Process Heating August 2011

www.process-heating.com | August 2011 | Volume 18, Number 8

On Fire Use our Equipment Overview on Burners to fire up your burner search. Online and in print, it helps expedite the selection process.

Periodical Class

18 Don’t be a Risk Taker 25 Metering Boiler Water Treatment 30 Custom Cooling Can Deliver

These heaters will be fully assembled and checked at our factory before delivery.

Get a complete heater package Need a new heater? Get a complete heater package from Heatec. A complete package eliminates hassles, saves you time and saves you money. Our package includes design, manufacturing, factory assembly, on-site setup and startup. We also offer maintenance contracts and provide free phone support. Heaters have many components from a variety of manufacturers. It’s always best to mate these components with the heater and adjust them before the heater is shipped to you. This eliminates most compatibility problems. Our goal is that setup of our heater at your plant will be trouble free, without undue rework. Most setups should only require re-assembly of parts dismantled

for shipping, plus connection of electrical power and piping. Complete factory assembly eliminates last-minute fieldwork that can cause startup delays. It also eliminates buck passing if things don’t go right. Moreover, if a problem develops later, you won’t have to wrangle with a variety of component suppliers to fix it. So, when you buy a new heater, always choose a manufacturer that provides a complete package. Heatec has this capability, which sets us apart from others. Call today and let us answer any questions you have about our heater packages.

HEATEC

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The Heat Technology Company

August 2011 Volume 18 • Number 8

www.process-heating.com WEB EXCLUSIVES: READ MORE AT WWW.PROCESS-HEATING.COM Q Don’t Add Fuel to the Fire

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The gas piping running into and through a facility is another overlooked hazard. Natural gas leaks can create an explosive and flammable atmosphere inside a building. Explosions can also occur outside if a gas line is eroded, damaged or struck during construction.

Q Planning a Metering Pump Installation A metering pump installation must be planned from the day tank or liquid source up to the injection point.

Features 18

Combustion Controls Don’t be a Risk Taker Being aware of potential dangers can help prevent electric tank heat explosions.

21

Ovens Start Me Up: A Heater Guide Learn how to properly handle the startup and maintenance of electric resistance heating elements. This guide will provide an overview of electric heaters.

25

Pumps Choosing a Metering Pump for Boiler Water Treatment Metering pumps are used to pump many chemical solutions and additives. For boiler water applications, these devices must dispense accurate chemical dosages every time to ensure the proper chemical treatment for the conditioning of boiler feed water.

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Equipment Overview: Burners On Fire

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UPDATED DAILY Q New Products

Q Industry News

ALWAYS ONLINE Q Archives Q Calendar of Events Q Drying Files columns

Q Energy Notes column Q Equipment Overviews Q Heating Highlights

Q Digital Editions Q Buyers Guide Q Archived Webinars

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

Custom Cooling Can Deliver Solutions Customizing off-the-shelf chillers provides many benefits with a smaller price tag than you’d think.

The reader works on most current smart and advancedd ffeature phones, h includi l d ing Windows Mobile (5.5 and above), iPhone, Blackberry, Symbian and J2ME.

Chillers

Equipment Overview: SCR Power Controls Want to Learn More About SCR Power Controls? Our annual Equipment Overview on SCR Power Controllers allows you to compare supplier offerings and find the controllers that meet your application’s requirements. Because it is exclusively online, you can use our interactive search to narrow the field for you automatically.

Columns & Departments 6 8 16 34

While heating elements usually do not have a projected service life, the possibility of ultimate failure should be considered. Make provisions for ready replacement if the potential downtime will be expensive or critical to production.

Use your smart phone to read Process Heating, wherever you are! Simply visit http://gettag.mobi/ with your phone’s browser to install the Microsoft Tag app. Then, point your phone’s camera at the tag below to be taken to our current issue online — instantly.

Use our Equipment Overview on Burners to fire up your burner search. Online and in print, it helps expedite the selection process.

30

Q Element Suggestions and Practices

Editor’s Page Inner Workings Calendar Products

37 Classified Directory 37 Advertiser Index 38 Places & Faces

About the Cover The Furnnox ultra low emission furnace burner from Eclipse Inc. (www.eclipsenet.com), Rockford, Ill., fires into a test furnace. To create a visible flame, the temperature was intentionally lowered to 1,900°F (1,038°C). When the burner is operated at the optimum temperature, the flame becomes invisible. To learn more about burners, see page 28.

PROCESS HEATING (ISSN 1077-5870) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

www.process-heating.com • Au g u s t 2 0 1 1

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By Linda Becker

Commentary Cellulose-Digesting Microbe Likes it Hot

In Search of Heat-Tolerant Bio-Tools Research into biofuels continues to yield surprising and encouraging results. For instance, as a part of joint research by the University of California, Berkeley, and the University of Maryland School of Medicine, scientists have discovered a hot springs microbe that can consume — and even prefers — cellulose near the boiling point. The two schools are conducting joint research to analyze microbes found in hot springs and other extreme natural environments around the United States to find enzymes that can be used in extreme industrial processes, including the production of biofuels from hard-to-digest plant fibers. “Our hope is that this example, and examples from other organisms found in extreme environments — such as high temperature, highly alkaline or acidic, or high salt environments — can provide cellulases that will show improved function under conditions typically found in industrial applications,” said Douglas S. Clark, a UC Berkeley professor of chemical and biomolecular engineering, while announcing the findings. Clark is co-authoring a paper with coworkers and colleagues on that will appear in Nature Communications, an online publication. Called a hot springs microbe because it was discovered in a geothermal pool in Nevada, the “hyperthermophilic” microbe is

reportedly the most heat-tolerant enzyme found in any cellulosedigesting microbe to date, including bacteria. According to the researcher “bioprospectors,” the microbe’s key enzyme — the cellulose-digesting enzyme called cellulase — is most active at 228°F (109°C). Ironically, Clark notes that the newly found cellulase may actually work at too high a temperature for some industrial processes. Looking to nature for enzymes that amplify our understanding of processes and improve efficiency is not new. For instance, the researchers note that the enzyme used in the chain reaction to amplify DNA originally came from a thermophilic organism found in a geyser in Yellowstone National Park. Thus far, however, those found are not optimized for the conditions found in industrial processing, say the researchers. The hot springs microbes and others like it yet to be found could point the way to more efficient industrial processes. It will be exciting to follow this research.

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

DMV DMV Solution The DUNGS Dual Modular Valve (DMV) system provides a compact, integrated solution for reliable combustion control. Proof of Closure using a Valve Proving System or Valve Seal Overtravel-Interlock to meet code requirements

DMV Simplicity Comply with double valve requirements with a single control. The DMV features two valves in one body, available in single stage, two stage, fast opening or slow opening. Systems from 1/2” NPT to 5” ISO flanged.

DMV Advantage

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Au g u s t 2 0 1 1 • Process Heating

DMV-DLE 702/622

Streamline your combustion system by saving space, time and labor with the DMV by directly mounting a pressure regulator, pressure switches, butterfly control valve, valve proving system, and/or a vent line connection. Call, Fax or E-Mail for more information

Karl Dungs Inc. 3890 Pheasant Ridge Drive NE Blaine, MN 55449 Phone: (763) 582 1799 Fax: (763) 582 1799 E-mail: info@ karldungsusa.com

Inner Workings

ITT Blogs Practical Tips on Boiler Use During the warm weather months, it is a good time to undertake a boiler inspection and maintenance program. Proper upkeep can prevent dangerous boiler operating conditions; however, the only way to be confident that a unit is functioning properly is to perform maintenance, testing and inspection. And of course, regular inspection of boilers is the law, which typically is controlled and governed by states, municipalities and cities. Boilers must be examined by certified inspectors according to a mandated schedule. The day-to-day maintenance and servicing of boilers is the responsibility of building engineers, plant- and facilitymaintenance managers, or building managers. Most boiler problems do not occur suddenly. Instead, they usually develop slowly over a long period of time — so slowly, in fact, that they often go unnoticed by maintenance personnel. According to the National Board of Boiler and Vessel Inspectors, 81 percent of boiler incidents are caused by low water conditions, operator error or poor maintenance. All of which means they were preventable. H2O, a blog from Morton Grove, Ill.based ITT Residential & Commercial Water, notes several things to look for during boiler inspection besides regular wear and tear. Be on the lookout for: • Age of the control, which can be determined by checking the date code stamped onto each individual control. • Records of the unit under inspection. Sometimes, a log of past inspections and findings will be affixed to the boiler or attached in a packet. The inspector should focus on frequency of and specific maintenance performed on the unit. • Signs of poor maintenance. • Sediment buildup. 8

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Au g u s t 2 0 1 1 • Process Heating

• Erratically functioning boiler controls. • Overall boiler and boiler control performance and operation. The blogger also suggests having a licensed professional undertake the boiler inspection. For more practical information dispensed through the company’s blog, go to www.itth2opros.com.

Aerospace Firm Orders Composite-Cure Ovens Bristol Aerospace Ltd., Winnipeg, Manitoba, ordered several custom ovens and a control system from Minneapolisbased Despatch Industries to cure composite parts for aerospace equipment.

For the order, Despatch is modifying its high performance S-Series oven line to include vacuum bagging equipment and to provide custom heating and cooling ramp rates. The ovens maintain tight temperature uniformity, which is critical in composite-cure applications. In addition, Despatch is designing a control and data acquisition system specifically for the aerospace industry. For more information on the firm’s capabilities, go to www.despatch.com.

Heating Nuts Without Cooking Them U.S. processors of nut meats such as almonds, pistachios and macadamias face processing challenges because they require a system that both pasteurizes the nut products and meets validation requirements for proper log-kill doses

effective for salmonella and other bacteria. Over the years, various nut processors have asked Pittsburgh-based Chromalox for suitable solutions to processing nuts, which have a restricted shelf life. Because some processing facilities utilize batch processing while others use conveyor processing, a one-size-fits-all approach was not feasible. Chromalox had to engineer each system differently. Knowing that heating and power are critical to the overall processing of nut meats, Chromalox used its expertise in those to areas to develop individual solutions. For batch applications, Chromalox recommended circulation heaters used in combination with its SCR control panels for superheating the steam within prescribed temperatures to pasteurize the nuts and keep them dry without cooking them. In conveyor applications, Chromalox typically recommends its duct heaters to achieve the same heating needs. However, in some applications of this type, Chromalox will use its electric-fired boilers in combination with control panels. To learn more, go to www.chromalox.com.

Making a Big Flap with Plastic Automakers are always looking for ways to reduce vehicle weight and improve fuel economy, but incorporating those changes must fit into the manufacturing process, especially the heating stages. One automaker found a winning combination with a plastic fuel filler flap. Mercedes’ current E-class T-model has an especially large fuel-filler flap because it is intended to accommodate variable fueling options. The automaker converted the flap’s metal construction to Ultramid TOP 4000, a mineral-filled semi-aromatic polyamide (PA 6/6T) made by BASF, Florham Park, N.J. The conductive engineering

x Dependability proven in the field x Custom engineering and manufacturing x NOx as low as 5 ppm with EGR x Lowest Maintenance x Meeting your production, quality AND environmental needs x Greatest Fuel Savings x Leading the way in research and development x Fully trained and experienced Service Technicians with a world-wide reach

Photo courtesy of BASF, The Chemical Co., 2011.

Inner Workings

Duratherm Burner Uniform heating and low NOx. ALZETA’s “flameless” radiant surface is ideal for avoiding fragile fluid breakdown and localized hot spots.

CSB Burner Ultra-low NOx emissions for watertube and firetube boilers up to 150 MMBtu/hr. Simple controls; no FGR required. • Burner systems for new and retrofit applications • OEM and custom designed burner elements • Applications and custom engineering • Contact ALZETA with any specific needs

Firestar Modules in Boiler ALZETA’s newest premixed, surface stabilized burner. Low NOx and modular design for small boilers and heaters up to 10 million Btu/hr.

The Mercedes fuel-filler flap, no longer made of metal, is formed from autobody-grade plastic from BASF. It can be painted at the same time as the rest of the car’s steel body, helping to streamline the manufacturing process.

resin offers greater stiffness and dimensional stability. According to the company, the conductive material is suitable for on-line painting, which means it can, without additional effort or costs, withstand the various baths and painting operations, including drying, to which the rest of the autobody is subjected. Therefore, the gas flap now can be painted at the same time as the rest of the car’s steel body using classic automotive coating techniques. According to BASF, the material represents one more step toward a lightweight plastic automobile body.

Save Thousands of Dollars with Steam Tips ALZETA Corporation | 2343 Calle del Mundo | Santa Clara, CA 95054 408.727.8282 | 408.727.9740 fax | www.alzeta.com

PH08114Alzeta.indd 1

Whether steam is generated in-plant or purchased from a utility, the efficient use of its heat requires effective and reliable

7/20/11 9:58 AM

SYSTEM DOWN!

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Au g u s t 2 0 1 1 • Process Heating

Inner Workings control. Spirax Sarco shares steam tips in its e-newsletter to help users of steam systems achieve effective control. In a recent edition, Spirax Sarco explained how a pressure-and-temperature regulator can save a facility thousands of dollars in steam costs each year by allowing the most heat to be transferred from each pound of steam. Regulators also help prevent waste and overheating from lowering plant productivity. While many valves operate in fully open or tightly closed mode, a modulating pressure-and-temperature regulator will enable the system’s equipment to function more efficiently by adjusting itself to each pressure or temperature requirement. To obtain a lower steam pressure downstream than that which is supplied calls for a pressure-reducing valve. This device holds the reduced pressure constant whether the demand load requires little or no steam, or its maximum flow. A back-pressure regulator opens when the upstream pressure increases beyond its setpoint. It can relieve excess steam from a flash vessel or it can shut down the supply to less essential steam equipment at times of peak demand. Finally, the valve may be required to vary the steam flow to maintain a constant temperature in the process itself. Temperature regulators are used most frequently to control air or water temperature. Be sure to select control valves according to the different types of control functions they are required to perform. To learn more about how Spirax Sarco, Blythwood, S.C., can help you save steam and increase productivity in your plant, visit www.spiraxsarco.com/us.

PVC Pipe Heated from Inside for Easier Bending A pipe-bending system from PVC Bendit, Colorado Springs, Colo., heats pipe from the inside to enable uniform and rapid heating. The Build-A-Bend system includes a set of precut pipe sections that are aligned to create forms used to bend PVC pipe into precise, repeat-

able shapes. According to Bendit, the system allows bending lengths up to 18' and diameters up to 4" into nearly any curved shape without misshaping, crimping or changing the properties of the PVC. The product is especially useful when attempting to build multiple items of the same shape and form. The product is offered online through the company’s store at www.pvcbendit.com.

Oxy-Fuel Combustion Test for Power Plants Ends A joint research and development project on oxy-fuel combustion technology is making headway in reducing the CO2 emissions of power plants. The work being done by Helsinkibased Metso and Fortum in Espoo, Finland, has taken place at a Metso 4-MW test plant in Tampere, Finland, which was modified for the technology. The project is based on circulating fluidized-bed technology because it can be operated with a range of fuel types such as coal, biomass or a fuel mixture. The research involves switching from air combustion to oxygen combustion. In oxy-fuel combustion, the flue gas consists of almost-clean water vapor and CO2, which can be captured. Adding a carbon dioxide recovery system to a biomass-fired power plant creates a carbon sink that abates climate change. “We have carried out a comprehensive series of tests ranging from laboratory measurements to continuous pilot-scale tests,” says Jussi Mäntyniemi, general manager of technology at Metso’s power business segment. “In the pilot-scale testing, we focused on developing both the actual boiler process and safe operation of the boiler plant

Because our products are top quality Despatch never cuts corners. The products we build are manufactured to the highest industrial standards. Despatch ovens have a reputation for superior process control and dependable operation. Every oven is thoroughly tested and inspected prior to shipment.

INSPIRED INNOVATION

Thermal Processing Technology

phone: 1-952-469-5424 [email protected] www.despatch.com © 2011 Despatch Industries. All rights reserved.

NEW FULL FEATURE

COMBUSTION SAFEGUARD FORM 6642FF

Monitor and control burners in new, replacement or retrofit applications. Designed to reach new levels of operating control and safety. Full Feature Combustion Safeguard including: r


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Inner Workings during oxy-fuel combustion. Modifying Metso’s 4-MW test plant for oxy-fuel combustion has been challenging, and we are pleased with what we have achieved. With circulating fluidized bed technology, coal and biomass can be co-fired, thereby turning the power plant into a carbon sink.” The pilot program has ended and results now are being evaluated.

Recovering Steam Leaks, Boiler Improvements Yield Benefits Improving boiler feedwater heating, recovering steam leakoff and reducing ester still heat use are among the ways the Eastman Chemical Co.’s Kingsport, Tenn., plant has won multiple Significant Improvement in Manufacturing Awards from the American Chemistry Council (ACC). In 2011, Eastman’s winning projects included five at the Kingsport site. Recovery of Steam Leak-Off. Six Sigma techniques were used to recover 15 psi steam leak-off from shaft seals on turbo-generators in a powerhouse. New construction and use of an abandoned recovery system resulted in an annual energy savings of 44,391 MMBTU and an annual reduction in greenhouse gas emissions of 4,661 tons annually. Improvements in Boiler Feedwater Exchange. The stage heaters at a powerhouse were operating at reduced efficiency due to material wear in the heat exchangers, resulting in the

Where would you like to spend all your savings? Save thousands on your fuel bill with a burner upgrade. Industrial Combustion’s burners have quality components and proven performance that can save you significant dollars with high turndown and parallel positioning with O2 trim and variable speed drive options. Capacities range from 12 to 2,200 horsepower, firing gas, #2 - 6 oil, combination and alternative fuels, with low NOx emissions.

Visit www.ind-comb.com or call 608-325-3141

©2011 Industrial Combustion

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Inner Workings boiler feedwater bypassing the heaters. A monitoring program compared temperatures of the feedwater exiting the stage heater with an entitlement value, which returned the heaters to optimum efficiency and resulted in an increase in the feedwater’s temperature. As a result, the heat input required during steam generation was decreased and topping power from the generators was increased. These changes led to annual energy savings of 180,456 MMBTU and an annual greenhouse gas emissions reduction of 17,330 tons. Improvements in Distillation Columns. Two changes — adding a new distillation column and replacing an existing column with a new more efficient design — led to lower reflux rates, tighter control and greater energy efficiency while maintaining production. The new column was started up when the existing column was shut down to replace sieve trays with distillation trays and optimize tray spacing for greater efficiency. The changes resulted in annual energy savings of 44,150 MMBTU and an annual greenhouse gas emissions reduction of 4,635 tons. Reduced Ester Still Heat Use. An ester still had been heated with 600 psig steam modulated through a valve to a lower pressure. Experiments with the still revealed that the column could be heated from an existing 100 psig steam header with decreased energy use and increased control. The heater was repiped to take the steam from the header and drain it to a lower pressure condensate header, resulting in annual energy savings of 81,000 MMBTUs and an 8,500-ton reduction in greenhouse gas emissions. Reduction of Natural Gas Use in Three Heat Transfer Material Furnaces. The furnaces provide heat for dimethyl terephthalate production. A new control strategy now automatically shifts the load from less efficient furnaces to more efficient ones, so the overall heat duty required is provided at maximum efficiency. When compared to 2008, natural gas consumption was reduced by 80 scf per MMBTU of heat delivered to the process, with

a savings of 35,393 kscf in 2010, or 6.3 percent of total gas used. This converts to an annual savings of 36,455 MMBTUs and 1,922 tons of greenhouse gas. Improved Steam Turbine Discharge. At Eastman’s Longview, Texas, site, the company was recognized with an ACC award for improving steam-turbine discharge. The company added an additional steam line to maintain a constant 175 psig steam-discharge pressure, which resulted in lower 1,500 psig steam demand, an annual savings of 34,000 MMBTUs and 2,250 tons of greenhouse gas emissions. This is the 18th consecutive year that Eastman has earned the energy awards, receiving six of the 48 awards presented to 17 ACC member companies.

6 Things You May Not Know About Prepainted Metal Prepainted metal requires different handling and processing than bare metal. With many common misconceptions about prepainted or coil-coated metal vs. post-painted metal, the National Coil Coating Association in Cleveland provides six facts to set the record straight. • Fact 1. Precoated metal can be handled successfully without harming the painted surface. It can be shipped on flatbed trucks, moved with forklifts and stored as coils for long periods, yet it will retain a flawless surface. The coilcoating supplier can provide proper packaging such as wraps, bands and tape to protect the coils. Padded fork lifts also are used at service centers when moving coated coils. • Fact 2. Coil-coated metal is more durable than post-painted. In the process, sheets are uniformly cleaned, pretreated and painted as a flat surface, so the edge-to-edge and sideto-side variability sometimes found on post-painted metal is virtually eliminated. In addition, prepainted metal often has two coats (primer and top coat) with each tightly bonded to the metal, compared to post-painted parts that may only have one coat of paint. In many cases, a prepainted part has paint on the backside also,

Because we have the most experience Despatch has over 100 years of proven success in partnering with customers to deliver complex thermal processing solutions. We are committed to working with you to learn the details of your unique process in order to design and engineer a custom piece of equipment that will meet your specific requirements.

INSPIRED INNOVATION

Thermal Processing Technology

phone: 1-952-469-5424 [email protected] www.despatch.com © 2011 Despatch Industries. All rights reserved.

Inner Workings

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but a post-painted part usually has a minimal amount of overspray. Uniform pretreatment and paint on the backside of a part increases its corrosion resistance. Fact 3. Prepainted metal with cut-edge weathers better than post-painted surfaces. Some manufacturers are concerned with exposed cut-edge on prepainted metal, but the NCCA says that field research has shown that prepainted cut-edge metal holds up better over time than post-painted surfaces. Fact 4. Using prepainted metal can reduce costs for manufacturers. Outsourcing metal treatment and coating operations can alleviate or eliminate the costs associated with meeting environmental and health regulations, and overhead costs. Fact 5. Prepainted metal can be formed without any loss in surface quality or appearance. With the coil-coating process, the paint system can be designed to have greater flexibility than the metal. After metal has been precleaned, preprimed, pretreated and prepainted, it can be formed without degrading the painted surface. Fact 6. Precoated metal can be joined using adhesives, mechanical assemblies (with or without fasteners) or welding and retain a flawless surface.

The NCCA offers manufacturers help in determining whether prepainted metals are right for their products. For more information, go to www.coilcoatinginstitute.org.

Two Coils

are Better than One Designed with twin helical coils the General Combustion HYT Series heaters offer the highest efficiency available. The HYT is designed for high temperature applications and its small, compact package makes it the ideal choice for limited space environments and easy installation. The General Combustion HYT is suitable for use with a wide range of fuels and thermal fluids making it the most versatile and efficient heater available. For reliability you can trust and efficiency you can bank on... Call the experts at General Combustion.

HERE’S WHY . . . • • • • • • •

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Highest efficiency available Reduced operating costs Lower stack temperatures Compact construction for easy installation Safe, low-pressure operation No castable refractory Factory tested for optimum performance

Au g u s t 2 0 1 1 • Process Heating

5201 N. Orange Blossom Trail, Orlando, FL 32810 • Phone (407)290-6000 • Fax (407) 578-0577

Inner Workings Carton Manufacturer Celebrates 100 Years

The food compositions required extruder experimentation in Akron, Ohio-based Diamond America’s machine laboratory and at the production plant to achieve the right moisture content for optimum extruder forming, throughput and subsequent baking time.

A fourth-generation, family-owned business adheres to a favorite axiom: Are you here by default, or are you here by design? James A. Gordon, president and CEO of Winston Packaging in Winston-Salem, N.C., oversees the century-old company that rose from a job shop founded by his great-grandfather to a provider of branded and private-label printed retail folding cartons. In 2008, Gordon’s son

Photo: Business Wire

Digital Sensors Replace Mercury Thermometers

Winston Packaging was founded in 1911 by Alexander G. Gordon, a journeyman bookbinder and entrepreneur, who steered the company through the first two World Wars operating as a modest job shop for commercial printing.

became the fourth-generation involved in the business, a distinction only five percent of family businesses in the United States can claim. Winston prints for national companies such as R.J. Reynolds, Target and Kodak.

Achieving Right Moisture Level for Pet Food Extruder Doggie Lunchies of Corazz Corp., Missouri City, Texas, has installed a Diamond America extruder to automate and increase production of a kit that includes a resealable pouch with a water compartment, a package of Doggie Lunchies pet food with its own compartment, and a dog cookie — all wrapped up in a single disposable and recyclable package.

Earlier this year, the National Institute of Standards and Technology stopped providing calibration services for mercury-filled thermometers, marking the first milestone for the phasing out of potentially hazardous mercury thermometers in the United States. Mercury, a potent neurotoxin, has long been a standard in thermometers used in a number of industrial processes. If released into the environment though, mercury makes its way into streams, rivers and, eventually, the oceans, where it is absorbed by sea life. There, mercury accumulates in the larger fish that people consume — a source of mercury poisoning in humans. Phasing out mercury thermometers is one way to reduce mercury entering the food chain. However, before mercury thermometers can be eliminated completely, the American Society for Testing and Materials will have to align its standards with the regulations many states already have enacted that outlaw the sale and transportation of mercury thermometers. To date, nearly half of the ASTM standards have been modified. An alternative to a mercury thermometer is a digital unit. Most portable digital thermometers are more durable than mercury-filled thermometers. Process manufacturing of chemical, pharmaceutical, food or petroleum products requires accurate temperature measurements. Also, because temperature sensors are subject to drift over time, regular calibration or verification against a reliable reference thermometer is necessary. For more information on alternatives to mercury-filled thermometers, go to www.epa.gov/hg/alternatives.htm.

Now through July mention this ad and

SAVE $200 on LAC Series High Performance Ovens With a combination of forced convection and horizontal airflow, the Despatch LAC Oven provides exceptional uniformity and the shortest possible processing time. The result is proven reliability in demanding production and laboratory applications, such as curing, drying, sterilizing, aging, and process-critical applications. Special offer ends July 31, 2011

INSPIRED INNOVATION

Thermal Processing Technology

phone: 1-952-469-5424 [email protected] www.despatch.com © 2011 Despatch Industries. All rights reserved.

Calendar of Events August 16-18 — Ipsen-U Vacuum Furnace Technical Training, Rockford, Ill. Call (815) 332-2518 or visit www.ipsenusa.com.

22-24 — Ethanol Conference and Trade Show, Des Moines, Iowa. Hosted by American Coalition for Ethanol. Call (605) 334-3381 or visit www.ethanol.org.

19 — Pumping Systems Management Workshop, Dayton, Ohio. Call (937) 2169452 or visit www.eere.energy.gov.

23-24 — Web Coating and Drying Seminar, Brussels, Belgium. Call (803) 8027820 or visit www.convertingschool.com.

24 — Steam Systems Management Workshop, Downey, Calif. Call (562) 8037570 or visit www.eere.energy.gov.

September 7-9 — Semicon Taiwan, Taipei, Taiwan. Hosted by Semiconductor Equipment and Materials International (SEMI). Call 886 3 573 3399, ext. 239, or visit www.semicontaiwan.org. 12-15 — International Pump Users Symposium, George R. Brown Convention Center, Houston, Texas. Hosted by Turbolab, Texas A&M University. Call (979) 845-7417 or visit turbolab.tamu.edu. 13-14 — Web Handling and Converting Seminar, Ontario, Calif. Hosted by AIMCAL. Call (803) 802-7820 or visit www.convertingschool.com. 14-17 — Association of Water Technologies (AWT) Annual Convention and Exposition, Atlanta. Hosted by Association of Water Technologies (AWT). Call (301) 7401421 or visit www.awt.org. 17-20 — SPE Thermoforming Conference, Renaissance Hotel, Schaumburg, Ill. Call (706) 235-9298 or visit www.4spe.org. 19-21 — International Dairy Show, Atlanta. Hosted by International Dairy Foods Association (IDFA). Call (202) 2203526 and visit www.dairyshow.com. 19-20 — Process Burner Fundamentals Seminar, Tulsa, Okla. Call (918) 234-5710 or visit www.johnzink.com. 19-20 — Process Burner Operator Training Seminar, Tulsa, Okla. Call (918) 234-5710 or visit www.johnzink.com. 20-22 — Plastec Midwest, Rosemont, Ill. Call (310) 445-4200 or visit www.canontradeshows.com/expo/plastecshows. 21-22 — Advanced Process Burners Seminar, Tulsa, Okla. Call (918) 234-5710 or visit www.johnzink.com. 16

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Don’t be a Risk Taker Being aware of potential dangers can help prevent electric tank heat explosions. By John. R. Puskar, CEC Combustion Services

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lectric tank heaters present several possible dangers in process heating applications. Recent incidents include one at a manufacturing plant and another at an oil-and-gas processing facility. The manufacturing facility incident occurred on the hydraulic oil storage tank similar to thousands in use all over the world. Because of the commonality of these systems, and the prolific use of electric tank immersion heaters, it is important to be aware of the potential danger associated with this setup. The other explosion occurred at an oil-andgas processing facility outside of Pittsburgh. There, a fire broke out at a complex of three storage tanks, each about 25' tall and 8' wide. At the facility, the natural gas was pressurized within the tanks and moved along

a pipeline to a processing plant, leaving behind a “briny fluid” made up of liquid hydrocarbon waste called condensate. The tank’s electric heaters are designed to keep the liquid mixture from freezing. The local fire chief explained that the tank designed to hold the liquid apparently was empty or nearly empty but contained gas vapors. When the liquid mixture is low, the heating element is designed to shut off. But in this case, the electric heater continued to operate, eventually warming the vapors to combustible levels, setting off the explosion. Seeing such disasters, it becomes apparent that any electric tank heaters should be reviewed for design and installation issues that can lead to explosions so facilities can take action to avoid an incident.

Temporary storage tanks may be used for oil, natural gas or produced water. 18

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How would someone know that they might have a problem? In this article, several key electric tank heater design and installation issues — that, if left unchecked, could lead to fires or explosions — will be reviewed. Know the Risks of Electric Bayonet Immersion Heaters. The electric heaters to be concerned about typically extend into a tank through the sidewall. They might be 12 to 36" long, or longer. Typically, they are in the form of a bundle of elements such as a coil, wire or other shape that resists the electric current, causing the bundle to give off heat. It is the same concept used in an electric stove or toaster. In many cases, these elements work acceptably if they are covered with a fluid. If they are uncovered and the watt density is high enough, however, they can become an ignition source. Consider Watt Density and Protection. Watt density — defined as the number of watts per square inch of heating surface or element — is what the designer planned for the unit selected. It makes sense that if you squeeze a whole lot of watts through a small heater, the heater elements can get very hot. The free air temperature of some of these elements can be more than 1,000°F (537°C). Remember, the flashpoint of many hydraulic oils is only 400 to 600°F (204 to 315°C). It is not just oil tanks that are an area of concern. Any tank that can accumulate flammable elements must be considered. For instance, a wastewater tank that drains machining fluids may primarily contain water. But just a small amount of oil mixed in can cause a problem. The oil can be thermally cracked or broken down under certain conditions, filling the vapor space of the tank with hydrocarbon fumes. Then, when the level changes in the tank and air is brought in, a flammable mixture can be created.

Heaters The Fire Triangle

Use common sense and caution: fuel plus heat plus oxygen equal explosion.

When a flammable mixture is confined and ignited, you have everything you need for an explosion. The flammable materials try to expand to many times their volume in fractions of a second. When they cannot escape whatever vent is provided in a timely manner, the vessel or tank is pressurized and usually comes apart at some weak point. Often for cylindrical tanks, the weakest spot is at the top of the container. If an explosion does occur, the flying metal and resulting fireball can be deadly and destructive.

Strategies for Safety Consider also the case of a wastewater tank that is part of a food process or sewage system. Whenever biological activity consumes organic materials, methane can be released. If the elements become exposed and there are no protections in place, you can create an ignition source directly in the tank. Understand the Fire Triangle. The fire triangle concept is that when you bring fuel, oxygen and an ignition source together, you have all of the elements needed for a fire.

All users of electric immersion heaters must verify that they have minimized risks related to electric tank heaters wherever they are installed. Methods to minimize risks include the following. Verify Watt Densities and Maximum Temperatures. Many options are available when buying electric heaters. You can purchase heaters that have features to minimize the maximum temperature, or you can specify lower watt densities.

Use Operating and High Temperature Limit Controllers. Operating temperature controllers are essentially like thermostats in your home. They seek to provide the right temperature on a routine basis. High temperature limit controllers are special, separately installed controls that have a manual reset feature once exceeded. In this case, the device shuts the unit off until a person manually hits a button or takes some action. This feature forces someone to investigate and hopefully understand that some unusual event occurred and that an unsafe condition was reached. If a high temperature limit is installed, the setting has to be well below whatever flashpoint could be reached. Employ Level Controllers or Low Level Shutoffs. Level controls are available to help ensure that minimum levels are maintained in tanks for the heaters to operate. Level controls, however, are sometimes difficult to maintain. There are many things that can fool them. For this reason, in the case of boilers, there usually are two level controllers: one as a primary and one as a backup.

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Heaters Chemical industrial storage tanks are prone to danger. When electric tank heaters are used, extra care must be taken to ensure safety.

WEB EXCLUSIVE Don’t Add Fuel to the Fire The gas piping running into and through a facility is another overlooked hazard. Natural gas leaks can create an explosive and flammable atmosphere inside a building. Explosions can also occur outside if a gas line is eroded, damaged or struck during construction.

Remember that when replacing elements, care must be taken to consider watt densities and safety controls. There also needs to be consideration for how safety devices might be wired. In all cases, safety devices should be again checked whenever elements are replaced. The National Fire Protection Association’s codes could be a good starting point for investigating tank issues. NFPA 22, in particular, has information about tank heating systems that might be helpful. Practice Preventive Maintenance and Safety Device Testing. There was a tank explosion in an offshore facility in 2009, which was identified to have occurred because of the corrosion of a protective sheath on an electric heater. This incident illustrates the need to conduct periodic inspections of “at risk” electric heating elements and for testing of level controls and high temperature limits. Most combustion equipment codes

READ MORE @ WWW.PROCESS-HEATING.COM

It would never be a good idea to rely on level controls for the safety of your system, but it would be an extra layer of protection over and above a high temperature limit device. Consider Tank Design and Practice Good Maintenance. Tank system design also needs to be considered. Several national safety code standards exist for fuel oil tanks that call out venting requirements. In some cases, relief valves also might be required. In most cases, the vents for oil systems are larger than one might otherwise consider.

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It’s Time for You to...

and standards call for at least annual testing of safety interlock devices. The implementation of a testing and inspection program for electrical heaters in tanks needs to be risk based for the application and should consider what is installed, the watt density, the materials in the tank and other factors such as operating levels vs. tank volume. PH John R. Puskar is the founder of Cleveland-based CEC Combustion Services Group, a company that provides expert consulting, training and engineering services for all types of fuel-fired equipment. For more information, call (888) 8263473 or visit www.combustionsafety.com.

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Heaters

Start Me Up:

A HEATER GUIDE

Learn how to properly handle the startup and maintenance of electric resistance heating elements. This guide will provide an overview of electric heaters. By James E. Brocklehurst, Thermcraft Inc.

A

lthough electrical resistancetype heating elements have been around for many years, with new applications occurring daily, there still exist some misunderstood aspects of use. Also, quite frequently, the elements are misused due to assumptions or lack of readily available information. This article discusses general issues relating to the use, care and maintenance to help ensure the longevity of these heaters. Although the complexity of issues relating to resistance-type heaters indicates the need for a universal guide, it can be just that — a guide only. Actual specifications of heating units should be made only after consultation with knowledgeable engineers.

Application and Maintenance Factors With regard to the electrical lead considerations, it is important to consider the type of electric heater as well as placement and wattage requirements. It also is necessary to consider the types of electrical leads used and the methods by which they exit and terminate the heated area. Some general considerations in selecting various lead types are: • • • • • •

Temperature of lead area. Contaminants in the lead area. Flexibility required. Abrasion resistance required. Relative cost. Accessibility to controls.

When selecting heating element leads, be sure that the line voltage matches the heater’s rated voltage.

With heating element leads and power connections, be sure that the line voltage matches the heater’s rated voltage. Electric wiring to the heater must be installed in accordance with local regulations and the National Electric Code. Polarity must always be observed, and adjacent leads should always be connected to the same polarity. Failure to observe polarity may cause premature heater failure.

Lead Styles Element leads are available in a range of styles but they generally can be grouped www.process-heating.com • Au g u s t 2 0 1 1

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Heaters into categories. They include: • Single conductor. The single conductor concept is quite common and normally is the standard form of supply for ceramic and vacuum-formed-fiber heating elements. • Twisted pair conductor. Twisted pair indicates a lead in which the element conductor has been folded back upon itself and then twisted together in a specific manner. In this method, the effective cross-sectional area of the lead has been in effect doubled. This allows the lead to run at substantially reduced temperatures. This type of lead configuration is recommended where possible. • Rod conductor. This lead design involves fastening a lead of much heavier crosssectional area (typically a minimum of twice) to the actual element. Again, this allows the lead to run at much lower temperatures than the actual element. Typically, the rod will be welded to the heating element conductor. Although the rod is heavier than the element, care must be exercised when handling because the welding process generally will result in a fairly brittle area in the immediate area of the weld site. The rod type of connector can be used with either wire or strip heating elements. • Pad or bar conductor. The pad or bar lead is similar to the rod concept. In this design, either a flat bar is used or, if the element in question uses strip rather than wire, the strip is folded back on itself once or twice to increase the cross-sectional area. It typically is provided with a hole near the end for terminating via bolted connections. If the pad has been welded to the element conductor, the same concerns about weld site brittleness will apply.

Bending Radius Lead wire extending from the heater elements usually can be bent to conform to specific needs. Caution must be taken so that the integrity of the internal connection is maintained to prolong the life of the heating element. To avoid placing excessive stress on this junction, use soft nose pliers to hold the lead wire secure where the wire exits from the heating element and then 22

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Above: The single conductor concept is usually the standard form of supply for ceramic and vacuum-formed fiber heating elements. Right: In some of the larger elements and on certain lead assemblies, it may be possible to repair a mechanical break where the conductor is not extensively melted.

bend. Be aware that some pliers can gouge the wire, creating a weak spot. The minimum bending radius of the wire should be four to eight times the diameter of the wire. This works for both nickel-chrome alloys and iron-chrome-aluminum alloys. However, even at the proper bending radius, in very cold ambient conditions, iron-chrome-aluminum alloys still crack or break when any bending is done.

Brittleness Many of the high temperature metallic alloys used for heating elements suffer from poor ductility and brittleness, especially after they have been at operating temperature for any length of time. This is especially true for the iron-chrome-aluminum based materials that are often used in higher temperature applications. Traditional iron-chrome-aluminum materials will become very brittle once they have reached a temperature of 1,742°F (950°C), and this brittleness occurs almost instantaneously. The newer powder metal based ironchrome-aluminum alloys also become brittle once they have been heated, but this is a more gradual process and is strictly dependent on time and temperature. Once these alloys are cooled to room temperature, attempting to move them most likely will lead to breakage. Heating these brittle elements to a “color” temperature (above 500°F [260°C]) should allow them to be moved or repositioned without mechanical damage.

Terminations Proper terminations are critical to a successful heating element application; if not done correctly, poor terminations can adversely affect element life. One of the major goals is to ensure that the largest amount of element lead wire is in as close “hard” physical contact with the actual termination as is practical. In cases where insufficient contact exists, either through a lack of material or loose physical contact, a condition known as a high resistance joint can develop. This phenomenon will cause localized heating in the termination area, creating further degradation of the connection, leading to failure at the joint. Generally, this will require the replacement of what is otherwise a perfectly good heating element. When terminating small gauge wire leads such as those commonly found on ceramic plate or vacuum-formed fiber heater panels, the recommended practice is to use a mechanical compression procedure. This can be: • A bolt (binding post) with washers and jam nuts.

Heaters Although electrical resistance-type heating elements such as this flat plate example have been around for many years, there still exist some misunderstandings about how to use them.

Lead Protection

• Split bolt with washers and nut. • A specialized terminal strip. In all cases, the lead wire should be cleaned thoroughly at the area of contact using steel wool or light sanding to ensure a good electrical connection. The lead wire must be wrapped completely around the binding post and compressed between the washers and jam nuts or the terminal strip hardware. Insertion through the split bolt and compression between the washers generally will suffice. The preferred terminal material is brass although stainless steel is acceptable in many applications.

Often, it is desirable to provide a protective covering over the element leads. This may be required due to electrical or mechanical considerations. Great care should be taken when selecting a protective shield for the leads. The most common practice is to run the lead either inside a high temperature ceramic tube or place high temperature ceramic beads over the lead. Either of these methods can also have a flexible sleeve placed over the top for additional protection. In addition, the grades of insulation used should be examined carefully. Many of the lower rated materials contain a significant

amount of free silica. When iron-chromealuminum based alloys are used for a heating element conductor (generally higher temperature applications up to 2,372°F [1,300°C]), the protective alumina oxide coating formed on the outside of the conductor will react with the free silica starting at temperatures around 1,832°F (1,000°C). This reaction will lead to a eutectic melting phenomena occurring at the point of the reaction. Excessive insulation of the leads also could contribute to overheating conditions in both the lead and in the area of the terminations.

Repairs In some of the larger elements (rod style) and on certain lead assemblies, it may be possible to repair a break that is mechanical in nature, or where the conductor is not extensively melted. To do this, for nickelchrome alloys, the oxide must be cleaned off, the wires joined together, and then welded using approved methods. For ironchrome-aluminum alloys, a similar operation is used, except that material should be heated to “red” color temperature before it is moved. This will allow bending of the conductor segments without causing additional breakage.

Handling, Storage and Environmental Factors

Proper care and maintenance of heating elements such as this large air heating element will help ensure a longer operating life.

One of the reasons modern metallic-based heating elements can operate at such high temperatures — to 2,552°F (1,400°C) — for extended periods of time is they form a protective oxide on their outer surface. Surface contamination by a variety of substances will interfere with the oxide formation process, which occurs only at elevated temperatures. This will lead to premature failure of the element. Because most elements are shipped in a “green state” (no oxide on the surface), it is imperative that the material be kept as clean as possible until the element is installed and has been heated to form the oxide. Another important area of consideration is storage of the elements. They must be protected from the weather and must be www.process-heating.com • Au g u s t 2 0 1 1

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Heaters WEB EXCLUSIVE stored inside a cool, dry location. Ideally, this would also be a low humidity location but this is not always possible. Many of the alloys used for heating applications have a high percentage of iron in them and they are susceptible to rust when exposed to high moisture. The rust will interfere with oxide formation and lead to premature

failure. In cases where ceramic-based or vacuum-formed fiber elements are used, the ceramic and fiber can absorb moisture either directly from the air or from direct exposure such as condensation, leaky overhead pipes or spills. This absorption characteristic can compound the rusting potential because in many cases, the alloy will be

Element Suggestions and Practices While heating elements do not have a projected service life in most applications, the possibility of ultimate failure should be considered. Provisions should be made for ready replacement if the potential downtime will be expensive or critical to production or other operations. READ MORE @ WWW.PROCESS-HEATING.COM

Did you know that 90% of heat transfer fluid breakdowns are caused by equipment issues?

embedded and not visible for inspection. Another area of contamination is body oil present on your hands. It is recommended that clean, cotton gloves be worn when handling the exposed elements to protect them. If this is not possible, thoroughly wash hands with soap and water before handling the elements. It should be noted that the smaller the element material, the more significant this contamination becomes, especially for wire sizes below BSA 18 gauge and strip thickness of 0.04". In general, all petroleum-based products and most “shop dirt” will adversely affect oxide formation. Therefore, never place elements directly on the shop floor without first putting down a protective barrier such as clean paper or cardboard. If there is a lot of oil vapor present in the atmosphere, do not expose the elements to the atmosphere any longer than absolutely necessary. When heaters are removed from storage, they should be warmed to a minimum of 68°F (20°C) before attempting to install. Many of the high temperature alloys show increasing problems with ductility and brittleness at lower temperatures. If the leads or elements are below this temperature, attempting to bend or shape them could lead to cracking or breakage. Ceramic-based heater systems by their nature are susceptible to mechanical damage from mechanical shocks and stresses, thus do not drop them or force fit them. PH

Listing and temperature range chart for all Paratherm heat transfer fluids.

If you just check your hot-oil on a regular basis you could practically eliminate unplanned shutdown or loss of production. The easy way to do this is by conducting a Fluid Analysis. Because Fluid Analysis isn't just to check your fluid; it's to test your system. When we test your fluid (we suggest annually or more frequently for demanding service) the values we get from boiling range, viscosity, and acidity tell us what's going on in there. Better yet, together with a one-to-one system review with you, those same test results can help pinpoint emerging issues with oxidation, overheating, or possible mismatches in those interrelated components that could lead to a downtime-causing problem. This can help you keep the system up when it's supposed to be up, and know in advance if any corrections are needed for when you do have scheduled downtime. Your system runs better, your fluid lasts longer, and your process earns its keep.

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James E. Brocklehurst is a sales engineer for Thermcraft Inc., Winston-Salem, N.C, a manufacturer of industrial ovens and furnaces. For more information, call (336) 784-4800 or visit www.thermcraftinc.com.

Pumps

Choosing a Metering Pump for

Boiler Water Treatment A t their simplest, metering pumps are used to inject liquids at precisely controlled, adjustable flow rates, which is a process that often is called metering. As defined by the Hydraulic Institute’s Metering Pump Section, controlled volume metering pumps are reciprocating, positive-displacement pumps that typically are used for the injection of chemical additives, proportional blending of multiple components, or metered transfer of a single liquid. Metering pumps normally consist of a solenoid drive or a gearbox with a motor, a control mechanism, and a pump head with valves. It is through the latter that the liquid being pumped enters the inlet connection and exits the discharge connection. Metering pumps are designed to pump into low or high discharge pressures at controlled flow rates. For boiler water treatment applications, the metering pumps used must be able to dispense accurate chemical dosages every time in order to ensure the proper chemical treatment of the boiler feed water. Nearly every process within boiler feed water treatment requires metering pumps to dose treatment chemicals to help eliminate erosion, corrosion and scale buildup. Metering pumps meet these requirements because they have the flexibility to easily vary the amount of chemical dosage rates according to the process conditions. They are also suited for boiler water treatment applications that include the injection of phosphates to control phosphate levels in boiler feed water, and the injection of hydrazine, morphaline and ammonia for corrosion control. Taking all of these parameters into account, metering pumps rightfully remain one of the most versatile and relied upon technologies for the safe,

Metering pumps are used to pump many chemical solutions and additives. For boiler water applications, these devices must dispense accurate chemical dosages every time to ensure the proper chemical treatment for the conditioning of boiler feed water. By Tom O’Donnell, Neptune Pump Co.

Hydraulic diaphragm pumps are a popular selection because of their longevity in process applications.

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Pumps usually include electricity, air, gas or other means of driving the pump. When the pump’s parameters are determined, you must then consider the environment in which the pump will operate. Hazardous area requirements also must be identified when selecting the driver. When evaluating a hazardous environment, remember to consider dust, which can ignite just like fumes or vapors. Is the pump to be utilized indoors or outdoors? If it is located outdoors, it should be sheltered from direct sunlight. As far as temperature requirements, most pumps will operate in freezing conditions provided that the fluid to be pumped will not freeze and that the correct lubricants are selected. In this case, freeze protection and heat tracing may be required. Finally, operation in corrosive environments may require special pump coatings.

accurate and efficient injection of an array of chemicals in boiler water treatment applications. To employ them effectively, the user must effectively define the process-specific variables that need to be evaluated when choosing and installing the proper metering pump or complete chemical feed system. Having the proper metering pump and chemical feed system can help users inject liquids or slurries regardless of viscosity and help ensure that the metering is done in an efficient, environmentally friendly and energy-wise manner.

Metering Pump Selection As seems to be the case with most everything, size really does matter when determining the proper metering pump to be used in a boiler water treatment application. More specifically, selection begins by understanding the proper size in terms of capacity of both the pump’s flow rate and discharge pressure. Simply put, metering pumps should not be oversized. In fact, a metering pump should be sized so that its maximum expected flow rate is 85 to 90 percent of the pump’s capacity, which leaves additional capacity, if needed. At the other end of the spectrum, a metering pump’s minimum capacity should never be less than 10 percent of the capacity. Anything less will, in many cases, affect the pump’s accuracy. Selecting a metering pump cannot be done until the proper flow rates, discharge pressures and type of fluids are identified for the specific application. Once that is determined, the type of metering pump can be selected, i.e., hydraulic diaphragm, mechanically actuated diaphragm, solenoid driven or piston style. Hydraulic diaphragm pumps are a popular selection because of their longevity and robust design. Most hydraulic diaphragm pumps handle clear liquids with viscosities generally ranging from water (which has a viscosity around 1 cps at 68°F [20°C]) to 1,500 cps. Special liquid ends or special heads are available for applications outside this viscosity range (fluid viscosities to 20,000 cps and slurries up to 10 percent solids). 26

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Total Control Metering pumps normally consist of a solenoid drive or a gearbox with a motor, a control mechanism, plus a pump head with valves — through which the liquid being pumped enters the inlet connection and exits the discharge connection.

Another key determination is materials of construction. Selection of a metering pump must take into consideration any corrosion, erosion or solvent action that may occur when handling specific substances. For example, solvents may dissolve pump heads constructed of plastic. Acids and caustics only may be compatible with stainless steel or certain steel alloys, and abrasive slurries can erode some materials. Fortunately, metering pumps are available in a range of materials of construction. When considering the type of head the pump should have, consider whether special features are required for your application. For instance, some models are offered with double-diaphragm heads with leak detection and alarm capabilities for applications where any diaphragm failure must be sensed immediately. Selecting a driver is another area of concern. A driver should be chosen by matching it to the available utilities, which

Determining the pump’s method of control is next on the list of determining factors. The choices usually include: • Manual continuous operation. • On/off operation. • Automatic proportional control in response to a process signal. In general, metering pump flow rates can be adjusted manually through the use of a micrometer dial. This manual control allows the pump to be operated between 10 and 100 percent of capacity by changing the stroke length. By comparison, a manual variable-speed drive changes the stroke speed. A combination of the two may allow additional adjustability or turndown over the range of the drive, depending upon the stroking speed of the pump. For example, a pump operating at 75 strokes per minute (which could be turned down to 15 strokes per minute) would allow a 5:1 turndown on speed when using the variable-speed drive, and a 10:1 turndown on stroke length when using the micrometer dial. Metering pump flow rates also can be controlled automatically — in response to a process signal — by electric positioners

Pumps that change the pump’s stroke length, or by variable-speed drives that alter the stroking speed. Using a positioner gives the operator a full 10:1 turndown, which is the full adjustable range. Using a variable-speed drive will supply only as much turndown as the ratio of the pump stroking speed divided by the minimum operating speed of the pump. Remember that it is not practical to use a variable-speed drive on motor-driven pumps that normally operate at less than 100 strokes per minute. Slowing the motor causes each stroke to take longer from start to finish and, as a practical matter, hydraulic motor-driven pumps should not be operated at less than 15 strokes per minute. Electronic diaphragm pumps, which are pulsed by a solenoid, can operate at less than a single stroke per minute because the characteristic and timing of each stroke, from start to finish, is the same at all stroking speeds. The moving parts in modern diaphragm pumps offer long service at all stroking speeds. The highest stroking speeds should be avoided with viscous or abrasive chemicals. When a metering pump is controlled by automatic or electric stroke positioners, the number of doses remains constant and the size of each dose is reduced, thus keeping the doses uniformly distributed in a constantly flowing line. Use of a variable-speed drive changes the stroke speed. Also, the size of the dose injected on each stroke remains the same, but the variablespeed drive makes the doses less frequent as the motor speed is slowed. This, however, can produce an undesirable process result in a constantly flowing line as the discreet slugs of chemical are more widely separated than if a constant dose interval were maintained. Finally, consider the application and level of quality. • Is the unit to be used for intermittent operation in light-duty applications where economy is an important consideration? • Is the unit for an industrial plant, refinery, power plant or waste-treatment facility where ruggedness and additional features are required? • Is initial cost or lifecycle cost more important?

Oxidizers Ovens Furnaces

Metering-pump flow rates can be controlled automatically (in response to a process signal) by electric positioners, which change the pump’s stroke length, or by variable-speed drives, which alter the stroking speed.

In boiler water treatment applications, metering pumping technology that comprehensively offers the best in operation, reliability and energy efficiency when handling an array of liquids, chemicals and slurries is the way to go. When boiler feed water must be treated to eliminate erosion, corrosion and scale buildup, having the best chemical metering pumps on hand makes meeting those goals much easier and safer. PH Tom O’Donnell is senior product specialist for Neptune Chemical Pump Co., Lansdale, Pa., an operating company with the Pump Solutions Group of Dover Corp. For more information from Neptune, call (215) 699-8700 or visit www.neptune1.com.

¾ Oxidizers RTO Recuperative Catalytic Ovens & ¾ Furnaces Conveyorized Low Temp. & High Temp. Batch

WEB EXCLUSIVE Planning a Metering Pump Installation A metering pump installation must be planned from the day tank or liquid source up to the injection point. READ MORE @ WWW.PROCESS-HEATING.COM

936-273-3300 [email protected] www.epconlp.com www.process-heating.com • Au g u s t 2 0 1 1

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Equipment Overview

Burners

Whether your process requires direct or indirect heating, if you need a burner, this is the place to look. Our Equipment Overview on Burners, an apples-to-apples comparison of the capabilities of a range of burner man-

ufacturers, will help you narrow the field of potential suppliers to those that can satisfy your process needs. Find the type of burner you want and run down the column to see which manufacturers supply it.

You also can conduct your search for a burner at www.process-heating.com. The online version includes advanced search capabilities: You set the criteria and let the search engine work for you.

BURNER TYPE

ENERGY SOURCE

You also can conduct your supplier search online!

Click on Equipment Overview, then on Burners.

Supplier Companies

Atomizing Catalytic Ceramic Endothermic Exothermic Fuel Oil Immersion Tube Impingement Infrared Line Low NOX Luminous Flame Oxy-Fuel Packaged Premix Radiant Cup Radiant Tube Regenerative Ribbon Self-Recuperative Velocity, High Velocity, Low Velocity, Medium Coal Cogeneration/Biogases Dual Fuel Liquid Waste Natural Gas Natural Gas/Oil Oil Propane Solid Waste

www.process-heating.com

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Alzeta Corp. www.alzeta.com

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Bloom Engineering Co. Inc. www.bloomeng.com

Fives North American Combustion Inc. www.fivesna.com

General Combustion Corp. www.gencor.com

Hauck Mfg. Co. www.hauckburner.com

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Indesco Oven Products www.indescoop.com

Industrial Combustion LLC www.ind-comb.com

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Maxon, A Honeywell Co. www.maxoncorp.com

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Selas Heat Technology Co. LLC www.selas.com Abutec Aecometric Corp. Babcock & Wilcox Power Generation Group Inc. Bekaert Combustion Technology Callidus Technologies by Honeywell Combustion Carlin Combustion Technology Casso-Solar Technologies LLC Charles A. Hones Inc. Cleaver Brooks Coen Co. Inc. Combustion Depot Eclipse Inc. ERB-Ensign Etter Engineering Co. Inc. Flynn Burner Corp. Glenro Inc. Intelligent Heaters LLC/CLEPCO JF Swinehart Johnston Boiler Co. Marsden Inc. Micron Fiber-Tech Midco International Inc. Ordan Thermal Products Power Flame Inc. Red-Ray Mfg. Co. Inc. Solaronics Inc. Thermal Engineering Corp. Trimac Industrial Systems LLC Universal Dynamics Inc. Webster Engineering & Manufacturing Co.

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Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire burners market. For contact information or to be included in future listings, contact Linda Becker at (847) 405-4020; fax (248) 502-1001; e-mail [email protected]. Companies within front of their names have an advertisement in this issue.

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INDUSTRIES SERVED

Waste Oil Wood Other Air Heating, Direct Air Heating, Indirect Boilers/Steam Generators Cleaners/Washers Dryers Incinerators/Oxidizers Liquid Heaters Ovens Thermal Fluid Heaters Hot Water Heaters Chemicals/Petrochemicals Electronics Ethanol/Biodiesel Fuels Finishing Food Packaging Pulp/Paper/Forest Products Pharmaceuticals Plastics/Rubber/Vinyl

APPLICATIONS

AFTERMARKET COVERAGE: Do you manufacture and market replacement/aftermarket parts for your burners?

If you would rather contact a supplier directly, Process Heating can help. Call, fax or e-mail Linda Becker for the phone number, address and contact name for the companies in which you are interested: (847) 405-4020; fax (248) 502-1001; e-mail [email protected].

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Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes * Yes * Yes Yes Yes * Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes * Yes Yes

ARI Valves can take the heat… There’s no margin of error when it comes to reliability of the valves in your system. While you may not have to protect against lava flow, we can solve your problems up to 800˚F! ARI Valves are the choice of industrial professionals. Our quality assurance system is in accordance with DIN ISO 9001. You can trust our bellows-seal valves to perform under adverse conditions and never need to replace stem packing. ARI Valves are in Heat Transfer Service Around the Globe. So if you are responsible for the security and safety of your company’s system, make certain that ARI Valves are the choice. When things get hot, you should specify ARI Valves for Thermal Transfer Fluid Applications. ARI Valves…The Obvious Choice

ARI Valve Corporation 1738 Sands Place, S.E. · Marietta, Georgia 30067 U.S.A. Fax: (770) 933-8846 · Phone: (770) 933-8845 www.arivalve.com

www.process-heating.com • Au g u s t 2 0 1 1 PH04104ARI.indd 1

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3/26/10 2:13:40 PM

Chillers

CUSTOM COOLING Can Deliver Solutions

Customizing off-the-shelf chillers provides many benefits with a smaller price tag than you’d think. By Ray Fremont Jr., General Air Products Inc.

T

he phrase “custom cooling equipment” usually brings to mind a large, overly complicated and expensive piece of equipment unique in every aspect. This is a costly misconception because the truth is, custom cooling units can save money, save energy and help protect process equipment from excessive wear and tear. For every specialized application that requires a unique and costly piece of custom equipment, there is a common process that can be made more efficient with a simple tweak to an off-the-shelf cooling solution. Here, several case histories show how this can be achieved.

Air-Cooled Chiller for Optics Take the example of a job recently completed for an optics company. The customer needed an air-cooled chiller specially designed to work with a reverse osmosis (RO) water optics process. The optics company contacted a chiller manufacturer, described the need for elaborate customization of the internal piping and components of the air-cooled chiller to ensure the integrity of the RO water, and asked for pricing. Changing the internal components was both costly and unnecessary, the chiller manufacturer explained. Instead, the manufacturer suggested a loop-in-loop process so the RO water would not have to run through the chiller itself (figure 1). The loop-in-loop process would utilize an off-the-shelf, fiveton air-cooled chiller with a small amount of specialized piping for the process side, and a shell-and-tube heat exchanger mounted to the chiller frame to maintain the RO water 30

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Au g u s t 2 0 1 1 • Process Heating

A standard air fluid cooler can be used in free cooling and energy saving applications.

process. By adding a few standard components, the out-of-the-box approach to the process allowed for a significant cost savings for the optics manufacturer. Keep in mind that a loop-in-loop design is not limited to RO water applications. This process design is used regularly on deionized water (DI) applications, food-grade applications and with all sorts of corrosive chemical and hazardous material cooling. Loop-inloop designs also are used in more commonplace applications where large temperature drops are required. In these cases, the heat exchanger is used to add a large amount of surface area, allowing the chiller to handle large-differential process temperatures. This saves the customer from having to buy an expensive chiller and tank system.

Saving Energy with Free Cooling Free cooling, a method that uses low ambient air temperatures — by way of an air fluid cooler — to cool process water, is making a buzz in the process cooling world, and for good reason. Simply put, when the ambient temperatures rise in the summer, a chiller is used to cool the process; likewise,

when the temperatures fall in autumn, winter and spring, the chiller is bypassed and the air fluid cooler is used at much lower operating costs due to the energy savings (figure 2). Employing a free cooling process design, a facility can save money by reducing utility consumption and saving energy. Of course there is a tradeoff — initial investment cost goes up. When free cooling is employed, a chiller and air fluid cooler must both be purchased, which raises the cost of the job significantly. However, if you can muster the foresight and reach out to an expert in the field to do the energy-saving calculations, you could find that these units typically have a payback of one to two years. For instance, a free cooling system was designed for a glass manufacturer in Pittsburgh. Before free cooling, their glass manufacturing process involved the consumption and elimination of a large amount of city water used to cool the glass when it came out of the ovens. Not only was the company being charged for all of the water they consumed but the sewage authority began charging them for the water that they were discharging because it was such a large volume.

Loop-in-Loop Process at Optics Company

Chillers

Chiller

Heat Exchanger

Pump

Tank with Evaporator

An off-the-shelf air cooled chiller was customized with a city water bypass valve assembly. Customer Process

Protecting a Process by Customizing a Chiller

Figure 1. The manufacturer suggested a loop-in-loop process so the RO water would not have to run through the chiller itself.

Common Free Cooling System Process

Fluid Cooler Located Outside Diverter Valve Chiller

Pump Tank with Evaporator

Figure 2. Employing a free cooling process design a facility can save money by reducing utility consumption and saving energy.

A closed-loop, free cooling system was recommended following a thorough examination of the process as it would be the total cost of ownership solution. The completely integrated cooling system included a chiller, a fluid cooler, two pumping stations, a thermocouple-operated three-way valve and dual 2,000-gal holding tanks (figure 3). The process now consumes far less water, and they are discharging almost none. The process water is recycled through the cooling loop and stored in the holding tanks.

In the summer, the water is cooled by the chiller; during most of the rest of the year, the water is cooled by the air fluid cooler. Their process is more efficient and they are saving real money today, resulting in a short return on investment. Free cooling requires more upfront cost compared to the purchase of just a chiller, but this type of equipment can last up to 15 years. With the cost of utilities going up, especially for water, a free cooling consultation is a good idea.

A city water bypass valve assembly is used to protect many processes from catastrophic failure, and the cost of this important assembly is minimal when compared to the cost of a new chiller. A city water bypass valve assembly, sometimes called an emergency bypass valve, is mounted on the inlet of a standard, off-the-shelf chiller. It is designed to automatically switch from using the cooling fluid recirculating in the chiller to using city water to cool the process. On city water bypass assemblies, the solenoid valve manifold is wired “hot” to a standard chiller alarm so that when the alarm on the chiller trips or the hot contact loses power, the valves go into action and switch to city water. By now you might ask why someone would want to use city water to cool their process when they have just bought an air-cooled chiller — fair question. The answer is maintenance or component failure. As reliable as the best chillers are, they are still composed of many components that are not bulletproof. Applications that benefit from a city water bypass are those that are common but vital. For instance emergency bypass valve assemblies are used on most of the chillers sold to the medical field, specifically for MRI and LINAC machine cooling. In this environment, there is the real possibility of a fuse blowing and shutting down the power to the chiller. If this were to happen to a chiller cooling an MRI machine while it is in use, personal injury could occur and the million dollar MRI www.process-heating.com • Au g u s t 2 0 1 1

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31

Chillers

Free Cooling System for Glass Manufacturer Process

machine would be destroyed. If the chiller is cooling a process that runs 24/7, the addition of a bypass valve assembly will allow it to continue uninterrupted in the event of maintenance. As you can imagine, there are many applications where this minor customization will save money by protecting the process machinery. Chillers customization is about creating a solution that is as economic as it is efficient. Customers are regularly surprised that a custom solution using off-the-shelf components is an option when they are expecting the price tag that comes with building a specialized chiller from the ground up. “Custom” does not always mean expensive. “Custom” does not mean specialized design held together by a wing and a prayer. Custom chillers save money. Custom chillers improve process efficiency. PH Ray Fremont Jr. is a marketing manager with General Air Products Inc., Exton, Pa. For more information, call (888) 764-4058 or visit www.generalairproducts.com.

Process Pump Tank 1

Process Process Pump Tank 2

Duplex Pump Station

Fluid Cooler Located Outside Water/Glycol Exchanger

Diverter Valve

Chiller

Simplex Pump Station

Check Valve

Tank with Evaporator

Figure 3. The completely integrated cooling system for the glass manufacturer included a chiller, a fluid cooler, two pumping stations, a thermocouple-operated three-way valve and dual 2,000-gal holding tanks.

WE KNOW ELECTRICITY Questions about SCR power control systems? We can help. • Fusing • Cooling • Heatsink Design • Voltage protection • Application assistance For more than 40 years we have been designing and building SCR controls for hundreds of thousands of users like you.

For answers to your solid state control questions

Call 1-800-331-1345 Box 70 Scott Depot, WV 25560-0070 • Fax: 304-757-7305 E-mail: [email protected] • www.payneng.com 32

Au g u s t 2 0 1 1 • Process Heating | PH06074Payne01Blue.indd 1

5/21/07 9:53:59 AM

Equipment Overview

Want to Learn More About

SCR Power Controls? Use our Equipment Overview on SCR Power Controls, offered only online.

F

or industrial process heating applications, the advantages of SCR power controllers outweigh their disadvantages. For example, SCR power controls provide high reliability and low maintenance requirements. Because the SCR is a solid-state device, the control does not have any moving parts that could wear out. Another advantage is its control options. Compared with an on/off electromechanical contactor, an SCR provides fast response and the ability to limit current and regulate load voltage, current or power. Disadvantages to using an SCR

control can include low power factor, high harmonic currents and radio frequency interference (RFI) when using phase-fired power controllers. Our annual Equipment Overview on SCR Power Controllers allows you to compare supplier offerings and find the controllers that meet your application’s requirements. Because it is exclusively online, you can use our interactive search to narrow the field for you automatically. To get started gathering the information you need on SCR power control suppliers, visit the address shown below. By clicking on the headings on the left, you can reveal additional subcategories under the main

heads. To find suppliers that match multiple specifications, expand the main section headings using the arrows. Then, hold the Control button on you keyboard and click each desired specification to include it in your search results. You can expand multiple main sections to select across all categories. The results list in the middle of the page will update with each click to reflect your choices. To deselect criteria, hold the Control key and click on the heading again. To contact a specific manufacturer, click on the company name in the search results and use the contact information shown in the lower right corner of the online Equipment Overview. PH

View online and search by multiple criteria at: http://www.process-heating.com/buyersguide/420/ibg.html

Packaged Gas Burner

PBGII New and Improved

Many standard and configurable options available to suit a wide variety of applications with high thermal turndown and low CO and NOx emissions

• Choose from three standard fuel manifolds suitable for natural gas and vaporous propane

• Three options for air flow control including low cost VFD for energy savings and quiet operation

• Straight and 90º firing tubes in customer specified lengths

• Flame rod or UV scanner flame supervision

• Multiple control options including full function panel

• Multiple mounting configurations ®

Hauck Manufacturing Company, PO Box 90, Lebanon, PA 17042 Phone: 717-272-3051 Fax: 717-273-9882

www.hauckburner.com www.process-heating.com • Au g u s t 2 0 1 1

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33

Product Highlights Wondering where to find products beneficial to your process? This department provides a number of new products each month and allows you to easily request more information. Simply call those companies in which you are interested, or visit those companies’ web sites using the published web addresses.

Low NOX Burners Series 1510 and 1530 are designed for each individual application. The burners are capable of firing with cold air up to moderate levels of air preheat while providing ultra low NOX emissions in the range of 9 to 30 ppm. The burner designs utilize the latest technology along with FGR to achieve the desired emissions level. Applications include boilers, air heaters and process heaters. Bloom Engineering Co. (412) 653-3500 • www.bloomeng.com

Feed-Through Terminal Blocks DIN-rail-mountable Series AVK consists of screw-connection style devices with vibration-resistant wire clamps. The screws and clamps are made of steel with zinc plating, and together they generate a high locking action and provide a vibrationand corrosion-resistant connection. The terminal block plastic

housing is made from polyamide 6.6 thermoplastic resin with a UL 94 V2 rating for 221°F (105°C). Accessories include end plates, end brackets, cross connectors for bridging and marking tags. Omega Engineering Inc. (203) 359-1660 • www.omega.com

Safety Shut-Off Valves Series 8000 meets tough Class VI leakage standards and carries global endorsements like FM, CSA, EN, ATEX, hazardous locations and safety assessment to IEC 61508, making them SIL-3 capable. Searing heat or bitter cold gives sure closing at temperatures to -58°F (-50°C) while meeting API 6FA fire safe standards. The large open/closed indicator clearly announces valve position in high-contrast colors. Unique metal-to-metal seats wear in — not out — with each cycle. Maxon, A Honeywell Co. (765) 284-3304 • www.maxoncorp.com

IHEA FALL EDUCATION PROGRAMS! 42nd 42 dA Annuall IHEA C Combustion b ti Seminar & Exhibition Sept. 27 & 28, 2011 • Omni William Penn, Pittsburgh, PA 18 Sessions Designed to Give Complete Exposure to Combustion Technology Including:  Environmental Regulations  Efficiency Enhancements  Infrared Technologies

Reception & tion Tabletop Exhibi27 Tues., Sept.

Fall 2011 On-Line Distance F Di t Learning L Courses Register Now! Registration Closes - Sept. 9 • Classes Begin - Sept. 19 R R REGISTRATION OPEN NOW! • EARN CEU CREDITS! 1 Fundamentals of Industrial Process Heating – and – 2 Advanced Industrial Process Heating In conjunction with the Emerging Technologies Applications Center of Northampton Community College.

FOR COMPLETE DETAILS AND TO REGISTER, VISIT: www.ihea.org Combustion Seminar & OnLine Distance Learning buttons can be found on the right side of the home page. Click them for information & to register. QUESTIONS: Call 859-356-1575

34

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Au g u s t 2 0 1 1 • Process Heating

Product Highlights Autoclave Temperature Sensors Model SAC is suited for smaller autoclave or walk-in applications where the sensor will experience minimal handling stress. The precision sensor, housed in a lightweight package, has a waterproof design built to withstand the harsh, repeated steam/vacuum cycling of the autoclave process. With a 316 stainless steel sheath in 0.25" or 0.188" dia., the sensor has either a single three- or four-wire, or dual threewire element/lead wire configuration. Burns Engineering • (800) 328-3871 www.burnsengineering.com

Class 100 Clean Room Oven The 750°F (399°C) electrically heated Class 100 clean room oven is used to bake various coatings onto products. Workspace dimensions of No. 836 measure 36 x 36 x 39", and 30 KW installed in Incoloysheathed tubular heating elements provide the maximum temperature. A 1,000 cfm, 1.5-hp recirculating blower maintains horizontal airflow across the load. Grieve Corp. • (847)546-8225 • www.grievecorp.com

PH03104Indesco.indd 1

1/27/10 3:28:43 PM

3++XEEHOOLQGG

www.process-heating.com • Au g u s t 2 0 1 1

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35

The 2011 NAI Coating Show gives you what no other coating event can. t
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5040 Enterprise Boulevard Toledo, Ohio 43612 Tel: 419-729-9726 www.exothermics.com

(952) 933-2559 [email protected]

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PROCESS HEAT

The Next Generation

Phone: 412-306-4355 Fax: 248-502-1076 Email: [email protected]

LHS Air Heater

Built-in thermocouple with digital temperature readout

CAN-ENG FURNACES INTERNATIONAL LTD. z

Upgrade your LE to a Next Generation LHS air heater today www.leisterusa.com Toll-free: (855) Leister [email protected]

Advertising Index

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Liquid Cooled

PAGE 35 29 10 9 11 13 15 16 33 27 39 7 14 2 40 29 35 34 35 12 6 14 10 36 24 20 32 19 12 3 4 17

COMPANY ACS Group/Sterling ARI Valve Alzeta Corp. Bloom Engineering Co. Despatch Industries Despatch Industries Despatch Industries Dickow Pump Elster Hauck Kromschroeder Epcon Industrial Systems Fives North American Combustion Fulton Thermal Corp. General Combustion Heatec Heatec Hix Corp. Hubbell Electric Heater Co. IHEA Indesco Products Inc. Industrial Combustion Karl Dungs Inc. Maxon, A Honeywell Co. MultiTherm NAI Coating Show Paratherm Corp. Parker Boiler Co. Payne Controls Precision Quincy Corp. Protection Controls Selas Fluid Processing, subsidiary of Linde Group Wisconsin Oven Yokogawa

z

Rebuilds z Retrofits z Combustion Controls z

Control Panels z Thermal Profiling z Ovens z Burners z Elements z

t: 905-356-1327

f: 905-356-1817

e: [email protected]

www.can-eng.com

Contact: JOE SALIBA (ext:2058) z KIM IAMARINO (ext:2037) z ANNA ROLFE (ext:2056)

PHONE (262) 641-8610 (770) 933-8845 (408) 727-8283 (412) 693-4232 (952) 469-8278 (952) 469-8278 (952) 469-8278 (770) 933-8845 (717) 272-3051 (936) 273-1774 (216) 271-6000 (315) 298-7182 (407) 290-6000 (423) 821-5200 (423) 821-5200 (620) 231-8568 (203) 378-2659 (859) 356-1575 (217) 622-6345 (608) 325-3141 (763) 582-1700 (765) 284-3304 (610) 408-8361 (832) 585-0770 (610) 941-4900 (323) 727-9800 (304) 757-7353 (815) 338-2675 (847) 674-7676 (610) 832-8757 (262) 642-3938 (770) 251-8700

FAX (262) 641-8653 (770) 933-8846 (408) 727-9740 (412) 653-2253 (952) 469-8206 (952) 469-8206 (952) 469-8206 (770) 933-8846 (717) 273-9882 (936) 273-4600 (216) 641-7852 (315) 298-5311 (407) 578-0577 (423) 821-7673 (423) 821-7673 (620) 231-1598 (203) 378-3593 (859) 356-0908 (217) 632-5504 (608) 325-4379 (763) 582-1799 (765) 286-8394 (610) 408-8365 (713) 992-0485 (610) 941-9191 (323) 722-2848 (304) 757-7305 (815) 338-2960 (847) 674-7009 (610) 834-0473 (262) 363-4018 (281) 340-3838

WEB www.sterlco.com www.arivalve.com www.alzeta.com www.bloomeng.com www.despatch.com www.despatch.com www.despatch.com www.dickow.com www.hauckburner.com www.epconlp.com www.fivesna.com www.fulton.com www.gencor.com www.heatec.com www.heatec.com www.ovens-dryers.com www.hubbellheaters.com www.ihea.org www.indescoovenproducts.com www.ind-comb.com www.dungs.com/usa www.maxoncorp.com www.multitherm.com www.thenaicoatingshow.com www.paratherm.com www.parkerboiler.com www.payneng.com www.precisionquincy.com www.protectioncontrolsinc.com www.selasfluid.com www.wisoven.com www.us.yokogawa.com

E-MAIL [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected]

www.process-heating.com • Au g u s t 2 0 1 1

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®

Places & Faces Jim Kuzara joined Anguil Environmental Systems, Milwaukee, as

tractor gauges, hot water thermometers, syphons and snubbers.

a regional sales manager. Anguil designs, manufactures, installs and services oxidizer and energy recovery systems.

ABB, Singapore, won an order from Marubeni Corp., Tokyo, to Kuzara

launch an enhanced corporate website at www.cleaverbrooks.com. The site serves as a central information resource for the complete boiler system and includes product pages that can be accessed by application or need. In addition, the site includes links to current and archived editions of the company’s “Boiler Book” manuals.

Tecumseh Products Co., Ann Arbor, Mich., now has 11 authorized wholesale distributors in Mexico. For a list of the locations, go to www.tecumseh.com.

EDL, Danville, Va., released its “2011 Temperature Product Catalog” showing its temperature measurement instruments and sensors, compression fittings and metrology line. Order or download the catalog at www.edl-inc.com. Toronto-based Winters Instruments has signed a distribution agreement with Fastenal, Winona, Minn. The retailer will offer Winters pressure gauges, thermometers and instrument accessories to its customers in the United States and Canada at more than 2,500 local Fastenal stores as well as its online store. Fastenal will stock Winters products such as industrial thermometers, thermowells, valves, liquid-filled pressure gauges, low pressure gauges, all purpose gauges, con-

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Au g u s t 2 0 1 1 • Process Heating

Senior Group Publisher, Manufacturing Group TOM ESPOSITO • (610) 436-4220 ext. 8530 Publisher • ANNE ARMEL (847) 405-4043 • [email protected]

Cleaver-Brooks Inc., Thomasville, Ga.,

38

PUBLISHING STAFF

de-bottleneck the pulp production facility at PT. Tanjungenim Lestari Pulp and Paper in South Sumatra, Indonesia. ABB will provide electrical and automation equipment to help the mill improve its energy efficiency and production processes.

Alfa Laval, Lund, Sweden, received an order for a complete solution to a vegetable oil plant in India. The order includes heat exchangers, separators and mixers that will be used for refining different types of crude oils such as soya bean into high quality oils. Gas conditioning products manufacturer Perma Pure appointed Scott Brown vice president of sales and marketing. Brown will direct the company’s Brown global sales force and manage distribution channels for the Toms River, N.J.-based company.

Associate Publisher and Editor • LINDA BECKER (847) 405-4020 • [email protected] Contributing Editor • JOY LEPREE ANDERSON (856) 582-9554 • [email protected] Art Director • COURTNEY FATHERS (248) 244-1292 • [email protected] Production Manager • BETH MCCLELLAND (412) 306-4354 • [email protected] Reprint Sales • JILL DEVRIES (248) 244-1726 • [email protected] E-Media Sales • SUSAN HEINAUER (412) 306-4352 • [email protected] Classifieds • BECKY MCCLELLAND (412) 306-4355 • [email protected] Publishing Director, Manufacturing and Gaming Groups JOHN R. SCHREI • (248) 786-1637 Editorial Office 155 N. Pfingsten Road, Suite 205, Deerfield, IL 60015 (847) 405-4000 • FAX (248) 502-1001

BNP CUSTOM MEDIA GROUP CHRISTOPHER WILSON (248) 244-8264 • [email protected]

ADVERTISING SALES NORTH AMERICA • Sean Meaney • National Sales Manager 530 Humiston Drive • Bay Village, OH 44140 (440) 895-0919 • FAX (248) 502-1051 • [email protected] NORTH AMERICA • Anne Armel • Publisher 155 N. Pfingsten Road, Suite 205 • Deerfield, IL 60015 (847) 405-4043 • FAX (248) 786-1441 • [email protected] EUROPE • Carolyn Eychenne • European Sales Representative 7 rue de Maurepas • 78000 Versailles France tel/fax: 011 33 1 30 21 15 62 • [email protected]

CORPORATE STAFF BNP Media Corporate Office • (248) 244-6400

SINGLE COPY SALES ANN KALB • (248) 244-6499 • [email protected]

LIST RENTAL Postal contact: KEVIN COLLOPY (800) 223-2194 x684 • [email protected] Email contact: MICHAEL COSTANTINO (800) 223-2194 x748 • [email protected]

Lauren Manufacturing, New Philadelphia, Ohio, hired Andrew Duggan as an applications engineer, where he will be responsible for product development for new and existing customers as well as technical support for the company’s sales team. Also, the maker of standard and custom extruded and molded sealing solutions hired Staci Plumley as a customer service representative. She will be responsible for customer service, order entry, quoting and inventory control. Michell Instruments headquarters, located in the United Kingdom, has kicked-off a major construction project adding 14,000 ft2 of factory space. Michell manufactures moisture, humidity and oxygen measurement products and serves the North American market from its Rowley, Mass., facility.

AUDIENCE DEVELOPMENT Audience Development Coordinator • HAYAT ALI-GHONEIM Corporate Fulfillment Manager • MEGAN NEEL Corporate Audience Audit Manager • CATHERINE M. RONAN

SUBSCRIPTIONS Contact Customer Service at Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected]. Via Web: to subscribe or submit an address change, visit www.process-heating.com and click on subscribe. Via Mail. Send your old address label along with your new address to Process Heating, PO BOX 2146, Skokie, IL 60076.

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Got Maintenance? Plant operators are finding out the advantages of having their heaters serviced by Heatec on a regular basis. There are important benefits of having a contract for our service technicians to do preventative maintenance once or twice a year. An important benefit is safety. Our technicians make sure all limit devices are working properly. Insurance companies usually prefer that specialists, such as Heatec technicians, perform services related to safety. Fuel savings is another important benefit that results from maintenance that includes tuning the burner. Moreover, preventative maintenance usually eliminates unexpected heater

shutdowns at times that interrupt production. Preventative maintenance can usually be done without adversely affecting production schedules. Another benefit is usually a reduction in costs for each service call. This results from lower travel expenses when our technicians can make service calls at other plants in the same area. Moreover, many of our technicians reside in diverse locations that reduce travel to plant sites. Call today to find out what kind of service contract would work best for you.

HEATEC

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