Investing in high-quality process control valves have several operational advantages, including an extended service life. However, when just the valve actuators reach the end of their service life, the options can be limited, especially when the OEM parts are obsolete.
Fortunately for a UK based malt processer Bürkert has been able to provide a cost-effective retrofit solution for two hundred third-party valves, upgrading them with Bürkert Type 8691 control heads to keep the full complement operational for years to come.
The food and beverage industry uses process control valves extensively to manage the flow of liquids and gases throughout the manufacturing process. As such, their reliability is essential to the continued operation of the food manufacturing process: keeping sufficient spare parts available is therefore an important task.
However, as equipment ages, the original equipment manufacturer (OEM) may no longer support the product. At this point, maintenance managers can be left with just their own stock of spare parts, which will, inevitably, run out at some point.
In this case, the food manufacturer took the opportunity to investigate the alternatives, starting with replacing the control valves completely. With over 200 process control valves affected, replacement would be a substantial investment and the payback period would have been longer than desired.
At the same time, Bürkert, as an existing supplier to the company, was invited to offer a solution. Craig Kerr, Sales Manager at Bürkert, explains: “We were provided with a spare control valve from the production line and asked to deliver a proposal that would resolve the issue of ageing controls, while retaining the value in the valve body.”
As a major manufacturer of process control valves, Burkert could have offered a complete replacement valve, but having assessed the condition of the valve body decided that just the control head needed attention. The obsolete pneumatic actuator could be replaced with Bürkert’s Type 8691 control head with the simple addition of an adapting bracket to attach it to the legacy valves.
Plug & Play
Craig continues: “The manufacturing process operates a decentralised control system using ASI, with the valves either open or closed. Bürkert’s suggested solution would provide a simple, plug-and-play control head that would easily attach to the control valve body.”
In all, it would take less than an hour to replace each control head. This includes assigning an address for the PLC and using the tuning function where the operator presses the buttons to open and close the valve. The integrated valve position sensor registers these points and stores them to ensure reliable valve operation.
The Type 8691 is ideally suited to the food and beverage industry; being constructed from stainless steel, with excellent ingress protection ratings, it is easy to clean and has excellent chemical resistance properties. In addition, it is equipped with bright, coloured LED status indicators that show the position of the valve at a glance. Craig concludes: “The customer had the first unit on trial for a short period before ordering a further one hundred units. These were all installed and commissioned by the customer and one year on, they are all continuing to function reliably. This solution has been very cost-effective, saving thousands in process hardware and replacement costs by allowing the customer to retain the original valves and minimise any potential downtime from the upgrade.
Burkert Fluid Control Systems is one of the leading manufacturers of control and measuring systems for fluids and gases. The products have a wide variety of applications and are used by breweries and laboratories as well as in medical engineering and space technology. The company employs over 2,500 people and has a comprehensive network of branches in 36 countries world-wide.
Butterfly valves… the ideal valve for sugar!
Sugar manufacturing poses a challenge to valve makers. The characteristics of the material to be handled, fluctuating pressures and high temperatures and viscosities present great demands to valve engineering.
Due to the competitive market situation in the world of sugar, nowadays the responsible factory managers of sugar factories are required to pay increasing attention to all available options of rationalization and cost savings. The availability of all system components has been especially scrutinized. Thinking in terms of life cycle cost and cost of ownership is gaining significance. While in the past many system components such as pumps and valves were simply replaced after the campaign, they now require much higher durability.
According to the sugar factory managers a high reliability and long service life, service friendliness and functional reliability are just as much on the priority list as the potential for automation. However, the most important element during the campaign is service around the clock. Most of the times the sugar factories expect service by mobile phone from the supplier any time of the day and night. Of course, all this also applies to the numerous valves and fittings. Valves are used everywhere in sugar production: From juice production to juice purification, juice concentration and sugar crystallization. While a typical production facility (referring to a 10,000-ton factory) has “only” 200 to 220 pumps, valves (typically: butterfly valves) can be found much more often. A beet processing factory of 13,000 tons/ day is estimated to utilize approximately 3,000 installed valves. With roughly 1,000 valves in the beet end (that is one third of the total number) most valves are used here; large quantities can also be found in the evaporation crystallizers in the sugar house, in the power station and especially in waste water treatment. When the factory is running sugar juices at the crystallization point, even the smallest temperature variations or thermal bridges are enough to crystallize the medium. A regular valve would clog immediately. Butterfly valves are not as sensitive and can be heated more easily.” Butterfly valves therefore cover the largest application scope of most media handled in the sugar factory.
Section of a soft sealing flucon shut-off valve, series, series 23/24. The fact that the elastomer (EPDM-H) is vulcanized onto the support ring can be clearly seen.The high temperatures and especially the vacuum are extremely critical for the valves used here.
The soft sealing flucon series 23/24 butterfly valve with replaceable EPDMH liners (resistant up to 130°C) by Airpower, showing best results in many evaporation crystallizers worldwide, provides the solution. With the flucon butterfly valves the elastomer is permanently vulcanized on the interchangeable support ring thereby ensuring a vacuum tight housing liner; the elastomer cannot be deformed caused by the vacuum. These valves are therefore particularly suitable for vacuum processes. Combined with the robust twintorque pneumatic actuators on/off or control valves offer the perfect solution for most critical applications in the sugar factories.
New hydraulic tipping valve will increase productivity in tipping operations
Edbro is introducing a new hydraulic valve for tipping trucks, which will allow faster lowering than was previously possible. This will lead to a quicker turnaround time of tipping operations and therefore increased productivity.
Edbro, a member of the JOST World since 2012, is a highly regarded leader in the manufacture of on-vehicle hydraulics systems. It maintains its position at the forefront of the tipping market by always working to increase payloads, reduce tipping times and provide “fit and forget” solutions that require little or no servicing over their entire working life.
Replacing the incumbent CT range of valves, the UT valve is completely interchangeable with the older part. This ensures that vehicle operators can continue to maintain their existing hydraulic kits without any issue. Like its predecessor, the UT valve increases safety during lowering and offers lightweight performance.
The UT range introduces an optimised internal oil flow which reduces flow restrictions. As a result, the maximum lowering speed of the valve has been increased, reducing the time taken per tipping cycle. While this will be appreciated by all users, it will be particularly useful in quarrying and other operations where multiple tippings are made each day – the time savings on each cycle adding up so that the trucks can complete more runs per shift.
Danny Broomfield, Sales Director for UK & Ireland, comments: “The Edbro slogan is Lighter, Faster, Stronger. We achieve these goals by maximising the performance capabilities of every components found in our systems. The introduction of the UT valve will play its part in making sure our customers have the fastest and safest tippers on the market.”
AB-QM 4.0 Pressure Independent balancing and Control Valve (PICV) for smart buildings
After 15 very years of successful collaboration we are starting to say goodbye to one of our most acknowledged products in HVAC heating and cooling systems, the AB-QM Pressure Independent balancing and Control Valve (PICV).
AB-QM and its pressure independent functionality totally changed the market of hydronic balancing and control valves for terminal units in non-residential buildings.
Today we are proud to introduce you to its successor; AB-QM 4.0.
Meet AB-QM 4.0, our new PICV with re-defined value for HVAC designers, building owners and building users. The valves are designed for use in combination with conventional actuators or the Danfoss NovoCon® S digital actuator. In particular, they enable HVAC 4.0 solutions in smart commercial buildings concepts such as hotels or offices.
100% valve authority
The new Danfoss AB-QM 4.0 valves are designed in sizes from DN15 to 32 and add new features and improved specifications to the proven capabilities of the well-known AB-QM series. The unique 100% valve authority, achieved by a built-in differential pressure controller, remains unchanged. This ensures the accurate control performance of the valves. Several significant changes and improvements have been implemented, making it a whole new valve rather than an upgrade.
Better resistance to scaling and clogging
Most remarkable is the re-design of the inner construction. By using innovative PPSU Polymer material the resistance of the valve to scaling and clogging has been considerably improved compared to any other HVAC control valve. Intensive testing proofs continued stability of the flow characteristics and accurate control performance, also after years of use.
The pressure class has been increased from PN16 to PN25 while the required differential pressure continues to be just 16 kPa.
Increased flow capacity per DN size
The adjustable flow rate of the AB-QM 4.0 valves has been significantly increased, for example from maximum 450 to 600 l/h with DN15, allowing bigger terminal unit capacities to be controlled by smaller dimension valves. The minimum flow pre-setting has been reduced from 20% previously, to just 10% now. Alternatively, the valves are also available as high-flow or low-flow versions. Such as the DN15 HF with 120 to 1200 l/h adjustable capacity. Or the DN15 LF with 20 to 200 l/h adjustable capacity.
All AB-QM 4.0 valves are available with either internal or external threads and with or without test plugs. And they feature a pre-setting scale that remains visible from several directions, even with an actuator mounted on the valve.
Phased global introduction
The new AB-QM 4.0 valves in DN15 and DN20 are, initially in Asia, India, Middle East, Latin America, Spain and DACH region, available during Q4 2019. After the production ramp-up the valves will, together with the also new thermal actuator TWA-Q, be available in Q1 2020 in the rest of Europe and China. The versions DN25 and DN32 are expected to be available in Q3 2020.
Hydronic HVAC connectivity with BMS
All valves are intended for use both with conventional (on-off or modulating) actuators and with the Danfoss NovoCon® S high-accuracy digital actuator, which can be integrated into Building Management Systems (BMS) via BACnet or Modbus bus-communication. In particular, this means the AB-QM 4.0 valves enable smart building concepts in commercial buildings such as hotels or office complexes.
Engineering HVAC 4.0 for smart buildings
Danfoss is engineering HVAC 4.0 for smart buildings. The combination of AB-QM 4.0 and NovoCon® S actuators is a good example of the digitalization in HVAC. The combination does not only establish high precision, dynamic, hydronic balancing and control. The digital actuators provide BMS with real-time HVAC data to enable Active Energy Management (AEM). Digital valve control via fieldbus also offers advantages in remote commissioning, flow setting and flushing. Continuous logging of all system data enables predictive maintenance and energy allocation. And automatically generated alarm messages support fast and accurate troubleshooting. HVAC 4.0 continuously optimizes the energy efficiency and comfort of buildings by using smart and connected products and services.
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