Designing Systems

System Design

Professional Solutions For Your Design Needs

Air System Design – The proper initial design of the compressed air system will result in superior compressed air system operation. Process & Power can offer air system design that will meet your present needs and offer flexibility for future expansions. We specialize in multiple types of air compression technologies, and are skilled in selecting the proper equipment design and layout for your operation.

Air System Optimization – The ability to optimize a compressed air system comes from years of being in the business. Process & Power can optimize your system to save you energy costs, reduce maintenance and provide a reliable air system. Optimization involves ensuring that each piece of equipment in the air system is working at properly and each component is tuned to work efficiently with all the parts of the system.

For more information, please check out our website at https://www.processnpower.com/system-design/

System Controls

A new family of central controls for industrial compressed air systems can be customized to your company’s needs, eliminating waste and offering savings on your energy bill and a short pay back period. The X-Series System Automation Package, introduced by Ingersoll Rand, is offered through Process & Power, Inc.

Central control of your air compressors creates efficiency and cost savings. The versatile and innovative Ingersoll Rand X-Series System eliminates wastes by efficiently managing up to twelve compressors. In the past, Lee Majors explained, capabilities now found in the X-Series would have required a custom engineered system that could easily have cost four to five times what this central-control system costs.

Some of the many benefits of the X-Series:

• Sold in modules, the X-Series can be customized for each customer’s needs. You don’t have to pay for features you don’t need or can’t use.
• It can be applied with any manufacturer’s air compressors or a combination of brands.
• The X-Series handles different types of controls, including VFD-controlled compressors. This capability often is available only with very expensive control systems.
• The system receives input from other instrumentation, including flow meters, dew point meters and compressed air dryers.
• The Visualization module option provides Ethernet access with its own IP address. Through your web browser, you can observe what’s happening in your compressed air system, and on an administrative level, you can make changes.
• The X-series has the capability to send you an email alert upon a warning or alarm in the system.

Process & Power can provide local support for installation and training on the X-series, eliminating the need to get expensive help from elsewhere. Industries interested in a free evaluation of whether the X-Series can help their operation save money can contact Lee Majors at lmajors@pnpmail.com or 800-264-8939.

Empire Blast Cabinets

"With an off-the-shelf Pro-Finish cabinet, you get a tunable media reclaimer, a dust collection system, your choice of pressure or suction powered blast, and many other standard features. In addition, you can select from a wide range of in-stock factory options to meet your particular finishing requirements. If you need a powered or manual turntable, gun oscillation, additional blast guns, timer packages, special electrical, extended wear components or a vertical door, we can provide this equipment and other options without custom modifications.

Built-in system components:

• Dust Collector
• Tunable Reclaimers
• One-cubic-foot Pressure Vessel
• One-cubic-foot Suction Hopper"

For more information, please click on the link below!

https://www.empire-airblast.com/products/manual-blast-cabinets/

Compressed Air Treatment

"Air Dryer | Refrigerated Dryers, Desiccant Dryers and Filters; Air quality can have a significant impact on compressed air systems. Properly treated compressed air, and the right air dryer, will improve productivity, system efficiency, and product or process quality. Choosing the appropriate air dryer and compressed air filter is very important. By choosing an Ingersoll Rand air dryer or compressed air filter, you are buying high quality treatment products that will enhance your entire air compressor system. An air dryer is an integral piece in your air treatment system, making Ingersoll Rand's wide knowledge and expertise in this field a key aspect to the success of your compressed air system. Ingersoll Rand has the widest selection of air treatment products and application knowledge to protect your investment and compressed air system."

Shock Pulse Monitoring

"Shock pulse method is a signal processing technique used to measure metal impact and rolling noise such as that found in rolling element bearings and gears. Much more refined than other high-frequency measurements, shock pulse is widely used as a basis for predictive maintenance. Rolling element bearings are the most common measurement for shock pulse, but this technique has other applications including gear condition, compressor condition, and other applications where metal-to-metal contact is a source of wear."

You can take a look at the website provided for any questions that you may have!

http://www.conditionenergy.com/whatisshockpulse.html

At Process & Power, we offer the latest in Shock Pulse Monitoring. Our website offers the most up-to-date information about the process. 

https://www.processnpower.com/shock-pulse-monitoring/

"A simpler, if somewhat inaccurate, illustration enables an easier visualization, and invites very good credibility."

Ingersoll Rand: Ingersoll Rand Expands Line of Precision Fastening Tools with QX Series High Torque Angle Wrench

Ingersoll Rand, a global leader in reliable and innovative power tools, has expanded its QX Series™ of cordless power tools for assembly markets by introducing the new High Torque Angle Wrench. The new angle wrench reaches a pinnacle of 60 newton metres of torque (44.2 foot-pounds) for the toughest jobs, while providing high accuracy and comfort the QX Series is known for.

The QX Series delivers the right tool for the right job in industries that require high accuracy for fastening and connecting parts, whether in the heavy equipment, light manufacturing, automotive or aerospace sectors.

“Our assembly manufacturing customers asked for power tools with higher torque and higher speeds to address the needs of advanced manufacturing methods and new materials,” said Brian Welborn, global channel marketing leader, Ingersoll Rand Power Tools. “Our experts have delivered all that in the High Torque Angle Wrench – a versatile tool that meets the specific demands of a variety of applications, whether simple or complex, while maintaining comfort, accuracy and reliability.”

High Torque Angle Wrench Reaches New Heights of Torque and Speed

The High Torque Angle Wrench is a cordless, right-angle fastening tool that expands the QX Series to cover high-torque applications and compliment the existing range of Haz Tools, Precision Screwdrivers and low-torque Angle Wrenches already available. It is equipped with a bolstered 40-volt battery that delivers 2.5 amp hours of operation, enough to power the tool through a grueling five to six hour assembly shift without having to recharge the battery.

The High Torque Angle Wrench is ergonomically balanced to increase operator comfort, and comes in a sleek but tough, black housing. It comes in five different model variations that range from low torque to high torque options, with or without wireless capabilities. The models are available in the following torque to free speed ratios:

• 20 Nm (14.75 ft.-lb.) at 1,045 RPM
• 30 Nm (22 ft.-lb.) at 775 RPM
• 35 Nm (25.8 ft.-lb.) at 640 RPM
• 40 Nm (29.5 ft.-lb.) at 540 RPM
• 60 Nm (44.2 ft.-lb.) at 375 RPM

The Technology in the QX Series High Torque Angle Wrench

The QX Series High Torque Angle Wrench is built with Ingersoll Rand’s patented closed-loop transducer control at the heart of the tool, delivering precise torque and accurate, traceable results. The multi-function display is the interface for programming multiple torque, speed and angle configurations—saving time and eliminating the need for additional tools.

It features a wireless communication option that integrates the tool and the assembly line into a true plant-wide network with managed data, process control and the ability to adjust tool configurations in real time. Like all QX Series tools, the communications to and from the tool are exchanged over Ingersoll Rand’s dedicated Process Control Module (PCM). The PCM allows connectivity of up to 10 tools per module to give operators total control of their assembly line, precision fastening tools, and the valuable fastening data it produces.

“More and more manufacturers are finding that the highest operational cost in the plant is the cost of quality,” says Mark Hasz, product manager, Precision Fastening Tools, Ingersoll Rand. “Manufacturers need an assembly process and the corresponding tools that get the job done right, the first time. With traceability and connected technology options in every tool, the Ingersoll Rand QX Series enhances the assembly process with diligent tracking mechanisms.”

For more information on Ingersoll Rand Power Tools, please visit www.irtools.com or www.facebook.com/ingersollrand; or follow Ingersoll Rand on Twitter at @IRProducts or on Instagram at @IRTools.

Watson Marlow: Bredel's newly expanded APEX hose pump range delivers improved process uptime and significantly reduces pump maintenence

• Seal-less, valve-less design of two new hose pump models lowers total cost of ownership
• More reliable than air-operated diaphragm pumps and progressive cavity pumps in chemical or abrasive applications
• Newly expanded flow range to 6,200 litres/hour at 8 bar

Bredel Hose Pumps (part of Watson-Marlow Fluid Technology Group) has added two new models to its APEX range of seal-less, valve-less hose pumps.  Widening the APEX performance envelope to 6,200 litres/hour at pressures of up to 8 bar, the new APEX28 and APEX35 pumps offer significant capex and opex savings compared to other pump technologies in chemically aggressive or abrasive applications.   

User feedback

Recent international product trials across a range of applications have put the new APEX models to the test in process-critical abrasive slurry transfer operations. User feedback has demonstrated that, when compared with existing pump technologies such as air-operated diaphragm pumps and progressive cavity pumps, the new APEX models can extend the time between scheduled maintenance intervals dramatically.

Proven savings

The most notable feedback relates to significant reductions in abrasive wear on the previous pumps. For example, one of the trials undertaken in the USA showed that, while the user’s existing air-operated diaphragm pumps need to be maintained every 7 or 10 days, the APEX35 ran continuously for over three months without maintenance. Additionally, there was no requirement for compressed air which equated to another significant saving.

The impressive results in the USA were not in isolation: a brine dosing application in Germany showed that during the first six months of the trial, the APEX35 required no maintenance whatsoever and the operator made huge savings over the downtime previously experienced each month with a progressive cavity pump.

Uptime and process continuity

In addition to the financial benefits associated with reduced maintenance, APEX pumps have been engineered to deliver additional cost savings through increased uptime and process continuity.

Precision machined hose elements and optimised hose compression, combined with medium pressure operation, enable the pumps to meter or transfer fluids reliably and accurately for long, uninterrupted periods of time.

The trials in Germany demonstrated that project payback periods for APEX are expected to be extremely short; as the only wear part in APEX pumps is the hose, which can be replaced quickly and easily, without removing it from the process line.

Reduced spares inventory

With no internal valves, Bredel APEX hose pump technology also helps users improve their processes by eliminating troublesome ancillary equipment such as anti-siphon valves, back-pressure valves, degassing valves or run-dry protection. Finally customers can simplify spares inventory and need to keep just a single part – the hose - in stock.

Chardon Finds A Highly Reliable Transport Pump In The TX Series From Blackmer

When it comes to transporting and handling light petroleum liquids, Chardon Oil and Tank Truck Service & Sales find out firsthand that knockoff brands can't supply the operational reliability of Blackmer TX Series Sliding Vane Pumps.

Flexicon capabilities match up to e-liquid

The filling of cartridges for electronic cigarettes based on e-liquids is booming. According to Watson-Marlow Pumps Group, this has resulted in a rapid rise in orders for refilling solutions such as the company’s Flexicon peristaltic liquid dosing technology. Indeed, one manufacturer in Europe says it has sold more than 20 filling lines for e-liquids in the past year alone. Its customers are contract packers working for distributors, as well as people who have started their own business. Almost daily, more and more companies are switching away from the manual refilling of cartridges.

2500+ e-liquid types

Cartridges for e-cigarettes are dosed commonly with 10ml volume, but sometimes with 20ml or 30ml. Along with up to 19.9 mg/ml of nicotine, the refills contain various flavours as well as propylene glycol and vegetable glycerine. In total, there are thought to be well over 2500 e-liquid types available on the market. 

With this in mind, the main requirement is to change batches quickly with minimum product loss, ambitions made possible through the adoption of a Flexicon peristaltic filler in the filling process. Here, the product only comes into contact with the tube of the pump, so the machine does not need to be cleaned - only the tube only has to be replaced or discarded whenever a batch is changed. No cross-contamination is possible using Flexicon pumps. In contrast, using piston or syringe type pumps would be entirely unsuitable due to the number of cleaning operations required. Flexicon peristaltic fillers easily can also prevent dripping between each fill and also reduce foaming.  

Flexicon pumps can be supplied to suit a range of applications, including semi-automated or fully automated variants in line with throughput requirements. Watson-Marlow says that many companies filling e-liquid cartridges are now upgrading to fully automatic solutions.  

Volumes climbing

For instance, one customer which bought its first semi-automatic filling solution for producing between 500 and 600 x 10ml cartridges per hour using four operators, has since found that volume requirements have increased and it now needs to go five times faster. As a result, an automated line has since been built in accordance with pharmaceutical standards that is capable of filling up to 5000 cartridges per hour. Furthermore, only one operator oversees the line.

As things stand, no specific standards exist in this sector. It is up to manufacturers to convince customers of the need for machines that guarantee hygienic filling, facilitate good traceability and are capable of working on a wide variety of different batches. Only this is likely to keep the regulators at bay in the long term.

Shanghai Xinyang Utilizes Almatec E-Series AODD Pumps

Huang Lianxin, an employee at Shanghai, China-based Shanghai Xinyang - a chemical company for the semiconductor industry - discusses how Almatec E-Series air-operated double-diaphragm (AODD) pumps are the ideal choice for chemical applications. Shanghai Xinyang chose Almatec pumps for their reliability, lower air consumption cost, lower noise level and superior containment.

Qdos 60 attributes ideal for dosing application at French winemaker

Watson-Marlow Pumps Group has supplied Qdos 60 metering pumps to Fauchier Company, a France-based specialist in the design and manufacture of automated filtration systems. The pumps are being used as part of a double skid for a winemaking customer of Fauchier – Qdos technology is dosing a wine ingredient known as gum arabic. The pumps were chosen for their high performance characteristics, which combine both high accuracy and low pulsation.

 Process overhaul

“Our customer had to revise their entire filtration process with respect to filtration quality, process standardisation and, above all, the provision of a fully automated control system prior to bottling,” explains Mr Fauchier. “In addition, they wanted to use telemetry to operate the system by remote control via the intranet.

 The Fauchier Company set about designing a cartridge filtration system fully connected to the factory’s IT system. The advantage of the system is the optimised and controlled arrangement of the start-up phases, while sterilisation and cleaning times are also reduced.

 For this particular project, Fauchier sought calibrated peristaltic pumps for dosing gum arabic, a natural gum extracted from specific species of African Acacia trees that is used for ‘rounding out’ tannins in wine to reduce astringency.

 Based on a double skid configuration with automatic dosing, the aim was to reduce pulsation and achieve very precise dosage which could be controlled by a flowmeter without a non-return valve in order to perform washes.

 Accurate dosing

“We chose Qdos 60 pumps from Watson-Marlow for precisely these reasons,” says Mr Fauchier. “The pumps also have the advantage of not requiring any additional ancillary equipment, while ease-of use, reliability and robust build were other factors in the purchase decision.”

 Another major benefit is the unique design of the patented ReNuTM pumphead which maximises process uptime with no-tools maintenance. For the user, this means  quick, safe and easy pumphead replacement.

 “Importantly for this application, the pumps can be operated by remote control thanks to their analogue function, enabling us to gather information or to change settings remotely,” adds Mr Fauchier. “In fact, Watson-Marlow pumps seem fully adapted to this new era of e-solutions and Industry 4.0.”

 The company purports to be extremely pleased with the performance of the Watson-Marlow pumps and is now interested in another Qdos 60 model for a new project requiring greater flow rates. Mr Fauchier is also showing interest in the Watson-Marlow OEM DriveSure pump, because it is a fully integrated panel mount pump.

 Willing partner

“We particularly enjoyed working with our contacts at Watson-Marlow who were always willing to help during tests and after the system had been set up at our customer’s site,” he concludes.

 The Fauchier Company, located in Saint André De Cubzac near Bordeaux, has over 15 years’ experience in supplying filtration systems. The systems devised by the company often also incorporate a CIP washing process and automated testing and measuring equipment – all connected to a network, website and monitoring system. The use of sensors gives the system a self-diagnostic capability, enabling it to be operated by remote control and better integrated into the production process as a whole.

LAKOS Pump Protection Separator

The LAKOS PPS Pump Protection Separator prevents sand damage to submersible and turbine pumps in water well applications. Such damage would typically lead to loss of pump efficiency and eventual pump failure. Dramatically extend pump life and save energy by keeping sand out of water well pumps.

New discovery could make oil refining more efficient

A new technique developed by scientists in the United Kingdom and the United States could significantly reduce the amount of energy used in the refinement of crude oil. It utilizes a porous material that is said to work like a chemical sponge to separate a number of important gases from mixtures generated during the refinement process.

Researchers from the University of Nottingham, the Science and Technology Facilities Council's (STFC) ISIS Neutron Facility, the U.S.-based Oak Ridge National Laboratory and Diamond Light Source Ltd. have proved that a porous material, a metal-organic framework, can be used to separate hydrocarbon mixtures without the need for the high pressures or very low temperatures that current processes require.

The material, called NOTT-300, is made from inexpensive organic materials, aluminum nitrate salt and water. According to the University of Nottingham it is able to adsorb different gases found in mixtures of hydrocarbons at different rates, making it possible to separate them and extract the most useful ones.

NOTT-300 operates at ambient temperatures and normal pressures, which means that it requires less energy to function than existing methods.

Moreover, the gases that are adsorbed into NOTT-300 can be removed without a significant energy input and the material can be easily reused.

This new separation technique can potentially reduce the energy usage associated with oil, petroleum and chemical industries which require the separation of raw hydrocarbons from crude oil, said Dr Sihai Yang, a Senior Research Fellow at Nottingham, who led the project together with Professor Martin Schrˆder.

"The next step is to launch in-depth collaborations with materials engineers and R&D from industries," Dr. Yang added.

The findings of the research have been published in Nature Chemistry.