Submit an Info Request button to create a prepopulated form. Fill in your contact information and send it. All responses from suppli-ers will be sent directly to you or the contact(s) designated by you.

Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire industrial boiler market. To be included in future listings, contact Linda Becker at [email protected].

SAFER BY DESIGN▶ Low-water content design means less stored potential energy.▶ Unique technology and boiler geometry ensures greater safety.▶ Advanced, numerous safeguards maximize safer operation.▶ A better watertube boiler built around safety, reliability, e� iciency.

miuraboiler.com Manufactured in Rockmart, GAManufactured in Manufactured in Rockmart, GA

Miura_Process Heating Boiler Listing Ad.indd 1 3/19/18 4:55 PM




Image?


(Provided in BHP | BTU/hr | lb/hr of Steam) Kilowatt Rating Design Pressure Auxiliary Systems O˜ ered Industries Served

We

man

ufac

ture

aft

erm

arke

t par

ts/s

uppl

ies

for o

ur b

oile

rs.

Fire

Tu

be, H

orizo

ntal

Ret

urn

Tubu

lar

Fire

Tub

e, S

cotc

h/Sc

otch

Mar

ine/

Shel

lFi

rebo

xW

ater

Tu

be Oth

erCa

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Image?


(Provided in BHP | BTU/hr | lb/hr of Steam) Kilowatt Rating Design Pressure Auxiliary Systems Offere Industries Served

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Micropyretics Heaters International (MHI) • 513-772-0404, www.mhi-inc.com • • • • • • • *Nationwide Boiler Inc. • 510-490-7100, www.nationwideboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *Precision Boilers • 423-587-9390, www.precisionboilers.com • • • • • • • • • • • • • • • • • • • • • • • • YesRentech Boiler Systems Inc. • 325-672-3400, www.rentechboilers.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesRite Boiler • 562-862-2135, www.riteboiler.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesSellers Manufacturing Co. • 859-236-3181, www.sellersmfg.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesSolaronics Inc. • 800-223-5335, www.solaronicsusa.com • • • • • • • • • • • • • • • • • • • • • • • *Sussman Electric Boilers • 718-937-4500, www.sussmanboilers.com • • • • • • • • • • • • • • *Thermal Fluid Systems Inc. • 770-425-5556, www.tfsheat.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesU.S. Water • 866-663-7633, www.uswaterservices.com • • • • • • • • • *Unilux Advanced Mfg. LLC • 518-344-7490, www.uniluxam.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesVapor Power International • 630-694-5500 x115, www.vaporpower.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • YesWabash Power Equipment Co. • 800-704-2002, www.wabashpower.com • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *

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Best PracticesProper specification, installation and maintenance of desuperheaters and associated control valves will increase efficiency and uptime.

DESUPERHEATER APPLICATION

Valves


An ever-increasing need for steam at specific temperatures and pressures exists in many modern plants. Fortunately,

significant improvements have been made to increase operational thermal efficiency and heat rates by the precise, coordinated control of the temperature, pressure and quality of this steam. But, much of the steam produced in power and process plants today is not at the required condi-tions for each application, so conditioning

is required, often by a desuperheater system. The sizing, selection, application, in-

stallation and maintenance of the proper desuperheating and steam-conditioning equipment, including control valves, is therefore critical to optimum performance. This article will discuss superheaters and associated control valves in detail, but first I will look at common applications and is-sues in affected industries.

Power IndustryCompeting in the modern power market requires a heavy emphasis on the abil-ity to utilize multiple operating strategies. Increased cyclical operation, daily start-

stop and faster ramp rates are required to ensure full-load operation, particularly at daily peak hours, and to maximize profit and plant availability. Changes resulting from environmental regulations and eco-nomics also are combining to alter the face of power production.

At the same time, these changes are af-fecting the operation of existing power plants and the design of future plants. Ad-vanced plant designs include requirements for increased operating temperatures and pressures along with stringent noise limita-tions in urban areas. Steam is used through-out power plants in many ways, from driv-ing to turbines to feedwater heaters.

By Mark Nord, Emerson Automation Solutions, Fisher Business Unit

PH0419 Fisher.indd 24 3/19/19 12:31 PM

Hydrocarbon and Petrochemical IndustriesHydrocarbon and petrochemical indus-tries rely on the efficient conversion of low cost feedstock to high profit prod-ucts. Hydrocrackers, furnaces, distillation columns, reactors and other process units must be designed to meet a range of con-ditions to accommodate various modes of plant operation. Temperature is a critical factor that must be taken into consider-ation during the design of each process unit, and it must be controlled precisely to optimize each operation.

Temperature is controlled in many ways in these plants. The most common method is through the use of heat exchangers and process steam. Process steam must be con-ditioned to a point near saturation before it is transformed into a medium that is more efficient for heat transfer. The proper se-lection of equipment will ensure optimum plant availability, reliability and profitability.

Other process industries such as min-ing, pulp and paper, life sciences and food and beverage experience reliability issues caused by steam-conditioning challenges. These industries also use steam for mo-tive force and heat transfer.

Desuperheater BasicsA schematic of a typical desuperheating system is shown in figure 1. A typical system consists of four main components:

• Control valve.• Desuperheater.• Temperature transmitters.• Spray-water strainer.

When specifying a desuperheater, it is advisable to consult with the manufacturer because most desuperheater suppliers have multiple models from which to choose. Critical parameters (figure 2) include:

• Spray-water temperature.• Spray-water pressure.• Initial steam superheat temperature.• Final steam superheat temperature.• Minimum steam velocity.• Maximum steam velocity.• Pipeline size.• Downstream straight-pipe length.

• Steam-pipe liner.• Orientation.

While each components affects opera-

tion, a note on orientation is warranted. Orientation can affect the speed of vapor-ization. Horizontal installations are most common, but vertical flow-up installations

FIGURE 1. A typical desuperheating system consists of four main components.

Spray-WaterControl Valve

Spray-Water

Steam

Desuperheater TE

TC

FIGURE 2. When specifying a desuperheater, it is advisable to consult with the manufacturer because most desuperheater suppliers have multiple models from which to choose. Several desuperheater components have critical parameters.

TSLPSLDSPL

PI

USPL

KEY: DSPL = Downstream Straight Pipe Length PI = Proportional Integral Controller PSL = Pressure Sensor Length PT = Pressure Transmitter TE = Temperature Sensor Element TSL = Temperature Sensor Length USPL = Upstream Straight-Pipe Length

PT

TE

Valves


PH0419 Fisher.indd 25 3/19/19 12:31 PM

perform slightly better because of the posi-tive effect of gravity. Vertical flow-down pipes perform less efficiently because of the negative effect of gravity, which re-duces residence time.

Details of the actual control of a desuper-heater are beyond the scope of this article;

however, suffice it to say that pressure, tem-perature and flow sensors feed data to a con-trol system that adjusts the spray-water con-trol valve to deal with changing conditions.

Control Valve ConsiderationsWhen a desuperheating system is pur-

chased, often each component will be specified and purchased separately. In other words, the desuperheater will be purchased from one vendor, the control valve from another and so on. Unless the process plant has an extensive expertise in the design of superheating systems — not often the case — this approach is problematic due to the complexity of these systems.

The reasons are:

• There is generally a turndown specifica-tion for the system that needs to be met. The control valve has a turndown ratio, the desuperheater has a turndown ra-tio and the combination of the two has a completely different turndown ratio. Therefore, sizing and selection are critical to ensuring system performance is met.

• Different desuperheater designs will have different differential pressure (dP) requirements across the nozzles. The control valve differential pressure must be coordinated with the differential pres-sure across the desuperheater nozzles to ensure system performance is met.

• If there is a high differential pressure across the control valve — when a high pressure source is used to spray water into a low pressure steam line, for in-stance — cavitation can occur in the valve. The proper anti-cavitation trim must be installed in the control valve to suppress cavitation. If not, it is possible to have a cavitating pressure drop across the desuperheater nozzle, with catastrophic damage resulting, and potentially send-ing eroded desuperheater components into downstream equipment.

• A desuperheater nozzle has a specific

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If there is a high differential pressure across the control valve, cavitation can occur

in the valve. The proper anti-cavitation trim

must be installed in the control valve.

Valves


PH0419 Fisher.indd 26 3/19/19 12:31 PM

flow coefficient (Cv). A control valve also has a range of flow coefficients based on its design. The flow coefficient for the valve and desuperheater must be matched so that overall system flow co-efficient is optimized.

Given these reasons, the control valve and desuperheater should be sized and selected together, preferably by the same vendor.

Proper InstallationOnce the equipment is received, it is critical for it to be installed according to the manu-facturer’s specifications. First, a fine-mesh strainer must be installed in the spray-water line upstream of the desuperheater. The passages inside the desuperheater spray nozzles are small, and fine particulate will plug them and impede performance.

Over time, these strainers will start to plug, causing the spray-water valve to open further as demand on the system increases. Once the strainer plugs to a certain point, the spray-water control valve will be fully open but with insufficient water delivered to the system.

The second critical item is to verify the distance that the temperature sensor is in-stalled downstream of the desuperheater. This distance is determined by the manu-facturer, and installation must be at the di-mension specified or greater.

Third, the desuperheater itself must be

installed in the proper orientation to the steam line. It is not uncommon to see de-superheaters installed backward, or off one bolt circle segment on the mounting flange. This can cause the spray to be directed to-ward the pipe wall rather than down the center of the pipe, impeding operation.

Maintenance RequirementsIn most cases, desuperheater problems are caused by the spray nozzles. Problems caused by improperly maintained spray nozzles include:

• Poor temperature control.• Water fallout.• Nozzle failure.• Water hammer.• Liner cracking, failure and separation.• Warped headers.

Proper maintenance calls for nozzles to be inspected and spray-pattern tested annually using a desuperheater nozzle test skid (figure 3). During an inspection, check for cracks, loose nozzles, broken nozzles and even missing nozzles. Remove the insulation and inspect the welds and

piping for cracks, leaks and corrosion. Pull the nozzles, insert a borescope and inspect the internal pipes and liners for problems.

Figure 4 shows a damaged spray nozzle in operation (left) and a spray nozzle oper-ating as designed (right). The difference in the spray pattern is pronounced and has a significant effect upon operation. When a spray nozzle clogs or functions improperly, it is unable to provide the proper amount of cooling spray. The spray can be too much or not enough; in either case, the result can cause damage to piping or other components.

Desuperheater Types Although all desuperheaters share many of the operating characteristics described, there are three basic types: insertion-style, ring-style and steam-conditioning valves (figure 5).

Insertion Style. An insertion model is so named because it is inserted into a pipe instead of being mounted inline like the other two types. Insertion-style desu-perheaters are only used for temperature control. Some designs have the control valve integrated into the desuperheater as

FIGURE 3. Proper maintenance calls for nozzles to be inspected and spray-pattern tested annually using a desuperheater nozzle test skid. A desuperheater nozzle test rig with integral camera is one option.

Figure 4: A damaged spray nozzle in operation (left) and a spray nozzle operating as designed (right) demonstrate that differences in the spray patterns matter. Nozzle condition has a significant effect upon operation.

Valves


PH0419 Fisher.indd 27 3/19/19 12:31 PM

a single compact unit while others use a separate control valve.

Ring Style. A ring style desuperheater is used when very large amounts of spray water flow are required.

Steam-Conditioning Valve. Steam-con-ditioning valves provide both pressure and temperature control. A steam-conditioning valve is used when pressure and temperature downstream of the valve must be controlled. These valves are commonly used in process steam letdown stations, turbine bypass and auxiliary steam applications.

In conclusion, proper specification, in-stallation and maintenance of a desuper-heater will ensure optimum temperature control performance, long desuperheater life, correct operation, long life of down-stream equipment and minimal unexpect-ed shutdowns. Desuperheaters are complex devices, however, and should be selected with the aid of the manufacturer.

Mark Nord is the director of the power/OEM industry group at Emerson’s Fisher Business Unit in Marshalltown, Iowa. The company can be reached at 641-754-3011 or visit www.emerson.com/en-us/automation/fisher.

FIGURE 5. An insertion-type desuperheater (far left) has an integral control valve while this insertion-type desuperheater (left) has a separate control valve. A ring-style desuperheater (center) is used when very large amounts of spray water flow are required. A steam-conditioning valve (right) is used when pressure and temperature downstream of the valve must be controlled.

CLAYTON STEAMBOILERS

[email protected]

S AV E S PAC E

S A V E T I M E

S AV E M O N E Y

��

�

AdvancingBoiler TechnologyWorldwide

2019_Process Heating Magazine1/3 Square 4.5” x 4.625” (non-bleed)

Insertion-Type Ring-Type

Desuperheater TypesSteam-Conditioning

Valves


PH0419 Fisher.indd 28 3/19/19 12:31 PM

How to Select

Some applications use a modular approach to temperature sensing while others must be built from scratch. Fortunately, there is no shortage of temperature sensor options to solve even the most complex problems.

TEMPERATURE MEASUREMENT COMPONENTS

Temperature Measurement


Most people who purchase personal computers buy fully confi gured and assem-bled units. This is especially

true for computer buyers who plan to use them for everyday tasks like word process-ing or surfi ng the web. Some buyers, how-ever, prefer to design their own systems,

selecting individual boards, cases, drives, power supplies and so on. Technically de-manding applications like gaming or digi-tal video editing demand a computer built with certain requirements in mind.

Likewise, an engineer working on a new temperature measurement application has a similar choice. It is possible to buy an integrated instrument with everything in one package. Or, the application may call for a different type of solution that must be assembled from individual components. System selection and complexity depend

upon what is needed to deliver the neces-sary performance.

This article looks at how temperature-measurement applications can be analyzed to help users select the appropriate prod-ucts for the process application. For brevi-ty’s sake, it will concentrate on permanent-ly mounted temperature sensors capable of measuring liquids or gases rather than op-tical systems that use infrared approaches.

Start with the SensorAn electronic temperature sensor creates

By Todd Olin and Neil Larson, Emerson Automation Solutions

PH0419 Emerson Rosemount.indd 29 3/19/19 1:12 PM

an analog signal in response to the tem-perature it detects. Resistance temperature detectors (RTD) and thermistors change their resistance in proportion to changes in temperature. Thermocouples (TC) pro-duces an electrical voltage that changes in proportion to the difference in temperature detected at two different points. A ther-mocouple determines a temperature dif-ference, so it is necessary to have a known reference. As a result, a thermocouple ap-plication needs two sensors to determine the actual process temperature.

At some point, the raw analog signal from an RTD or a thermocouple has to be turned into a meaningful temperature value. This can be as simple as using a multi-tester to take an ohm reading. When

using a PT100 RTD, a reading of 113.61 ohms corresponds to 95°F. This figure can be found on an RTD Chart showing the range of resistance readings and their temperatures. Similar charts are available for the different thermocouple types. This might be useful for a science fair project or perhaps in a troubleshooting situation, but a real-world application calls for some-thing more practical.

Simple Displays and ControllersThe most basic signal-processing solution is a single panel meter temperature dis-play. These are typically off-the-shelf units designed to receive a signal from a single sensor. Most have the ability to work

with a variety of RTD and thermocouple types, depending on the specific termi-nal arrangement or software configuration step. Those able to work with thermocou-ples will have an internal sensor — usually an RTD or thermistor — to provide the reference temperature.

Typically, a panel meter provides a lo-cal visual display in degrees Fahrenheit or Celsius. It may have the ability to send a corresponding signal — a 4 to 20 mA value, for instance — to a programmable logic controller (PLC) or larger automa-tion system. Panel meters work well for applications where the distance to the sen-sor is relatively short and no higher degree of functionality is necessary.

More functionality can be provided by

FIGURE 1. Temperature transmitters encompass many functional capabilities and form factors whose use depends on the application.




a small controller or PLC, often with a human-machine interface (HMI) screen. These usually have an input card of some type to interface with a single or multiple temperature sensors. They can be config-ured to display or make calculations from the temperature readings. The way in which these units display or record the readings depends on the setup and application.

For both these approaches, the sensor is connected directly to the host device. With an RTD, this usually requires three or four wires; for a thermocouple, it requires two. If extension cabling is required, it must be the right type for the sensor.

Transmitter OptionsMoving to a higher degree of sophistica-tion requires a temperature transmitter (figure 1). A transmitter takes the raw signal from a sensor and converts it to a 4 to 20 mA signal with some other type. Depending on the type of transmitters used, the signal might be converted to HART; or to a fieldbus signal such as Foundation Fieldbus or Profibus PA; or to a wireless signal such as WirelessHART.

Transmitters incorporate three subsys-tems:

• Input subsystems convert the analog sensor measurement into a digital signal for internal processing.

• Signal-conditioning subsystems take the digital signal and perform various functions to produce a representation of the temperature measurement along with any diagnostic routines.

• Output subsystems convert the prelimi-nary digital signal to the desired output format, which may be analog or digital.

The signal-conditioning functions have different capabilities depending on the sophistication of the transmitter. The de-fault capabilities available from virtually any transmitter will include basic func-tions such as providing a reference for thermocouples, converting to appropriate engineering units, damping and ranging. Smart transmitters can add diagnostic functions to monitor the sensor itself, look for problems that might be developing and support redundant sensor arrangements.

Prepackaged Temperature InstrumentsSelecting a preconfigured sensor and transmitter assembly is like buying a new laptop. There are modules designed to fit together easily while still offering a range of capabilities to match applications (fig-ure 2). The specifier generally will have to check boxes for various options such as:

• Thermowell length.• Sensor type, to match the measurement

range.• Transmitter type, to match the desired

signal output format.• Housing configuration.

The assemblies usually consist of several components:

• A thermowell designed to mount to the process vessel or piping.

• A sensor with the correct threads and sheath length to mate with the thermowell.

• A transmitter in an enclosure mounting on the other end of the sensor assembly.

The lead wires from the sensor extend into the enclosure, where they mount on the transmitter terminals.

Having a transmitter at the head keeps the leads short to minimize the possibility of the signal being corrupted by electri-cal interference. It also makes it possible to change the type of sensor if this proves necessary. If a local display is needed, most suppliers have an option to add it to the configuration.

The connection to the host system can use conventional instrumentation cabling because the transmitter has already con-verted it to a more robust signal format. There is no need for special temperature sensor cabling.

Prepackaged temperature instruments are convenient and use the same types of components as custom configurations. Ac-commodating more complex applications

FIGURE 2. Basic sensor/transmitter combinations include a thermowell, sensor and transmitter designed to ease installation.




such as those designed for hygienic or hazardous environments usually can be ac-complished with an appropriate transmit-ter housing. Setting up a bill of materials for each assembly helps ensures the same components are available when it is neces-sary to replace one of the items.

Custom SetupsMore complex applications may require different types of components to solve a measurement challenge. Fortunately, there is no shortage of options when looking for the ideal items.

Sensor selection can take advantage of all the different types of RTDs and ther-mocouples (figure 3), which are offered in sizes and shapes to match different ther-mowell configurations. They can be rigid sheaths, flexible, spring loaded and so on.

A transmitter can be selected from a

range of transmitter types and packages. Different transmitter types offer capabili-ties from basic signal processing to sophis-ticated electronics that can handle redun-dant sensors, perform diagnostic routines, validate internal measurements, provide sensor drift alarms, retain calibration in-formation, log data internally and perform other functions. Some of these functions may be performed by the host system, but the ability to do them at the transmitter relieves the larger automation system. This frees up processing power to allow the host system to perform more pressing tasks.

The given plant environment is far more likely to influence sensor selection than the communication-protocol-to- host system. Therefore, while most transmitters can handle different sensors such as RTDs and various thermocouple types, they have only one output capability, such as 4 to 20

FIGURE 3. Sensors configurations run the gamut from rigid sheaths to flexible to spring-loaded designs. Many designs are available in to satisfy virtually any industrial process application requirements.

FIGURE 4. Transmitters have flexibility on inputs but normally only one output. This example is 4-20 mA with HART.




mA, with HART, Foundation Fieldbus or WirelessHART (figure 4).

The transmitter form factor reflects the application needs based on where the transmitter will be located and its degree of sophistication. The three basic ap-proaches are head mount, field mount and rail mount.

Head Mount. This approach places the transmitter directly adjacent to the sensor at the point of insertion. Mechanical ap-proaches vary, but the housing is attached to the thermowell or sensor. The sensor uses a DIN A or DIN B round-puck con-figuration, which has a hole in the center for the sensor leads. Connection terminals then are arranged near the perimeter of the puck so the leads spread like spokes on a wheel. DIN A is the larger of the two (67 millimeter diameter versus 45 mm); there-fore, it tends to be used for transmitters with more sophisticated capabilities. If a local display is desired, one can be added at the head although a larger housing may be necessary (figure 5).

As mentioned earlier, head mounting keeps the sensor leads as short as possible, minimizing the potential for picking up interference. There can be situations, how-ever, where it is not practical to mount the transmitter at the head. This is frequently due to accessibility constraints. Extended lead-wire options place the transmitter at a specified distance away from the ther-mowell. In most cases, this is tolerable and

solves the access problem.Field Mount. This approach is a varia-

tion on the conventional head mount. If the plant environment is particularly hos-

tile due to dust, moisture, corrosive fumes or other hazards, the transmitter can be enclosed in a dual-compartment housing. The transmitter itself with the sensor lead connections is isolated in one half of the housing while the terminal block with the host connections is in the other. If mainte-nance personnel need to check the termi-nals, this can be done without exposing the transmitter itself. This maximizes protec-tion from the physical hazards and electri-cal interference.

Rail Mount. In environments where a head-mount or field-mount approach is not necessary, transmitters also are avail-able in DIN rail-mountable enclosures (figure 6). These are suitable for insertion into a control panel or mounting directly on a larger piece of machinery. Many plant environments do not pose the hos-tile challenges of refineries and chemical processors, so sealed and explosionproof housings would be overkill. If a rail- or wall-mountable transmitter is available with an appropriate IP rating, it can be

placed in the open when no other enclo-sure is convenient.

The head-, field- and rail-mount de-vices are the primary categories, there are other transmitter types. One example is the multi-channel version able to cap-ture data from up to eight individual transmitters. These typically send the individual readings sequentially via one signal, and the host system sorts out the individual values.

Adding WirelessHART capability al-lows users to avoid cabling costs. A single internal power module can drive both the sensor transmitter and communication transmitter. Depending on the frequency of updates, these can operate for eight to 10 years without replacement.

In conclusion, the effectiveness of a self-designed temperature setup depends on understanding the function of each com-ponent and its position in the chain from sensor to host system. Accuracy depends on the sensor itself, but it also on the trans-mitter, lead wires and even the skill of the individuals making the terminations. The range of components available from manu-facturers can cover virtually any imaginable application, delivering whatever perfor-mance is required.

Todd Olin is the Rosemount product manager with Emerson Automation Solutions. Neil Larson is a design engineer for temperature product development with Emerson Automation Solutions. The Shakopee, Minn.-based company can be reached at 800-999-9307 or www.emerson.com.

FIGURE 6. Rail-mount transmitters can be designed for external mounting or placement inside a control panel enclosure.

FIGURE 5. Adding a local display usually requires a larger housing.




The Modernization of Temperature MeasurementWireless RTDs have bridged the gap from decades of hardware to remotely connected devices.

WIRELESS RTDS:



Rapid growth and innovation in the past decade have enabled companies to implement key technologies to monitor, ana-

lyze, control and automate their assets. Wireless resistance temperature detec-tors, or wireless RTDs, have bridged the gap from decades of hardware to remotely connected devices. This modernization has greatly increased the demand for re-liable, robust wireless technologies. From transmitting sensors to gateways and their

physical connections, understanding radio frequency (RF) basics and hardware prin-ciples is vital for accurate industrial tem-perature measurements.

An RTD is a device containing a re-sistive element constructed of a material whose resistance changes with respect to temperature. The electrical resistance of materials is different at different tempera-tures. Sometimes referred to as a bulb or sensing element, this relationship is based upon the type of metal used within the re-sistance source. The most common sensors are platinum based and provide established output curves that work well over a range of temperatures. RTDs are known for their stability, linearity and accuracy. Conse-

quently, RTDs are among the most widely used temperature sensor for industrial and process applications.

RTDs Available in 3 ConfigurationsRTDs come in three types of connection configurations: two-wire, three-wire and four-wire designs.

The basic two-wire RTD is the most cost effective but has performance draw-backs. It does not account for the added resistance from the lead wires on the tem-perature measurement. Even adding a short section of small-diameter nickel lead wires can vastly skew a very accurate two-wire platinum RTD sensor. This added

By Stephen Drake, Ph.D., Thermon, and Ted Johnson, SOR Controls Group

PH0319 SOR.indd 34 3/19/19 12:09 PM

resistance should be identifi ed for instal-lations that require high accuracy or long connection distances.

To compensate for lead-wire resistance, three-wire RTDs include a third wire. To account for the effects of lead-wire resis-tance, three-wire RTDs fi rst measure the resistance between the lead value wires. Then, they measures the resistance be-tween the lead wires and subtract the sec-ond from the fi rst. The remaining value is the resistance of the element itself, assum-ing the lead wires are all the same length and gauge.

Four-wire confi gurations provide the most accurate and foolproof connection. The additional wire allows for the creation of a four-wire Wheatstone bridge circuit. In a true bridge confi guration, the fourth wire provides even fl ow to the wires per-forming the temperature sensing while balancing and removing the inequalities of the lead wires. This fi ltering allows for inequalities such as uneven lead lengths, mixed wire gauges and dissimilar ambient conditions among the lead wires.

One disadvantage of using four-wire RTDs is that one more extension wire is needed. For long-length connections runs, this additional wire cost may be a small price to pay for accuracy or installation requirements.

Outside of these unique circumstances, three-wire RTDs have become the indus-try standard. They provide repeatable ac-curacy that meets industrial needs and of-fer economical trade-off between function and form. They are used in many indus-trial applications and processes, especially in chemical refi neries and petrochemical plants where temperature monitoring and control is of extreme importance. As a gen-eral rule of thumb, standard-construction industrial RTDs can be usable for both cryogenic temperatures as well as applica-tions up to 1200°F (649°C).

Wireless RTDs Reduces Installation CostsEven with the range of performance capa-bilities and price points for wired sensors, engineering teams have been challenged to continually reduce the total operat-ing and installed cost for temperature

sensing projects. Sustained lower com-modity prices have pushed oil-and-gas companies and others to demand increas-ing performance, productivity and efficien-cy of temperature-measurement devices.

One major area for cost reduction is eliminating the need for long or compli-cated wired connections. The larger cost to physically install RTDs is the associated burden of the conduit, cable trays, welding and fabrication, painting and insulation. Depending on the geographical region, the cost to install industrial RTDs is estimated at $25 to $45 per foot of installed RTD, which is not including the cost of the sen-sor itself.

An obvious solution to reduce associ-ated wiring cost is by changing to wire-less RTDs for some plant locations. This offers a hybrid approach, combining both the traditional hardwired options as well as the wireless remote capabilities. Early adopters of this emerging technology have laid the foundation for future cost savings by taking the fi rst steps toward enhanced productivity.

Wider Adoption of Wireless RTDsWireless RTDs are not a new concept; however, their adoption is far from wide-spread. Legacy plants and processing fa-

sensing projects. Sustained lower com-modity prices have pushed oil-and-gas companies and others to demand increas-ing performance, productivity and efficien-cy of temperature-measurement devices.

One major area for cost reduction is eliminating the need for long or compli-cated wired connections. The larger cost to physically install RTDs is the associated burden of the conduit, cable trays, welding and fabrication, painting and insulation. Depending on the geographical region, the cost to install industrial RTDs is estimated at $25 to $45 per foot of installed RTD,

Shown here is a typical RTD configuration when installed in a thermowell. Spring compression against a terminal block or transmitter provides good contact of the sensor tip to bottom of the thermowell.

This is a typical RTD configuration for installation where extension lead length provides for a remote connection option.



PH0319 SOR.indd 35 3/19/19 12:09 PM

cilities built prior to the wireless transfor-mation of recent years often rely on wired networks until outside forces (plant expan-sion, failed equipment and the like) force revisiting the temperature-measurement solution in place. Often, wireless RTDs are implemented when upgrades are sched-uled or when a spot-specifi c solution is required. That being said, there are nearly 100,000 wireless RTDs deployed in indus-trial applications worldwide. And, while wireless technology is becoming a more in-tegral part of our everyday lives, the tech-nology itself is not fully understood.

At their core, wireless transmissions are radio-frequency signals that are emitted by an antenna on the transmitting end of one device and received by another antenna on the receiving end of a different device. The data content is fi rst modulated by varying properties of the signal, which allows the data content to be physically transmitted. The signal is picked up by the antenna and then demodulated to recover the informa-tion after being received. The characteris-tics of the wireless signal are governed by the frequency, wavelength and amplitude.

Frequency ranges, or bands, are con-trolled by regulatory bodies unique to each country. The regulators dictate what spe-cifi c purpose each band of frequencies can be used for and where their use is allowed. In the United States, the Federal Commu-nications Commission reserved the indus-trial, scientifi c and medical (ISM) band, which provides a license-free operation in the 900 MHz, 2.4 GHz and 5.8 GHz

ranges. A common example of an ISM fre-quency is WiFi, which uses both the 2.4 GHz and 5.8 GHz bands. Other countries will vary, but most have an allocated ISM band or bands of their own.

The wireless signal’s shape is character-ized as a wave. As such, wavelength is sim-ply the distance between the cycle starting point and the starting point of the next cycle. It is also inversely proportional to the signal’s frequency (as described earlier). The higher the frequency, the shorter the wavelength. Conversely, the lower the fre-quency, the longer the wavelength. Know-ing the frequency allows for calculation of the wavelength by dividing the frequency by the speed at which RF signals travel. RF signals are a type of electromagnetic radia-tion, which all travel at the speed of light or 299,792,458 meters per second, which is typically rounded up to 300,000,000 meters per second. Thus, if a wireless transmission has a 2.4 GHz frequency, the corresponding wavelength is 12.5 cm, or approximately 4.9”.

The fi nal characteristic is amplitude. Amplitude is the peak height of the wave and is a function of power. The larger the amplitude or output power, the higher the wave’s peak. Almost all of the technologies being deployed in the wireless sensor fi eld have fully adjustable output power, allowing the signal’s amplitude to be adjusted too.

Wireless RTDs Provide More FlexibilityThe combination of proven hardwired RTD performance with the flexibility of wireless solutions has culminated in both cost-savings benefits and the creation of wireless platforms that allow for future smart-device connectivity.

Wireless technology has become more robust, and customers are no longer limited to a singular band that might be congested by WiFi of other sensors. Wireless RTDs — certifi ed for hazardous and nonhazard-ous environments and made for both 900 MHz and 2.4 GHz frequency spectrums — provide end users with the freedom to select what works best for their unique ap-plication. The overwhelming proliferation of embedded sensors and connected devices has opened up unprecedented visibility into

operations and process measuring. These sensors open up the possibility for new practices, procedures or workfl ows that fa-cilitate increased automation effi ciency.

Stephen Drake, Ph.D., is the research and development manager of testing with Thermon Inc. The Houston, Texas-based company can be reached at 800-654-2583 or visit www.thermon.com.Ted Johnson is the director of global temperature sales with SOR Controls Group. The Lenexa, Kan.-based company can be reached at 913-888-2630 or visit www.sorinc.com.

Currently wireless RTDs are being implemented whenever upgrades are scheduled or when a spot-specific solution is required. There are nearly 100,000 wireless RTDs deployed in industrial applications worldwide.

Often, wireless RTDs are implemented when upgrades are scheduled or when a spot-specific

solution is required. That being said, there are nearly

100,000 wireless RTDs deployed in industrial

applications worldwide.



PH0319 SOR.indd 36 3/19/19 12:09 PM

PROCESS HEATING

EQUIPMENT OVERVIEW

www.process-heating.com/equipmentoverviews

SEARCH YEAR-ROUND FOR INDUSTRIAL SUPPLIERS TO QUICKLY FIND WHAT BEST

SUITS YOUR NEEDS, ALL IN ONE PLACE.

• Boilers• Burners• Conduction/Convection Heaters• Dryers• Heat Exchangers• Infared Heaters• Ovens• Power Controls• Temperature Controls• Heat Transfer Fluids

PH Equipment Overview Directories_HouseAd2019_FP.indd 1 2/19/19 11:21 AM

Specialized furnaces with integrated presses provide superior control of pressure and temperature to create better diffusion bonds when joining similar or dissimilar metals.

DIFFUSION BONDINGPerfecting

One manufacturer developed multi-cylinder systems with large pressing plates that can accommodate a range of parts. The largest can process parts as large as approximately three feet by four feet.

Additive Manufacturing


Diffusion bonding has been uti-lized to join high strength and refractory metals — those that are either diffi cult or impos-

sible to weld by other means — for many years. The process — which involves ap-plying high temperature and pressure to similar or dissimilar metals mated together in a hot press — causes the atoms on solid metallic surfaces to intersperse and bond. Unlike traditional brazing techniques, the resulting bond exhibits the strength and temperature-resistance of the base met-als. It also eliminates the need for fi ller material that affects the fi nal weight and dimensions of the mated metals.

Despite its benefi ts, diffusion bonding

and its use in process applications has been limited by more practical considerations. These include the size limitation of the furnace chamber as well as limits to the amount, and uniformity, of the pressure applied across the entire surface area of the part. Run times also are long — often last-ing a full day. All that may change, howev-er, as advances in high vacuum hot presses used for diffusion bonding can eliminate many of those constraints.

The new equipment designs provide features such as:

• Pressure control.• Feedback from embedded pressure

transducers.• Physical ink tests that show variations in

pressure across the surface.• Rapid cooling systems to improve the

bond, increase yields and signifi cantly increase cycle time.

These developments may infl uence a number of industries. Diffusion bonding already is used to create intricate forms for the electronics, aerospace and nuclear in-dustries for items such as fuselages, actua-tor fi ttings, landing gear trunnions, nacelle frames and nuclear control rods. With the upgrades in equipment capabilities, diffu-sion bonding is increasingly being utilized for new applications. Products range from turbine blades to medical devices, heat ex-changers and even lithium batteries.

Typical materials utilized in products welded via diffusion bonding include stainless steel, titanium, zirconium, beryl-lium, high alloyed aluminum, Inconel and tungsten. The process also is used to weld

By the Engineering Team, PVA TePla America

PH0419 PVA.indd 38 3/18/19 4:19 PM

dissimilar metals like copper to titanium, copper to aluminum, copper to tungsten and even molybdenum to aluminum.

In addition to traditional diffusion bonding, the process also is being utilized for an additive-manufacturing process called laminated-object manufacturing (LOM). In this approach, thin sheets of metal (approximately 1 to 2 mm thick) are bonded in what is essentially an additive process. The layered sheets can be laser cut so that when combined together, they cre-ate cooling channels, for example, that can be used to dissipate heat. The final layered material, with all its layers, also can be ma-chined using traditional CNC turning and milling equipment if needed.

Heat Treatment Furnaces with Integrated PressesBecause diffusion bonding is a product of heat and pressure, the heating elements and integrated hydraulic press play key roles in the quality of the final bonded material.

For the atoms of two solid, metallic sur-faces to intersperse, they typically must be at approximately 50 to 70 percent of the absolute melting temperature of the ma-terials. To achieve these temperatures, the surfaces are heated either in a furnace or by electrical resistance to temperatures as high as 2552°F (1400°C).

The pressure is applied by a hydraulic press or dead weights. Because the two mat-ing pieces must be in intimate contact with each other, fixtures often are used. Once clamped, pressure and heat are applied to the components, usually for many hours.

Because oxidation also can affect bond-ing, most heat treatment furnaces operate under a high vacuum.

More Precise ControlsWhile heat and pressure — and the equip-ment to achieve the appropriate levels of heat and pressure — are common ele-ments of the process, the missing piece has been precise control of each.

In the case of the pressure applied, for example, integrated single-cylinder hy-draulic presses can apply a consistent, mea-surable amount of force, but this provides little control over large parts with more complex geometries.

To compensate, thick graphite pressing plates (approximately 10 to 15” in height) must be used to mate the layers of metal together at a more consistent pressure. Unfortunately, this takes up furnace space while adding to the time to heat up the surfaces of the metals.

To address these limitations, one manu-facturer developed multi-cylinder systems with large pressing plates that can accom-modate a range of parts. The largest can process parts as large as approximately three feet by four feet, which is quite large for diffusion bonding. The pressing force is 4,000 kN. By controlling each cylinder independently, the integrated press pro-vides consistent pressure across the en-

tire surface. The multi-cylinder diffusion bonding system includes built-in pressure transducers along the bottom of the press-ing plate. Based on the readings, the indi-vidual hydraulic cylinders can be adjusted to achieve uniformity even over large areas. In addition, a physical ink-test method can

be performed to identify areas on the part where uneven pressure is being applied.

To address temperature uniformity con-cerns, the multi-cylinder diffusion bond-ing system utilizes six heaters. The heaters are spaced to help ensure good temperature uniformity within the chamber. Cooling technology quickly reduces press tempera-tures so parts can be removed more quickly from the press without risk of cracking or

Multi-cylinder diffusion bonding technology can be used to join high strength and refractory metals that are either difficult or impossible to weld by other means. The process involves applying high temperature and pressure to similar and different metals mated together in a hot press, causing the solid metallic surfaces to mix and bond.

Two-layer designs of tool steel and stainless steel form conformal cooling channels that follow the shape of the

plastic injection-mold core or cavity to provide rapid, uniform cooling.



PH0419 PVA.indd 39 3/18/19 4:19 PM

other damage. The design features of the multi-cylinder diffusion bonding system also allow thinner fixturing plates (less than 3”) to be used. This frees up space in the furnace and allows for increased cycle times due to faster heating of the surfaces to the desired temperatures.

Additive Manufacturing Using Diffusion BondingAs mentioned previously, the diffusion bonding process is being used for additive technology via laminated-object manufac-turing. A key application for this technol-ogy is conformal cooling.

Parts are designed using traditional 3D-CAD modeling programs, then divided into two-layer layer sections that equal the thickness of each sheet of metal. The processing time is similar to 3D-printing (with a similar investment cost). Without

restriction in regard to materials, however, larger parts can be produced.

An application related to conformal cooling is for plastic injection molds made in two-layer designs of tool steel and ma-terial such as stainless steel. Conformal cooling channels are cooling passageways that follow the shape or profile of the mold core or cavity to perform a rapid uniform cooling process for injection- and blow-molding processes.

With the multi-layer LOM design, more complex cooling channel designs can be incorporated into injection molds, allowing for higher pressures to be used. This decreases cycle times.

An example of the additive process of diffusion bonding is for heat exchangers, which are usually made from aluminum. Blend circuit heat exchangers typically are made of stainless steel or even titanium

and titanium alloys. With LOM, the con-cept is to bond layers of sheet metal that contain machined micro-channel struc-tures. When combined, the channels can provide for cooling or heat dissipation.

In conclusion, whether applied in layers or simply to bond two parts, the diffusion bonding process is a suitable process for joining refractory and other high strength alloyed materials together without the need for brazing. Although it has been around for decades, with more precise con-trol of temperature and the uniformity of pressure across large parts, diffusion bond-ing opens up tremendous possibilities for a variety of next-generation products.

For more information, contact PVA TePla America at 951-371-2500 or visit www.pvateplaamerica.com.

Because diffusion bonding is a product of heat and pressure, the heating elements and integrated hydraulic press play key roles in the quality of the final bonded material.



PH0419 PVA.indd 40 3/18/19 4:19 PM


Product Highlights

Wondering where to � nd products bene� cial to your process? This department provides a number of new products each month and allows you to easily request more information. Simply call those companies in which you are interested, or visit those companies’ websites.

Tempco Electric Heater Corp.Temperature Controllers Offer Compact Design, Bright LCD DisplayModel TEC offers easy-to use programming and high accuracy, with a 200 ms sampling rate. The line of compact temperature controllers with bright, multicolor display is offered in 1/32 DIN through 1/4 DIN sizes and new DIN-rail-mount size. Features include Fuzzy+ PID control and autotuning; ease of programming; true universal inputs of thermocouple, RTD, milliamp and volts; soft-start function; ramp-and-soak profiler; and remote setpoint and up to six event inputs. Agency approvals include UL, cUL, CE and RoHS. They can be used to control temperature, pressure-flow and humidity.630-350-2252www.tempco.com

Moore Industries-International Inc.Humidity and Temperature TransmitterModel HTZ simultaneously measures humidity and temperature in industrial manufacturing applications. Based on the humidity and temperature values, the Smart HART transmitter also provides a dewpoint measurement as a calculated variable. The 2-wire (loop-powered) transmitter has dual isolated and scaleable 4 to 20 mA outputs proportional to two of the following (user-selectable): relative humidity (RH), ambient temperature or dewpoint calculation. The analog output signals are ready for direct interface with HART- or nonHART-based DCS, PLC and other computer-based systems. A wide ambient temperature operating range of -40 to 185°F (-40 to 85°C) allows installation in most indoor and outdoor environments.818-894-7111www.miinet.com

Circor InternationalMechanical, Orifice, Thermostatic, Thermodynamic and Clean Steam TrapsNicholson industrial steam traps are suited for condensate systems, main steam systems, process control and process heating. The product line includes mechanical, orifice, thermostatic, thermodynamic and clean steam designs. The mechanical steam traps have the fluid-level and venting capabilities of a thermostatic trap, says the company, and are available for pressures up to 650 psig. The cast-iron or cast-steel traps operate in maximum temperatures up to 1382°F (750°C) and are offered in sizes ranging from 0.5 to 2. The DFA and DUA orifice steam traps provide consistent condensate removal via devices that discharge air, condensate and other noncondensable gases with minimal live steam loss. Handling pressures up to 3000 psig, orifice steam traps are available in stainless steel or cast steel with maximum temperature range of 1562°F (850°C). Thermodynamic steam traps accommodate applications through 600 psi. Clean steam designs provide a high purity steam that is sterile and pyrogen free, making the traps suited for use in pharmaceutical, biotechnical, electronics, food, and cosmetics applications.813-978-1000www.circor.com/nicholson

GEA Ammonia Chiller with a Semi-Hermetic Compact Screw CompressorBluQ is an ammonia chiller with a semi-hermetic compact screw compressor. The heart of the system is the GEA CompaX, an ammonia screw compressor with suction gas-cooled electric motor. Compared to an open solution, the risk of leakage is minimized by eliminating the mechanical seal, making operation with ammonia as a refrigerant more attractive, says the manufacturer. A 3-in-1 design combines the motor, compressor and oil separator in a compact and hermetically flanged unit. To minimize refrigerant charge, the evaporator and the liquid separator are housed in a single housing.+49 211 9136-1505www.gea.com

PH0419 Products.indd 41 3/19/19 12:05 PM


Product Highlights

Epcon Industrial Systems LPUse Indirectly Heated Dry Air to Clean Parts Contaminated with Oils, LubricantsSuited for applications that require clean, dry parts such as brazing, coating, soldering and plating, thermal deoilers use indirectly heated dry air to clean parts contaminated with oils or lubricants. The difference between an industrial oven and a thermal deoiler is that the deoiler burns the oil vapor in a thermal oxidizer to provide clean, dry heat for the deoiling chamber. In effect, the oil itself helps to clean the parts while it is being oxidized to carbon dioxide and water. A secondary heat recovery system that uses a shell-and-tube heat exchanger to recycle the heat from the oxidizer back into a burnerless oven can be added to reduce energy cost and allow the recovered heat to be used elsewhere in the process.936-273-3300www.epconlp.com

Delta T SystemsCombination Process Heater and Chiller UnitDual-zone temperature-control heater/chiller allows manufacturers to implement energy-efficient control systems that include variable-speed compressors and fan motors to control temperature precisely. The combination units can be used for processes in pet and human food production, processes in the cosmetics or pharmaceutical industries and systems that require a combination of hot and cold rollers. Built-in controls can log data, predict future issues before they happen and provide adaptive control to allow any process to continue to operate at a lower, controlled speed before a mandatory maintenance shutdown. The units provide precise temperature control within 0.5°F using modulating valves and a PID control algorithm.800-733-4204 www.deltatsys.com

Honeywell Process SolutionsIndustrial Wireless Gateway with Cybersecurity CertificationModel WDMY (version R320) was certified that it meets the requirements for the ISASecure EDSA certification level 1 by exida. According to ISA, this model is the first industrial wireless gateway to achieve the ISASecure cybersecurity certification, which confirms the device meets the ISA/IEC 62443 international cybersecurity standards. ISASecure is intended to ensure that the gateway is free of known cybersecurity vulnerabilities and robust against network attacks.800-822-7673www.honeywellprocess.com

Marsh Bellofram, ATC Diversified ElectronicsMultifunction Meter Reads Multiple Electrical SystemsModel VCFP96M functions as a complete single- and three-phase digital-metering system, suitable for control panels (low, medium and high voltage), gensets, load banks and power-management systems. It allows plant engineers to monitor the power factor of equipment, which is helpful when attempting to determine where electrical inefficiencies exist. Plant personnel can use the information to eliminate phantom power usage.304-387-1200www.marshbellofram.com

Grieve Corp.500°F Vertical-Airflow Cabinet OvenUsed to finish batch loads of metal parts, No. 828 has workspace dimensions of 26 x 26 x 38”. The 500°F (260°C) cabinet oven has 6.6 KW installed in Nichrome wire heating elements. A 700-cfm, 0.5-hp recirculating blower provides vertical-up airflow to the workload. Features include 4” insulated walls, an aluminized-steel exterior and Type 430 stainless steel interior. Controls include a digital-indicating temperature controller, manual-reset excess-temperature controller with separate contactors and a recirculating-blower airflow-safety switch.847-546-8225www.grievecorp.com



Product Highlights

AalborgMultiparameter Volumetric Mass-Flow ControllerDigital mass-flow controllers provide stable control of mass-flow rates of process gases. With simultaneous display of mass-flow, volumetric-flow, pressure and temperature parameters, it can be used with manufacturing, bioreactors and surface depositions, and gas-sampling activities. Series DPC has totalizers with batch-processing mode (0.5 percent RD +0.2 percent FS) standard accuracy, 200:1 turndown ratio and less than 150 ms response time. The controller can be used with 90 gases and gas mixes.845-770-3000www.aalborg.com

InfraTec Infrared LLCLock-in Thermography Package for Electronics Development

Offered as stationary and handheld models, VarioCAM HDx thermographic camera and the IRBIS 3 active thermography software can be paired with a trigger unit and connection cables to create a lock-in thermography station. The focused induction or generation of a heat flux is a way of examining test objects non‐destructively for concealed material defects, cavities, cracks, joint flaws or delamination. In electronics, developers use the method for detecting faults and anomalies in the development of electronics because a focused input of heat can usually be attained easily by means of electrical excitation. Even in the case of the slightest power losses, errors can be detected and localized.844-226-3722www.infratec-infrared.com

Griffco Valve Inc.Chemical-Feed DampenersFusion dampeners combine the technologies of the company’s back-pressure valves and pulsation dampeners. The dampeners are designed to simplify chemical-feed system installations. The combination of these two devices will reduce the number of joints, says the manufacturer, thereby reducing leak points. The devices are available in NPT connection sizes of 0.25, 0.375 and 0.5” and two pulsation dampener volumetric sizes of 6 and 10 in3. Body materials of construction include PVC, CPVC, PP and PVDF, and the bladders are available in EPDM, Viton, Hypalon and PTFE. Maximum operating pressure is 150 psi (10 bar) at 70°F (21°C).800-474-3326www.griffcovalve.com

Palmer Wahl Instruments Inc.Heated and Cooled Temperature Circulation BathsPortable calibration baths are designed for on-site calibrations, allowing the technician to carry the bath to the location of hard-to-remove instruments. Models CLB30 and CLB31 units have cooling capabilities, allowing for calibration at temperatures as low as -31°F (-35°C). Models CLB50 and CLB51 provide heating for calibrations up to 437°F (225°C). Two models in the line have 4.3” color touchscreen PID controllers with memory, USB and Ethernet communications ports, trends graphing, datalogging, 10-point calibration and alarms. All models have an adjustable-speed magnetic stirrer controlled by a potentiometer.800-421-2853www.palmerwahl.com


PhotoA picture is worth 1,000 words. Check out these online photo galleries from select manufacturers at www.process-heating.com/studio.

ISTThe IST AG platinum RTD temperature sensor components are developed with the highest quality materials and cover a wide operation temperature range of -200 °C to +1000 °C. The sensors set the benchmark for the highest accuracy in the industry, with the class A accuracy from negative -200°C all the way to +600°C. The construction is robust against thermal shocks and due to a high � exibility of our production, they can be tailored for small batches of 100 pcs as well as millions of pcs per year. www.ist-ag.com

Hurst Stackmaster The Hurst internal stack economizer design is a factory-optional device engineered to increase the operating e� ciency the boiler, cutting down on its operational costs over its lifetime. By integrating the stack economizer directly into the boiler, it acts as a waste heat recovery device, ensuring the available heat does not go unused. Instead, the heat is recovered to preheat the boiler’s makeup water.www.hurstboiler.com

Heatec Heatec equipment is used in a variety of industries and applications from food processing to plastics manufacturing and beyond. As a manufacturer of thermal � uid heaters, bath heaters, water heaters, process heaters, liquid storage tanks and more you can be sure Heatec has a custom heating system right for you.www.heatec.com

Magnatrol Valve CorporationHigh quality two-way bronze (Type L & S) and stainless steel (Type K & W), full port valves for hot liquid, hot gas and steam applications in ½” to 3” pipe sizes ideally suited for � uid control in process heating applications. The valves are supplied with continuous duty Class H coils for all voltages, are normally open or normally closed, explosion proof, and available for quick delivery.www.magnatrol.com

Thermal Product Solutions Thermal Product Solutions (“TPS”), is a leading American manufacturer of industrial ovens, furnaces, pharmaceutical sterilizers, laboratory ovens, environmental temperature chambers, and stability test chambers. TPS provides thermal processing and test solutions for a range of industries. TPS brands include Baker Furnace, Blue M, Gruenberg, Tenney, Lindberg, Lunaire, MPH, and Wisconsin Oven.www.thermalproductsolutions.com DICKOW

Magnetic coupled DICKOW-pumps of the series NMW/PRMW are of sealless design. The containment shell forms a closed system with hermetically sealed liquid end.

ApplicationsThe magnetic driven NMW/PRMW pumps are designed for hot oil applications, to improve plant and personnel safety in industrial heating plants. Mechanical seals are eliminated. No utility cooling needed. In these cases, double mechanical seals are required in conventional pumps.www.dickow.com

Clayton IndustriesNEW!The Clayton Steam Master is easy to use, highly e� cient and reliable. This small steam boiler incorporates the best features, packaging, and automation available in the market. It is o� ered in three sizes, 15, 30 and 40 boiler horsepower and up to 150 psi.www.claytonindustries.com

A regen gas heater and a thermal ˜ uid heater at a natural gas facility.


PH0419 Photo Gallery.indd 44 3/21/19 10:16 AM


PH Classifieds Display Classified Rates: 1X $130 • 3X $125 • 6X $120 • 12X $110

Send advertising copy to: Process Heating/Attn. Becky McClellandPhone: 412-306-4355 • Fax: 248-502-1076E-mail: [email protected]

Page Company Phone Website

28 Clayton Industries 800-423-4585 [email protected]

10 Dickow Pump 800-880-4442 www.dickowpump.com

48 Heatec, Inc. 423-821-5200 www.heatec.com

26 Hurst Boiler & Welding Company 229-346-3545 www.hurstboiler.com

23 Innovative Sensor Technology 702-894-9891 www.ist-ag.com

2 John Zink Hamworthy Combustion 918-234-1800 www.johnzinkhamworthy.com

9 Magnatrol Valve Company 973-427-4341 www.magnatrol.com

22 Micron Fiber-Tech 386-668-7895 www.mft-com.com

20 & 21 Miura Boiler 888-309-5574 www.miuraboiler.com

8 Parker Boiler 323-727-9800 www.parkerboiler.com

23 Protection Controls 847-674-7676 www.protectioncontrolsinc.com

17 Sterling Steam Control Products 262-641-3808 www.sterlcosteam.com

7 Thermal Products Solutions 570-538-7200 www.thermalproductsolutions.com

ADVERTISING INDEX

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MEMBER

Morris L. Crafton, founder of Thermcraft Inc., Winston-Salem, N.C., died in February at the age of 93. Crafton and his wife Clara founded the

oven and furnace maker Thermacraft in 1971, initially focused on making replacement heating elements for indus-trial and laboratory furnace applications. Through new product development and various acquisitions, the company grew under the Craftons’ leadership. After Clara’s death in 1995, Crafton was eventually succeeded by his son, Tom Crafton, as CEO, though he remained involved with Thermcraft until his death. According to his son, Morris Crafton particularly enjoyed a daily walk through the factory, talking to his employees.

Understanding of how to deliver value to control-room operations is the focus of “Situation Management for Process Control,” a new book pub-lished by the International Society of Automation. It can be ordered from ISA’s bookstore at www.isa.org/store.

Uzwil, Switzerland-based Bühlerjoined the World Business Council for Sustainable Development (WBCSD), a network

focused on global corporate sustainabil-ity and on providing the world popula-tion with the nourishment and mobility solutions. Buhler’s cooking and drying technologies are used in food process-ing and production globally.

The Denmark-based subsidiary of Babcock & Wilcox Enterprises Inc., Barberton, Ohio, signed a licensing agreement to provide its water-cooled vibrating grate technology for biomass boilers to Thyssenkrupp Industries India Pvt. Ltd. Babcock & Wilcox Vølund A/S has an exclusive agree-ment for projects in India, Nepal, Sri Lanka, Bangladesh, Myanmar and Bhutan. The water-cooled vibrating

grate was developed for combustion of biomass and multi-fuels yet is particu-larly well-suited for fuels with high alkali and chlorine content such as rice straw, say the companies.

Komax Systems Inc., Huntington Beach, Calif., celebrates its 45th anni-versary in 2019. The company’s design team has more than 300 years of combined fluids-mixing experience and has developed technologies resulting in more than 40 patents inline static-mixing and heat-transfer technologies.

Thermal-cleaning solu-tions and fluidized-bed process technology manufacturer Schwingis opening a sales office in Princeton, N.J. The North

American office is headed by chemical engineer Michael J. Robinson, a previ-ous manager of the fluidized-bed pro-cess technique department at Schwing Technologies GmbH in Germany. Also in the Princeton office, Andrew S. Dickinson will serve as sales manager for North America. The two specialists will advise and support customers in the United States and Canada on all relat-ing to fluidized-bed process technology, heat treatment and thermal cleaning.

Kevin Brown, area manager at St. Paul-based U.S. Water, received the Paul Cohan Award for his 2018 International Water Conference pre-sentation, “Decreasing Filterable Iron Levels in an Air-Cooled Condenser at a Combined-Cycle Power Plant.” IWC will present Kevin with his award during the 2019 conference in Orlando.

Boston-based Industrial Physics Inc., a test and measurement equipment supplier, acquired C&W Specialist Equipment Ltd., a manufacturer of salt spray, humidity and cyclic corrosion test cabinets. C&W will become part of TQC Sheen B.V., a manufacturer of labora-tory equipment to test and inspect sur-face and adhesion properties of paint and coatings.

Crafton

Bühler

Robinson

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HEATEC,INC. an Astec Industries Company

5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com

• Waste Heat Recovery

• Thermal Fluid Heaters• Fuel Gas Conditioning

• Bath Heaters• Glycol Heaters• Electric Heaters• Regen Gas Heaters

SPECIALISTS IN PROCESS HEATINGHeatec has been designing and manufacturing process heating systems for over 40 years. Our experience and knowledge is a valuable tool for you. We will help you choose the right system for your process, custom design it and build it to meet your speci�cations. When you need a process heating system for your plant, talk to a specialist. Talk to Heatec.

423.821.5200 www.heatec.com

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