Based on flow rates and projections, its cartridge filtration has seen more than 350 billion liters of water filtered by UK water companies in the past year, ensuring a safe, clean and consistent supply to tens of millions of homes and businesses.

In recent weeks, the 39-year-old firm has highlighted how its ‘quick and able’ manufacturing of process filtration equipment can support customers’ sustainability, compliance and savings on capital expenditure.

In the days after the Devon parasite outbreak, a series of inquiries came in and engineers turned round two confirmed orders for skid rentals in the south of England including one they readied for emergency collection on a Sunday evening. A third order is awaiting confirmation.  

At the same time, a rental skid that had been in use and returned for refurbishment was purchased by a water company for permanent deployment.

As well as highlighting the benefits of good quality filtration to the water industry in the UK, experts from Amazon Filters reiterated the message to global customers when they exhibited at IFAT Munich, the world’s largest trade fair for environmental technologies.

On their stand was a specially-shipped ‘plug-and-play’ skid containing three housing vessels and 40 filter cartridges.

It became a major talking point for visitors to the exhibition booth keen to discuss potential applications in times of flood, drought and other emergencies and supply disruptions.

Since the show, held in mid-May, Amazon Filters has received multiple inquiries for cartridge filtration solutions from water companies in Germany and Austria which it is now following up.

Head of Marketing David Ridealgh, who was on the IFAT stand, said: “We’ve seen a marked rise in inquiries and orders since we reiterated our message to water companies here in the UK and elsewhere that we have a range of critical filtration solutions to support them that can go straight into action on site.”

Among products commonly used by water companies is Amazon Filters’ absolute-rated depth filter SupaSpun II.

This is officially approved for use in the UK public water supply under the Drinking Water Inspectorate’s Regulation 31. 

A sustainable polypropylene version of SupaSpun II has just been released and in March, after extensive testing, it gained KTW DVGW certification for safety in the gas and water sectors under German regulations by the standards body DVGW.  

The various product improvements and certifications comply fully with the recasting of the EU Water Directive (DWD) 98/83/EC and its new rules on cartridge filtration.

The directive revised down the previous indicator level of turbidity at the tap from <1NTU to <0.3NTU, something Amazon Filters had already achieved.

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A visit to the plant revealed the company was using an I-to-P transducer, steam valve, RTD (resistance temperature sensor), and PID (proportional-integral-derivative) loop to control the temperature. The issue arose out of a regular failure of the I-to-P transducer. 

While the failing I-to-P is what caught the customer’s attention, the complicated, expensive and inefficient control valve setup isn’t necessary to control the temperature of saturated steam. The temperature of saturated steam is directly related to its pressure. It’s a predictable and repeatable relationship.

The I-to-P was ultimately replaced with a Proportion Air QB1X, a product better able to withstand standard industrial air. I-to-Ps require instrument air, which is filtered to less than 5 microns and is moisture- and lube-free. A Burling Valve BD4 dome-loaded pressure reducing regulator took the place of the steam valve. This assembly was installed and subsequently performed extremely well, saving the customer time and money.

Benefits of Using the QB and Saturated Steam Regulator

There are many benefits to using a Proportion-Air saturated steam regulator system, especially when compared to the operation of traditional steam valves. 

Achieving and maintaining the correct temperature quickly is a priority for many applications. Since the manufacturer did not require the ultra-high accuracy of the QB2X, which can achieve ±0.5% of full-scale accuracy with external pressure feedback, a QB1X was used. QB1X on a steam regulator has +/4% accuracy. Regardless of whether the QB1X or QB2X was selected, the control loop did not have to work as hard, because the saturated steam regulator could compensate for changes in flow while maintaining pressure on its own, without the assistance of sophisticated electronic controls. An on-board analog comparator through the electronic pilot means no PID tuning is required.

Contrast that with a steam valve, which has no direct connection to pressure downstream and cannot connect for downstream changes without a PID loop closing the loop around pressure (or temperature). The temperature is also less accurate, because the link between flow and temperature is not directly related. The PID will constantly overshoot and undershoot setpoint, trying to compensate for pressure/temperature changes downstream. With a saturated steam regulator assembly, temperature is achieved more quickly and remains accurate and stable. 

Maintenance is also an issue in any facility. The Burling Valve regulator offers easy in-line repairs and maintenance. The reduces the downtime necessary when a regulator needs work.

The post Full Steam Ahead – Faster and More Accurately appeared first on Fluid Handling Pro.

“Our old pumps had been in use since 2004. At the start they were becoming blocked up to five times a week and even after various expensive adaptations, they were still doing so weekly,” reports Karl Neiss, Waste Water Manager at the Treis Sewage Treatment Plant of the Cochem Municipal Waste Water Works. The frequent breakdowns on the old pumps, which occurred disproportionately often on Sunday nights or public holidays such as Christmas Eve, kept staff at the Treis Sewage Treatment Plant permanently busy. Aside from the journey to the pump station involved, the affected unit had to be painstakingly dismantled by hand and the material that it was clogging it – cleaning rags, sanitary products and sometimes even old clothes – removed. All of these steps could take up to 75 minutes per blocked pump, in some cases several times a week. “It was therefore a happy coincidence when we got to know the staff from HOMA Pumpenfabrik at IFAT in 2018, and as a consequence heard about the EffTec pump series,” continues Neiss.

EffTec pumps cope with even high levels of solids in waste water

After carrying out an assessment of the problem at the relevant pump station in Treis, HOMA recommended installing EffTec pumps, which are specifically designed for use in situations affected by high levels of solids. Common problems causing the blockage of waste water pumps at the site include a low flow rate inside the pump and large gaps behind the impellers and in the intake area between the impeller and the pump chamber. “The EffTec pumps therefore have improved hydraulics with enclosed singlechannel impellers and optimised ball passages, allowing high rates of flow,” explains Florian Steiner, sales representative at HOMA Pumpenfabrik. “The flow-optimised impellers generate no turbulence, so solids are able to pass through the hydraulics without difficulty.”

At the pump station in Treis, a vertical dry installation of one EffTec unit was carried out each year in 2019, 2020 and 2021. “With the first installation we had to make a few adjustments because the new pump was not compatible with the existing pipework,” Steiner reports. In principle, though, we ensure a high level of adaptability with our units, so that the required conversion was unproblematic.” For the operators of the sewage treatment plant, the investment soon paid off: once the first EffTec pump was installed at the end of May 2019, it ran without any blockages for over a year until the first maintenance work was required in June 2020. “Since then, maintenance has been required only once a quarter,” concludes Neiss. “Compared to the weekly problems with the old units, that means a 95 % reduction in maintenance costs for us.”

Robust pumps guarantee reliable operation of the pump station

In addition to the safe and low maintenance running of the EffTec units, the operators of the pump station in Treis also benefit from their tough combinations of materials. So far, no repairs of any kind have been required and none of the impellers has had to be replaced, even though these are usually particularly susceptible to damage. “Through their optimised hydraulics, we have managed to make the EffTec series very smooth running, minimising the stress on the individual components,” explains Steiner. Furthermore, the pumps are fitted with the PermaCool system which allows for wet or dry installation. With this patented design, the motor is continuously cooled but the cooling jacket cannot get clogged with solids. Karl Neiss and his colleagues feel altogether well advised by HOMA and pleased with their collaboration over the long term too. Due to their positive experience, the operators are already planning to replace further old and fault-prone pumps with new units from the same manufacturer. “Just as the inhabitants of Treis-Karden can depend on the round-the-clock reliability of the sewage treatment plant, we also must be able to depend on the reliability of our pumps,” concludes Neiss. “Nowadays the only reason to go to the pump station is to clear away the cobwebs.”

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Axium Process has been helping such companies on the road to success.

“This is not new technology,” said Jamie George, Projects & Business Development Director at Axium Process, “this is a trusted technology applied in new ways. For over 20 years we’ve helped market-leading manufacturers achieve results. The premise is the same, but the execution is a different matter entirely; we have the knowledge and experience to know where things diverge, and what to do when that happens.”

“At Axium, we tailor our solutions to customers’ specific needs, whether it’s maximizing pea protein isolate for plant-based burgers or extracting soy protein for shakes.”

For companies looking to create plant-based products, membrane filtration can provide a cost-effective solution within a small footprint, helping maximize production output and efficiency. By embracing the automation of membrane filtration, companies can focus on product development and market demands, confident that their production line is up to the task.

The post Plant-Based Product Potential Soars With Help Of Membrane Filtration Technology appeared first on Fluid Handling Pro.

At the heart of chemical process optimization are the various categories of industrial valves. From versatile ball valves that provide precise flow control to robust gate valves that excel in tight shut-off applications, the chemical industry requires a diverse range of solutions. Globe valves find their utility in fine flow regulation, while butterfly valves offer an efficient option for controlling large volumes of fluid.

The variety of valve types allows companies in the chemical industry to tailor their systems to the specific needs of each process. Each valve type has its own unique characteristics, allowing for precise and customized selection according to operating requirements.

Materials Selection for Corrosion Resistance and Aggressive Chemicals

Corrosion resistance is an imperative requirement in the chemical industry, where components are constantly exposed to aggressive chemicals. This is where the choice of suitable materials becomes a critical factor. High-quality industrial valves are constructed using advanced materials that offer exceptional corrosion resistance.

Materials such as stainless steel, nickel alloys and special coatings provide an effective barrier against corrosion. The durability and longevity of these valves are directly related to the quality of the materials used in their construction.

Adherence to Rigorous Quality Standards and Regulations

Safety is a priority when handling chemicals, and industrial valves must meet stringent regulations and standards to ensure safe and reliable performance. Standardization and certification bodies establish specific guidelines for the manufacture and operation of valves in chemical environments.

The regulations and standards address aspects such as pressure resistance, leak-tightness, and durability of valves. Adherence to these standards ensures that valves meet the essential requirements for application in the chemical industry.

Automation and Control for Process Optimization

Process automation has revolutionized efficiency in the chemical industry, and automated valves play a key role in this advancement. The ability to control flow accurately and quickly contributes to process optimization, improving operational efficiency and reducing the risks associated with manual handling.

The integration of advanced control systems allows valves to be monitored and adjusted remotely, adapting them to variations in process conditions. This not only improves efficiency, but also reduces the possibility of human error.

Technological Innovations for Specific Challenges

The constant search for improvement has led to significant technological innovations in industrial valve design. Leading companies in the industry are incorporating smart features into our products to address specific challenges. Real-time monitoring sensors, self-diagnostic systems and advanced sealing technologies are examples of innovations that improve the reliability and safety of valves in chemical environments.

Continuous research and development in the field of industrial valves seeks solutions to particular challenges, such as chemical variability and extreme operating conditions. These innovations not only improve valve performance, but also contribute to overall process efficiency in the chemical industry.

Sustainability and Environmental Contribution

Sustainability is a central theme in all industries today, and the chemical industry is no exception. Industrial valves incorporating sustainable practices and eco-friendly materials are gaining prominence. Energy efficiency in valve operation, reduced emissions and the use of recyclable materials are key aspects of this sustainability trend.

The environmental contribution of industrial valves goes beyond their operation in chemical processes; it extends to manufacturing practices and waste management. Leading companies recognize the importance of this holistic approach to sustainability.

Overcoming Common Challenges in the Chemical Industry

The chemical industry presents unique challenges that quality industrial valves are designed to overcome. Corrosion, resulting from constant interaction with aggressive chemicals, is one such challenge. High-quality valves employ corrosion-resistant technologies and materials to ensure long service life and reliable performance.

Chemical variability, where the composition of products can change, is also addressed by valves designed to adapt to different conditions, and abrasion-resistant valves find application in environments where fluids are used.

Common Challenges and Solutions from FHT Valves

Corrosion, abrasion and chemical variability are common challenges. Discover how FHT Valves’ valves overcome these challenges, offering robust and durable solutions to maintain system integrity in demanding chemical environments.

We look to the future of valve technology in the chemical industry and how FHT Valves anticipates and adapts to the changing demands of the industry. Our vision is to remain a leader in providing innovative and sustainable solutions for the chemical industry.

With a wide range of products and an ongoing commitment to excellence, FHT Valves’ valves are the preferred choice for companies looking to optimize their operations in the chemical industry, such as vat bottom, integral seat or metal seated valves.

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The effluent treatment plant was expanded with very little disruption to R&R’s daily production and uses primarily both Ultrafiltration (UF) and double pass Reverse Osmosis (RO) separating technology.   

The 2.5 fold expansion scope of supply also incorporated fully automated additional processes designed, installed and commissioned by Axium Process to further enhance the quality and condition of the raw effluent entering the membrane system;  removable sump debris catcher, aeration and mixing of large effluent holding tanks, triplex liquid solid separator pre-filtration, vertical shell  and tube pasteurizers system (powered using excess heat from an onsite CHP plant), temperature controlled air cooling system and a pH adjustment tank were all new additions to the plant and located on the same size foot print as the old plant.

The superior quality conditioned raw effluent is now passed through the four UF skids, with the UF permeate passed through a pair of double stage, double pass RO’s to recycle 90% of the effluent received to clean water for reuse back in the factory.  The 10% concentrated waste from the UF/RO batch process is retained and transported to an anaerobic digester where it is used to produce bio-methane.

Axium Process specialises in the design, fabrication, testing and commissioning of customised membrane filtration systems for the concentration and separation of liquid streams utilising microfiltration ultrafiltration, nanofiltration and reverse osmosis technologies. 

The post Global Producer of Ice Cream is Using Effluent Treatment System Designed, Built and Commissioned by Axium Process appeared first on Fluid Handling Pro.

Accurate air/gas flow measurement helps breweries keep their customers happy while controlling costs and meeting environmental compliance requirements. FCI’s ST Series Flow Meters assists brewery teams in performing a wide range of tasks, such as optimizing their complex fermentation tank steam heating processes by accurately measuring the ratio of boiler burner fuel gas to air for efficient combustion.  For example, the CO₂ gas that is naturally produced during the brewing process and any additional CO₂ gas necessary for finishing the beer also require accurate air/gas measurement within tight tolerances. 

FCI’s ST Series thermal flow meters are calibrated under customer installation conditions in actual gases to achieve superior installed accuracy and repeatability in their intended application. They are direct mass flow measuring and inherently multivariable providing both flow and temperature outputs.  Thermal mass flow meters with their no moving parts design also virtually eliminate wear, breakage and maintenance. The ST series has a wide selection of process connections, including compression fittings, NPT male and female threaded connections, flanges, ball valves, hot taps and more to ensure installation site compatibility.

The versatile ST family offers solutions from meters for large pipe diameters to small pipe, compact meters with basic 4-20mA analog output to feature-enhanced versions with multiple   4-20mA outputs, digital bus communications such as HART, Modbus, Foundation Fieldbus, and  Profibus, in-situ calibration, self-checks, on-board data logging, and more.  Furthermore, all FCI ST Series air/gas flow meters are direct mass flow measuring, carry global agency approvals for installation in Div.1/Zone 1 environments, and offer superior ruggedness and long-life with NEMA 4X/IP 67 rated low-copper content aluminum or 316 stainless steel enclosures.

Standard turndowns of 100:1 and flow ranges from 0.25 to 1000 SFPS (0.07 NMPS to 305 NMPS) ensure their application versatility.  The ST’s transmitter/electronics can be integrally mounted with the flow body or may be remote mounted to 1000 feet (305m) away.  They are available in either DC or AC powered versions.  Their readout/display options include basic flow rate and totalizer to a best-in-class multivariable digital/graphic backlighted LCD with FCI’s exclusive through-the-glass activated 4-button array.

In crowded brewery plant air/gas measurement applications with limited straight-runs and/or for operating in transitional flow ranges that can adversely affect accuracy and repeatability, ST Series Flow Meters are also optionally available with and calibration-matched Vortab^® Flow Conditioners to ensure installed performance.

Vortab Flow Conditioners overcome challenging piping configurations by delivering a uniform, swirl-free flow profile to the meter inlet in as little as a few pipe diameters for accurate, repeatable measurement.  Upstream flow disturbers, such as pumps, elbows, expanders or reducers, and valves, often produce non-uniform, non-repeatable and swirling fluid flow entering the meter.  These flow disturbers impact the flow sensor’s ability to measure fluid flow accurately and consistently.

FCI solves flow and level measurement applications with advanced thermal dispersion technologies. With 60 years’ experience and the largest installed base of thermal flow meters, flow switches and level switches, count on FCI to know your application and have the solutions.

The post Beer Flavor, Fizz and Fun at Breweries Worldwide Requires Precision Process Air/Gas Measurement appeared first on Fluid Handling Pro.

The problem the end-user was having was that the fragility of the sensor and its susceptibility to frequently becoming blocked with debris meant that the sensor required regular maintenance. This subsequently resulted in the sensor cable regularly breaking as technicians pulled it out of the stilling tube. This was quickly becoming a drain on resources, both in terms of time and money. 

REFLECT to the Rescue 

Due to the narrow beam angle of just 6° on the REFLECT 2-wire Radar Level Sensor from Pulsar Measurement, it is possible to fire straight down the stilling tube located in the bottom of the tank to gain an accurate level measurement. 

The REFLECT level sensor from Pulsar Measurement provides accurate level or volume monitoring of liquids and solids in critical measurement applications, ensuring complete peace of mind with a product that requires minimal skills and human intervention, thereby minimizing lifetime cost of ownership. Outperforming products, that up until now, required frequent and costly manual intervention to validate measurement integrity. 

The hermetically sealed Pulsar Measurement REFLECT level sensors require no routine servicing, and are able to withstand the harshest environments while maintaining accuracy in the presence of extreme dust, temperature, moisture, pressure, and chemicals. The built-in DATEM software allows the sensor to focus on the true level while ignoring the effects of false obstructions, giving you the accurate data needed to make decisions about your operations. 

“It is another example of the benefits of non-contacting technology and also a testament to the capability of the REFLECT 2-Wire Radar.”

Reduced Call Outs, Saving Time and Money 

The end-user has been delighted with the results. Now that this level measurement solution is working properly, there are no longer any callouts (previously caused by the old sensor losing signal and requiring cleaning), and they have saved a significant sum of money on sensor replacements . 

Commenting on the application, Craig Leakey, Regional Sales Manager for Pulsar Measurement, said “This was a particularly pleasing outcome, given the regular problems that the customer was encountering. This included multiple callouts for technicians in the middle of the night. It is another example of the benefits of non-contacting technology and also a testament to the capability of the REFLECT 2-Wire Radar. The robust signal processing and narrow beam angle has enabled a positive outcome of a troublesome application, where previously, non-contacting sensors would not have been considered.” 

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When using ultrasonic measurement technology, it is essential to ensure that there are sufficient inlet and outlet distances to ensure an axially symmetrical flow profile. Before deciding on a stationary unit from Katronic, FEO carried out three tests with minimum and maximum process peaks at different points to find the optimum position for the measurement. The decisive element in the purchase of the two dual-channel flowmeters was the success of the previous tests and the associated prospect of being able to reliably measure large volumes of water in a turbulent environment with the KATflow 150.

The driving factor of the measurement comes from the requirement of the dam’s waterworks to supply the region’s drinking water. This pipeline operates around the clock with a typical capacity of approximately 6000 m³/h. In the bypass system the water is usually divided equally between the two pipes and is used whenever the turbine fails or cannot guarantee the inflow required by the waterworks.

Both KATflow 150 are dual-channel measuring instruments with an analogue 4 … 20 mA process output and a Profibus PA interface. The client’s control system receives four measured values simultaneously and are used for quality control. A critical factor in the installation is to achieve redundancy of the flow measurement channels. If one sensor or signal input fails, the flowmeter detects this and switches to the signal that is still available. If the current output signal drops to 0 mA, the programmable logic controller (PLC) switches to a substitute value and deactivates the control.

Although the location where the KATflow meters are installed is not ideal owing to the presence and influence of two annular piston valves, both devices have proven themselves capable of meeting the challenge of this application. The flows are turbulent and axisymmetric at both measurement points and the measurement is not helped by the proximity of the control valves. The PLC is used to limit the flow through the works by varying the degree of opening of the valves with the flowmeters providing the data needed to allow this remote control function. The data being collected from the plant indicates that so far the Katronic flowmeters are operating at an estimated 98 % accuracy in spite of the extremely difficult measurement conditions.

The post Control of Drinking Water Demand with Clamp-On Ultrasonic Flowmeter appeared first on Fluid Handling Pro.

Achieving this is a huge undertaking, with water being transported in pipelines that may stretch for thousands of kilometers across country that may be remote, difficult to operate in or hard to access.  While some countries have made progress in tackling and fixing water losses in their networks, others have a lot of work to do in tackling water losses that can run into high double figures.

Improvement starts with measurement

Detecting lost water starts with choosing the right flow measurement method. Depending on the application, a variety of flow measurement techniques can be used, ranging from constrictive methods such as flumes and weirs for open channel systems, to orifice, mechanical, ultrasonic or electromagnetic flowmeters in closed pipe systems. Each of these have their own benefits and drawbacks.

The second major factor is where to measure. Performing measurements as widely as possible gives utilities the maximum amount of data on the location and severity of water losses, which can be used to develop methods and strategies to resolve them. It follows that any device used to measure flows must be as easy as possible to install, access and maintain, as water pipelines pass through both towns and cities as well as through remote areas that may not be as easy to access.

One of the most capable methods is electromagnetic flowmeters. Highly stable and able to be deployed in a range of installations, they offer several advantages.

A major attraction is their greatly enhanced accuracy with uncertainty as low as +/- 0.4% or better compared to other methods, as well as their high level repeatability throughout their operational life. Accuracies of this level are important when measuring for lost water to discriminate between legitimate consumption and leaks or other sources of loss.

Reliability is another important benefit. With no moving parts, they are not subjected to the wear and tear that affects mechanical designs. This reduces the maintenance burden and saves costs by avoiding the need for upstream strainers to filter sediment.

Electromagnetic flowmeters can also handle distorted velocity profiles without affecting accuracy, eliminating the need for defined lengths of pipeline upstream or downstream of the point of measurement as required by other technologies. As such, they can be fitted in locations with limited space, such as sites in towns and cities.

The benefits of digital

Several technological developments are making electromagnetic flowmeters even more attractive and cost effective.

One of these developments is the ability to use alternatives to conventional mains power. In the early 1990s, ABB launched the world’s first battery-powered device. Today, the latest generation of AquaMaster electromagnetic flowmeters can be used in remote locations with no need for a mains supply.  Coupled with the benefits of a compact design, these options unlock the promise of enhanced flow measurement in many more locations. With a significantly lower power consumption than conventional mains-powered devices, they can also offer reductions in energy cost that can help further reduce their cost of ownership.

Getting measurement data from the devices is another important aspect. Manufacturers, including ABB, are looking at using Low Power Wide Area Network (LPWAN) band and Narrow Band Internet of Things (NB-IoT) technologies, which allow rapid exchange of measurement, configuration, and maintenance data with a much-reduced power requirement.  

Further benefits are possible using Power over Ethernet (PoE). Using the same cable for both power and communications, PoE technology improves flexibility by enabling flowmeters to be installed wherever needed. Another development is ABB’s  4-wire Ethernet, which combines classic outputs with future communication protocols, increasing the longevity of devices by ensuring they are future-proof.

Flowmeters with Ethernet connectivity increase simplicity, flexibility, and reliability, while offering access to previously hidden data, such as measurement of density, conductivity, or concentration of the medium.

The time needed to commission, operate, and maintain electromagnetic flowmeters and the skills and training of technicians and operators is another factor affecting total cost of ownership. ABB’s AquaMaster4 electromagnetic flowmeter offers Near Field Communications (NFC) technology, allowing users to download configuration settings and retrieve logger data by tapping the transmitter with a smart device such as a phone or tablet loaded with ABB’s Velox app. This allows a variety of operational, logging, and diagnostic data to be downloaded, interrogated, and shared.

Combining pressure and flow

Effective pressure management is critical to getting the best performance from a water distribution network. Utilities are increasingly attracted by the prospect of combining flow and pressure measurement into one device, enabling users to download logged data and investigate flow and pressure activity for a specific period. Combining these possibilities with the ability to download and share this data through a smart device greatly improves the ability to assess and enhance network performance.

Water sustainability transformed

Ultimately, flowmeters that offer the highest accuracy help ensure that major investments in water supply infrastructures are wisely spent and that water is well managed for the benefit of all.

The post How High-Accuracy Flowmeters are Transforming Water Sustainability appeared first on Fluid Handling Pro.