Articles

When manufacturing engineers are tasked with automating a process that is currently done manually, their main question for an automation supplier is, “Have you ever automated this specific process before?” In complex applications, the answer is typically, “no.” Even simple applications can be more complex than at first glance.

In Joe Nettemeyer's long and productive career, he has had a front row seat to a significant amount of change, and he’s learned how to help others embrace transition. Nettemeyer spoke to Industrial Distribution Magazine about guiding everyone—even the skeptics—through major business shifts.

Premature heater failures can lead to unexpected process downtime. Tactics such as testing, planned replacement programs and preventing moisture ingress can help prevent premature heater failures.

For many years, the industry has been guided to a liquid filter cartridge with an outside diameter (OD) measuring 2.5” or so with an inside diameter (ID) measuring 1”, and a length that varied from 5” to 40”. Of course, there are always a few exceptions to the length, but in general, these specifications were very much the standard.

Closed-loop stepper motors may be the best choice for tasks typically done by servos because traditional steppers couldn’t handle them.

A plant operator’s biggest fear is an unplanned shutdown. The process can place a heavy amount of stress on both operations and maintenance personnel. Alternatively, taking full advantage of a planned shutdown or turnaround is critical.

Developing a strong preventative maintenance plan for plant shutdowns and turnarounds is the best way for operators to minimize the risk of equipment failure, which can lead to unnecessary shutdowns and ultimately, higher costs.

In today’s refining and chemical manufacturing environments, the devil is always in the details. Choosing the right process design and the right equipment to ensure you’re operating efficiently without significant downtime is always a challenge. Your organization’s reputation, product quality, worker safety, and cost control are on the line all day, every day.

When working with highly technical equipment and toxic chemicals, safety in process filtration remains the top priority on the job. Fortunately, with the right technology, you have tools available to stay safe and get the work done quickly and efficiently.

Today, the average computer chip is comprised of more than 10 billion individual transistors that require more than 1,000 steps to assemble into working components. Estimates show that the loss of just one die per wafer can equate to more than U.S. $1 million in lost revenues each year. And, a major contributor of faulty dies is contaminant particles.

Predicting your plant’s future depends on collecting and analyzing the correct type and amount of equipment and process data. Predictive maintenance (PdM), much like “IIoT,” “Industry 4.0,” and “Plug ‘n’ Play,” among other terms, may be an exciting concept in plants, but many still aren’t leveraging it fully.

Specifying control valves and engineering a system in which the flow of a particular product is completely optimized for superior performance and yield can be a challenging process. A number of factors must be considered during this practice, not the least of which is trying to prevent any system or process-destroying problems that may arise.

Many engineers may wonder if it is possible to have flashing liquid flow in a control valve even if flow is not choked. The short answer is yes, but it is not very common. This article provides a more detailed answer to this question.

Within a refinery, four main utilities are considered essential to operations: electricity, natural gas, water and compressed air.

With the cold months on the precipice, November is a great time to review the actions that plant managers and operators should take to better ensure a winter free from incident.

Depending on the industry and specific environment, different rooms will have different cleanroom classification requirements. There is a litany of information out there regarding how classifications are tested and determined, but not as much about how to improve a specific room’s classification ranking.

I was recently asked how the installed flow characteristic of an equal percentage valve in a system that includes a significant amount of pipe or other pressure-consuming elements “magically” becomes a linear, or approximately linear, installed flow characteristic.

Fabs and OEMs in the semiconductor industry face a number of difficult challenges today, specifically in the etch and deposition/thin film processes. These incredibly specialized processes require extremely clean gases and vaporized chemical sources.

In the past, bulk storage systems have been used to house nitrogen on-site at the manufacturing plants, but this method of storage can result in a significant loss in revenue when all is said and done. So, what is the solution for plant owners? The answer begins with in-house nitrogen generation systems.

Engineers building linear-motion systems can use ground-up DIY approaches or purchase complete turnkey solutions. Here we explain where each tactic is most profitable.

Patlite innovation continues with improved functionality to drive productivity, improve efficiencies, and reduce waste. One of their basic themes is to help you make continuous improvements in your process. With that in mind, Patlite recently introduced the REVOLITE LA6 multi-informational signal tower.

Thermocouples and controllers themselves do not prevent a failure from occurring. What they can do is create a temperature profile for a heater that can be used as a maintenance log.

In the last ten years, the design of pneumatic systems has changed dramatically. Pneumatic manufacturers’ online tools for sizing components have evolved, the fieldbus systems are ever-changing, component designs are constantly improving, and network devices such as the Industrial Internet of Things have reshaped the industry.

Liquid choked flow in control valves results in either flashing, or more often, cavitation.

Though the lines can often be blurred, robotics and motion control are not the same thing. They are closely related in many ways, but robots lean towards more “pre-engineered” solutions while motion control leans towards more modular solutions. Before deciding to install a robot or motion control component, these are ten questions to ask yourself.

In the chemical processing industry, a significant percentage of measurement devices are not correctly matched to their application. This leads to decreased quality and consistency in their operation.

Controlling vibration and surge is one of the most critical aspects of keeping centrifugal and reciprocating compressors up and running. If improperly monitored and maintained, these types of compressors can experience frequent functional issues and ultimately shorten their life span.

Robotics can be narrowed down to five types: Cartesian, Cylindrical, SCARA, 6-Axis and Delta. Each robotic type has specific elements that make them best-suited for different applications. The main differentiators among them are their speed, size and workspace. Knowledge of each type can help machine designers choose the best robot for their process.

Parker’s Fulflo® EcoBond™ Cartridges are the most economical high purity filter cartridges available. Featuring a graded density matrix of uniform polypropylene fibers, the EcoBond™ provides consistent filtration for a wide variety of fluids. 

Valve sizing and proper application of control valves have always gone hand-in-hand. However, the tools available to valve users have changed and improved significantly over time.

The latest developments in servo technology allow for the benefits of high-performance motion control to be used in harsh environments.

We think of routine care and maintenance of a system to stave off failures as standard practice, but what about preventive maintenance of the replacement parts used when the system does fail?

Despite the demand for standardized communication protocols among manufacturers, both the manufacturers and end users face challenges when it comes to agreeing on a path.

Proper filtration is one of the most important functions performed inside refineries. Filtration is the removal of contaminants through some type of synthetic, paper, pleated or wound media. The goal of this process is to achieve a specific level of cleanliness.

Using lean principles in manufacturing is an important element when trying to reduce waste, control costs and ensure timely deliveries to customers. However, this concept of trimming back unnecessary work and reaping the production benefits can also be applied at an individual level in production lines or assembly rooms.

Electromechanical drives continue to capture more factory automation projects, but pneumatics technology still offers distinct advantages in many fields.

Semiconductors are the basis of most electronic circuits and exist in virtually all electronic devices. The manufacturing of these integrated circuits, also referred to as chips, is a multi-step process involving an intricate design system. The yield (chips or die) of these processes rely heavily on the effectiveness of point of use (POU) filters.

Employing flexible automation technology now is vital for companies to sustain growth, keep a diverse range of products flowing through their lines, and minimize downtime with product changeovers. Advances in industrial technology and the overall evolution of automation over the past century have been unprecedented.

There are many components within today’s coal-fired power generation plants. For these components to operate with maximum efficiency, one must do everything possible to minimize the risk of failure. One element of critical preventative maintenance is keeping everything at a temperature that will not cause instrumentation to freeze.

Inside of plants today, AC motors are becoming the industry standard. Many plants are shifting to AC motors from hydraulic motors and in some cases DC motors when powering heavy loads, which were more popular in the past. This shift can be attributed to a variety of reasons and most have to do with cost. 

For automation applications, one of the larger misconceptions in the industry today is that when someone uses the phrase “motion control,” they can just as easily use the term “robotics,” as if the two are interchangeable. Click on the "Read More" button below to read the full article featured in Product Design and Development Magazine.

When selecting the pipes and valves to be included in a cooling system, it is important to understand the options available — and the possible outcomes associated with each selection. The selection process is often overlooked or is not given proper attention by designers and contractors. Many factors can impact the effectiveness, longevity and quality of the overall cooling system.

Valin Corporation’s Vice President of Marketing, Anne Vrancic, recently did a Q&A with ID to discuss Valin’s journey from the planning phase, through the launch and how the site is being received now that it’s been up and running for 8 months.

Process automation is the term most used when talking about computer technology paired with software specifically engineered to help industrial plants or factories operate more efficiently and safely. Before process automation was implemented, individuals would have to physically monitor the components and outputs of a plant or factory. 

The distribution model of the past 50 years is changing rapidly thanks in part to the digital revolution. Joseph Nettemeyer, president and CEO of Valin Corporation, says that means distributors must find ways to add more value to solutions offered to customers. It also means they must become digital experts in communication.

Upstream bioprocessing, within the last 10 years, has been converted to a single-use disposable product rather than a housing that would be need to be regularly cleaned. The issue with single-use bioprocessing is that most systems will have a bottleneck at the chromatography column.

Liquid to liquid separation, at the very basic level, is a process where water is removed from a hydrocarbon. Over the last decade, there have been three prominent machines or mechanisms that can perform a liquid to liquid separation. These three mechanisms include a centrifuge, a vacuum dehydration system and a coalescer system.

It is all about connectivity. Now more than ever the industrial plant model has become heavily reliant upon the connectivity possibilities between equipment and the automation that it can provide. The future digital plant revolves around the idea of connecting machines to work faster, more efficiently and in collaboration with one another.

Contemplating an actuator for your pneumatic linear-motion system? Here are some tips on how to select the best one for the job.

Valin’s aluminum framing systems are being used in cleanroom environments to overcome many of the disadvantages associated with traditional painted steel shelving systems.

An extensive range of Panel Builder products feature time-saving, Push-In Plus terminals and reduced mounting depth and volume to fit smaller control panels.

Omron now offers FM Approved Temperature Limit Controllers in three E5_C series formats that help protect processes against runaway heating or cooling systems.

The Internet of Things (IoT) is a phrase that describes the connectivity between physical objects networked together using an Internet connection. These networks have a wide range of capabilities, mostly centered on collecting or exchanging data. A specialized version of the IoT, referred to as the Industrial Internet of Things (IIoT), enables industrial application engineers to implement new or retrofitted systems with upgraded levels of connectivity that allow more advanced process control.

According to the United States Energy Information Administration, coal power accounted for 39 percent of the country’s electricity production last year.

Creating meaningful and long-lasting change within an organization can always be challenging. Often, employees can become complacent in the way they operate on a day-to-day basis.

Valin Corporation now offers single-pump custody transfer units it estimates cost $10,000-$15,000 less than traditional two-pump designs.

In order to avoid unnecessary shutdowns and the high costs associated with them, manufacturing systems need to be flushed at regular intervals. The practice is a high-value maintenance practice that is required throughout the industrial world.

In a society with an “excess of everything,” a manufacturing or distribution business needs to be able to provide unique and clearly defined value propositions in order to gain that crucial market share.

Spectroscopy-based measurement on manufacturing lines yields greater process control

Join two dissimilar metals, add a little water, and you have set up a circuit that can lead to some serious corrosion. Understanding terminology like electrolysis and galvanic reaction can help you identify and avoid problems that can occur anywhere—not just in hydraulic systems.

In applications requiring heated concrete to prevent snow or ice accumulation, the ideal solution is mineral insulated heat trace cables embedded in concrete.

Inside power generation plants, there is a need to eliminate the dangerous oil mist produced by lubrication systems.  In any set of circumstances where there is significant metal on metal contact, there should be some form of lubrication system installed that will increase the lifespan of the machinery.

Dry Resin Ion-Exchange Cartridges have become the international choice for reducing Total Acid Number (TAN) in lubricating, hydraulic and insulating oil systems.

Oil and gas engineers face a major problem in accurately and reliably measuring and monitoring the various fluids that are introduced into oil pipelines from well site pumping stations. A thorough understanding of both the oil separation process and the properties of valves and actuators is required to correctly specify a system.

United Electric Controls has introduced a unique new family of HART capable transmitters that provides programmable switching functionality for industrial process monitoring applications. The new One Series 1XTXSW transmitter line is the first to integrate HART 7 compatible 4-20 mA output and two solid-state programmable relays for monitoring temperature or pressure in safety, alarm and emergency shutdown applications.

Making smart design decisions, particularly in relation to the suction line, can avoid potentially severe cavitation-induced damage to hydraulic pumps.

As electronics and technologies become smaller and more intricate, manufacturing engineers are running into new challenges in automating manufacturing processes. The challenges of manufacturing new products extend beyond the capabilities of precise motion control mechanics to include the control of environmental factors.

The Chromalox CS Series of solid state relays are an ideal, low-cost power control solution for rapidly and precisely switching resistive loads found in industrial applications such as furnaces, ovens, heat treating, injection molding, thermoforming, press platens, commercial food equipment, semiconductor, lighting and drying, just to name a few.

Omron has been providing automation solutions for more than 80 years. Their washdown rated products and extreme washdown products in the IP69k protection class help you deliver safer solutions to your customers.

Workplace safety is—or should be—a primary focus of every organization, regardless of whether we’re talking about a classroom, an office, a manufacturing facility, or an oil rig. Employees deserve a workspace that is as safe and secure as it can possibly be.

Sysmac is the latest machine automation platform from Omron with integration throughout: from controller to software.

Advantech’s new 12.1” and 15” TPC-1251T/1551T touch panel computers are the latest of their type to use the Intel® Atom™ E3827 1.75 GHz Processor and to feature the much heralded iDoor Technology, a truly flat screen and a multitude of I/O ports while being able to operate in a wide range of temperatures.

Advantech ProView Ethernet Switch is a SCADA manageable switches which are the convergence switches for process control and IT networking management.

In environments with persistent cold weather, ice buildup on flat commercial roofs is both a safety hazard and a costly liability for many businesses. There are three main roof drainage systems used by commercial facilities: internal drainage, scupper drainage and traditional pitch and gutter drainage. 

Meet Parker's new mSR (miniature square rail) linear motor positioner. The mSR integrates dual square rails for guidance, with one of two different linear motor technologies, and up to six different encoder technologies.

Precise combinations of valves and other equipment lead to process success. A biopolymer fermentation process provides an example of proper valve selection.

Nearly 30 years ago, in 1987, the Nobel-winning economist Robert Solow surveyed the impact of IT on the economy and concluded that “you can see the computer age everywhere but in the productivity statistics.”

Trying to size and space the electrical components before the mechanics are defined can lead to wasted time and rework.

The IPS PTFE Pressure Regulator is designed for use with high purity water systems and aggressive chemical applications to regulate and maintain a constant pressure downstream of the valve and prevent over-pressurization of sensitive equipment.

Plant engineers often fail to incorporate correct lubrication into system processes and do not realize its critical importance until something goes wrong.

This is Part IV in a four-part series based on the contents of the new textbook, “Control Valve Application Technology, Techniques and Considerations for Properly Selecting the Right Control Valve.”

Cavitation is the 2nd leading cause of a pump system failure. It’s for this reason that a full understanding of what cavitation is, how it is caused and how it can be prevented is critical in the fluid power industry.

In order to get good control with stability throughout the full range of required flow rates, one must use a control valve that has an installed flow characteristic that is linear, or at least as close to linear as possible in most systems.

In a world where most information is available in an instant, plant managers and engineers are continuously trying to find ways to improve the efficiency of processes along the manufacturing line.

Tasked with increased demand for high power output, many operators in North American sectors such as power generation, oil and gas, petrochemical and chemical have been challenged by low-voltage solutions and their associated logistical challenges.

When addressing the needs of measurement operations involving various densities and amounts of liquid, Coriolis mass flowmeters are often chosen for their accuracy, durability and reduced maintenance costs. Applications involving custody transfer benefit from their simple and dependable characteristics.

Purchase Valin’s Control Valve Application Technology book today to learn how to apply the right techniques to selecting the correct control valves.

This is Part II in a four-part series based on the contents of the new textbook, “Control Valve Application Technology, Techniques and Considerations for Properly Selecting the Right Control Valve.”

Advice follows on using proportional-integral-derivative (PID) tuning for motion control and robotics. High-end robotics with high dynamics and reasonably high accuracy of movement almost always require the use of these control algorithms for operation.

This article discusses the importance of selecting the correct flow characteristic and correctly sizing the valve in order for the valve to properly control the process.

Considering the number of variables present, gaining precise control of a process heating application can be a difficult task. In industries with a low tolerance for irregularities and a high demand for consistent quality, controlling the temperature of a substance from the start to the finish of a process is an absolute necessity.

IAI's new IXP Series Robots cost around 1/2 of that of a conventional model due to the adoption of the pulse motors. The IXP achieves a payload equivalent to that of a conventional model by adopting high-output drivers. All IXP models come standard with battery-less absolute encoders.

In its earliest days, Valin focused on fluid handling and developing products used in the manufacturing of semiconductor equipment and microchips. Over time, the company expanded its capabilities based on market and economic conditions.

It’s important to understand the importance of proper control valve sizing. If the valve is too small, it won’t be able to pass the required flow. In actual practice, undersized valves are fairly uncommon, but oversized valves are all too common.

The Reveal™ optical spectroscopy-based measurement system will help customers increase quality, yield, and productivity while reducing both risk and downtime in the manufacturing environment. Its measurement capabilities are unmatched by legacy techniques.

An HMI that is expressive, intuitive, and easy to implement makes industrial machines more attractive and competitive. The Omron Sysmac NA Series HMI enables faster, more efficient control and monitoring - and a more natural relationship between operator and machine.

With air cylinders, a compressor is operated with electricity to generate compressed air, and generated air is supplied though a line to the air cylinder where it is then converted to linear-motion force. This mechanism is subject to significant energy loss.

Loss of containment is one of the costliest things that can go wrong at a plant. Accordingly, smart enterprises employ a variety of measures that ensure loss of containment just doesn’t happen – or when it does, the adverse circumstances are kept to a minimum.

The noise abatement laws and health and safety legislation are becoming increasingly strict. Metso introduces Q2- Trim, the optimum solution for noise problems, that at the same time fulfills all legislative requirements and customer needs.

Emergency order required all rail shippers to test products from the Bakken to ensure proper classifications of the oil within federal regulations before it's transported. The intent was to ensure shippers properly classified crude oil for transportation and to quantify the range of physical and chemical properties.

The accurate allocation measurement of oil, water and gas is a constant priority for managers of surface operations, particularly with the recent oil boom in parts of the U.S. These measurements are the basis of the financial transaction between oil companies and royalty owners.

Valin introduced its new lease ­automatic-custody-transfer (LACT) configurator tool. This new software-application tool assists customers in LACT specification, quotes, component data, and reference documentation.

As the automation and motion control needs of industries using control and drive functions continue to change and progress, the technology that meets those needs must adapt to the growing demand for connectivity, accessibility, and efficiency, all while maintaining a high level of quality and durability. 

When developing a practical approach to leakage and pollution prevention, plant managers have a variety of options available in terms of instrumentation and equipment. Depending on the particular process, materials, and type of operation, the method of ensuring the containment of potential contaminants will vary widely.

Jon Monsen's book, Control Valve Application Technology, Techniques and considerations for properly selecting the right control valve, outlines the process of selecting control valves for a number of different applications.

The recent oil boom in the United States, driven by rapidly advancing extraction technologies, presents new and critical challenges to operators in the measurement of oil, water and gas produced in surface operations.

This innovative new software application tool assists customers in LACT specification, quotes, component data, and reference documentation. The configurator is easy to use and gives customers the flexibility to develop the right solution for their specified application.

Proper treatment of boiler systems when they are off line is a constant concern for those managing and overseeing the operations of a power plant. Many power plants are known in the industry as peaker plants, meaning they are not running constantly.

Precision measurement expertise is one of the most important parts of transferring oil from a producing oilfield into the oil pipeline, truck or other oil transport method. Precise measurement is absolutely critical. Water or natural gas content is not allowed in the saleable oil steam.

A primary goal of many a plant manager is maintaining continuous and cost-effective operation of a plant’s turbine engines. When considering this goal, it is important for plant managers to be aware of recent advances in filter designs for turbine air intakes.

When using a servo motor, one should consider torque, speed, and other applications for a specific motion control application.

The Snofree Roof Panel System protects against ice formations and resulting water damage. The material, shape, and mass of its extruded aluminum core and steel enclosure maximizes the transfer of heat and minimizes energy usage.

Valin is in the final stages of successfully commissioning 65 Lease Automatic Custody Transfer systems (LACT) for a very large project with one of the largest independent midstream energy companies in North America. The LACT systems were needed for an oil gathering project in the Myrmidon field in the Bakken Shale play in North Dakota.

Standard practices today simply use human machine interfaces (HMI) as windows into a system by allowing some information to be passed back and forth through those windows. This method anticipates the user having the knowledge to use that information both in and out of the system.

The future of the petrochemical refining industry will be driven by human-machine interfaces (HMIs) pushing information to where it is needed. An HMI that pushes production, quality and alarm information to the right level of user or management anywhere in the world has the ability to increase the visibility and reaction time.

Valin Corporation has introduced the Snofree Roof Panel System from Heat Trace Specialists, which is designed to protect facilities against ice formations and the resulting water damage. This product is part of the company’s heat trace technology solutions for commercial and residential markets.

A temperature sensor is a key component of any process heating application as it provides temperature feedback about the process, which can be used to monitor or control the process

Just as sound can have negative effects on the human body, certain frequencies can play havoc on industrial equipment. When control valves are not selected appropriately, there is an increased risk for cavitation, which causes high noise and vibration levels, resulting in very rapid damage to the valve's internals and/or the downstream piping.

Automation of processes that increase yield and raise productivity, is the core of what people think of when they speak of smart manufacturing. Smart is not limited to process change but opens the door to the use of new materials.

Advanced Process Control (APC) methods used to be so advanced as to be esoteric- too complex and unusable except by a few high-level experts. Today, however, it seems APC is little talked about for an entirely different reason: It’s become a commodity.

In a recent interview with VALVE Magazine, Dr. Monsen discussed how the analysis of installed gain can be a guideline for selecting the control valve that will provide good control with stability throughout the full range of required flow rates

To diversify Valin®'s business one acquisition at a time, it took the skills of an M&A M.D. named Joe Nettemeyer

Valin® Corp. has more than doubled since CEO Joseph Nettemeyer began diversifying the 38-year-old industrial process and supply company away from its chipmaking industry roots in 2001

When control valve professionals talk about "control valve sizing," they really mean the entire process of selecting the valve that will do the best job of controlling the process. Selecting the right size valve is an important part of the process, but there are other equally important considerations as well.

Services Drive Growth for Valin®

Services make up more than a third of Sunnyvale, CA-based industrial distributor Valin®’s revenue, up from just 5 percent five years ago. That growth has been no accident.