Thermal Mass Flow Controllers & Meters for the Harshest Environments

Thermal Mass Flow Controllers (MFCs) play a crucial role in process control applications by precisely and accurately controlling gas flow rates in various processes. They are used across multiple industries and applications to ensure stable, repeatable, and efficient process conditions. Some of the critical areas where Thermal MFCs are applied include:

1. Semiconductor Manufacturing: In semiconductor fabrication processes, such as chemical vapor deposition (CVD) and plasma etching, MFCs control the flow of process gases to maintain accurate gas ratios and reactant concentrations, ensuring consistent wafer quality.
2. Pharmaceutical and Biotechnology: MFCs apply in processes such as fermentation, cell culture, and gas chromatography, where they regulate the flow of gases like oxygen, carbon dioxide, and nitrogen to maintain optimal growth conditions for biological cultures or to separate and analyze various compounds.
3. Chemical Processing: In chemical synthesis and reaction control, MFCs manage the flow of reactants and carrier gases to maintain the proper stoichiometry and reaction conditions, ensuring high-quality product yields and safe operations.
4. Solar Cell Manufacturing: MFCs apply in processes such as thin-film deposition and chemical etching, where they control the flow of process gases to create uniform layers and achieve precise etching profiles for high-efficiency solar cells.
5. Fuel Cell Development: In fuel cell research and manufacturing, MFCs regulate the flow of hydrogen, oxygen, and other gases to maintain optimal conditions for efficient energy production and long-lasting performance.
6. Environmental Monitoring: MFCs are used in air quality monitoring and emissions testing systems to control the flow of calibration gases, ensuring accurate measurements and compliance with environmental regulations.
7. Laboratory Research: In various research applications, such as mass spectrometry, gas chromatography, and flow chemistry, MFCs provide precise control over gas flow rates for accurate analysis and experimental conditions.

Thermal Mass Flow Controllers are essential components in process control systems, providing the accuracy, precision, and repeatability required for maintaining optimal process conditions and ensuring high-quality results across diverse industries and applications.

Brooks Instrument SLAMf Series Thermal Mass Flow Controller

The Brooks Instrument SLAMf Series Thermal Mass Flow Controller is an innovative and cutting-edge solution for accurately controlling and measuring gas flow in a wide range of industries and applications. This state-of-the-art flow controller meets the highest performance, reliability, and flexibility standards, ensuring seamless integration into your process control systems.

The SLAMf Series boasts several unique features that set it apart from its competitors. With its patented MultiFlo™ technology, users can easily configure the controller for multiple gases and flow ranges without sacrificing accuracy or requiring recalibration. This results in a highly versatile device capable of meeting the demands of diverse applications.

Another standout feature of the SLAMf Series is its ultra-fast response time, facilitated by the advanced sensor design and high-speed digital signal processing. It ensures that your processes are consistently controlled with precision, minimizing the risk of variations and improving overall efficiency.

The robust construction and corrosion-resistant materials used in the SLAMf Series make it suitable for even the most challenging environments. Its compact design allows easy installation in tight spaces, making it an ideal choice for various industries, such as semiconductor manufacturing, pharmaceuticals, chemical processing, and research facilities.

Typical applications for the Brooks Instrument SLAMf Series Thermal Mass Flow Controller include gas mixing and blending, gas delivery, process control, and environmental monitoring. With its unparalleled performance, adaptability, and durability, the SLAMf Series is the ultimate choice for professionals seeking the best in flow control technology.

Miller Energy, Inc.
800-631-5454
https://millerenergy.com

Process Mass Spectrometers

Process mass spectrometers are versatile analytical instruments that accurately identify and quantify chemical compounds in a sample based on their mass-to-charge ratios. Mass spectrometers are crucial in monitoring and regulating various processes in industrial process control applications to ensure product quality, safety, and efficiency. Here, we will list applications for mass spectrometers in process control.

1. Process monitoring and optimization: Mass spectrometers continuously monitor the concentrations of various components in a process stream, providing real-time data on the composition of raw materials, intermediates, and final products. By analyzing these data, process engineers can quickly identify deviations from the desired process conditions and take corrective actions to optimize the process, reduce waste, improve energy efficiency, and improve overall process control.
2. Leak detection and control: Mass spectrometers can detect and quantify leaks in industries where hazardous or volatile gases are involved. They can rapidly identify the presence of specific gases and quantify their concentrations, enabling prompt corrective actions to minimize the risk of accidents, environmental damage, and product contamination.
3. Quality control and assurance: Mass spectrometers analyze product samples at various stages of the manufacturing process to ensure that they meet specified quality standards. They can identify and quantify impurities, contaminants, or undesired by-products that may affect the final product's performance, safety, or shelf life. This information is vital for maintaining product consistency and complying with regulatory requirements.
4. Reaction monitoring and kinetic studies: In chemical and pharmaceutical industries, mass spectrometers can study reaction kinetics and monitor the progress of chemical reactions in real time. By determining the concentrations of reactants, intermediates, and products, researchers can better understand reaction mechanisms, optimize reaction conditions, and improve the overall process efficiency.
5. Environmental monitoring and emissions control: Mass spectrometers are employed to monitor emissions from industrial processes, ensuring that they comply with environmental regulations. They can detect and quantify trace levels of pollutants, such as volatile organic compounds (VOCs), greenhouse gases, or particulate matter, helping industries to reduce their environmental impact and comply with legal requirements.
6. Catalyst evaluation and development: Catalysts are crucial in many industrial processes, and mass spectrometers can evaluate their performance by monitoring the reaction products and intermediates. This information is valuable for developing and optimizing new catalysts, ensuring that they are efficient, selective, and stable under the required operating conditions.

In summary, mass spectrometers are indispensable tools in industrial process control applications. Their ability to provide rapid, accurate, and sensitive analyses of process streams, emissions, and products makes them invaluable for monitoring, optimization, and quality control. As a result, they play a significant role in ensuring the safety, efficiency, and sustainability of various industries.

9 Reasons Why Industrial Control Valves Fail

9 Reasons Why Industrial Control Valves Fail

1) Improper Sizing

To properly size an industrial control valve, take the following steps:

• Determine the process flow rate, pressure drop, and fluid properties.
• Select the type of control valve based on the process conditions and application requirements.
• Choose a valve with the correct Cv (flow coefficient) for the desired flow rate and pressure drop.
• Consider the operating temperature, pressure, and any special requirements (such as high-temperature, corrosive, or abrasive fluids).
• Check that the valve meets all applicable industry standards.

Always consult a control valve manufacturer or an engineer with expertise in control valves for a more accurate and detailed evaluation.

2) Improper Installation

To ensure the proper installation of an industrial control valve, take the following steps:

• Verify that all valve components are correct and undamaged.
• Check that the piping and valve are correctly aligned and supported.
• Use the proper gaskets and seals to prevent leakage.
• Check the actuator mounting and connection to the valve body.
• Make sure the control wiring is correct and properly connected.
• Test the valve's operation and adjust as necessary.
• Flush the piping system to remove any debris before installation.
• Follow all relevant safety procedures and guidelines.

It is critical to consult with the valve manufacturer's installation manual and guidelines and have a professional trained in industrial control valve installation conduct the installation process.

3) Material Incompatibility

Material compatibility refers to the ability of a material to resist chemical attack, degradation, and corrosion from the process fluid. Material compatibility in industrial control valve installation is crucial because it ensures the valve's long-term reliability and prevents premature failure.

Ensure proper material compatibility by following these steps:

• Identify the chemical composition of the process fluid and any potential impurities.
• Determine the operating temperature and pressure of the fluid.
• Select valve components made of materials compatible with the fluid and conditions.
• Consider the effect of any potential impurities on the valve components.
• Choose materials that have sufficient corrosion resistance to prevent degradation.

You need to consult a control valve manufacturer or a materials engineer for expert guidance on material selection for a specific application.

4) Erosion/Corrosion

Erosion and corrosion affect industrial control valves because they can lead to valve failure and reduce the valve's lifespan. Erosion occurs when fluid velocity in the valve causes physical wear on the valve components. Corrosion is the chemical degradation of the valve material due to exposure to harsh chemicals or corrosive environments.

Mitigate erosion and corrosion with the following measures:

• Using corrosion-resistant materials such as stainless steel, Hastelloy, or titanium.
• Applying protective coatings like nickel plating, hard-chroming, or ceramic coatings.
• Regular inspection and maintenance to detect signs of wear and corrosion and replace parts before failure occurs.
• Using proper fluid handling practices, such as filtration, to remove abrasive particles from the process media.
• Installing isolation devices like piping spools, strainers, or blow-off valves to protect the valve.

These measures help ensure reliable operation and extend the life of industrial control valves.

5) Overloading

Overloading refers to a situation in which an industrial control valve is subjected to a load or stresses greater than its design capacity, causing damage or failure. Overloading occurs due to various factors, including improper sizing, incorrect application, or changes in operating conditions.

Prevent overloading with the following measures:

• Proper sizing of the valve based on the operating conditions and fluid characteristics.
• Use a suitable type of valve for the specific application, such as a high-pressure control valve for high-pressure systems.
• Regularly monitor operating conditions and fluid characteristics to detect changes and adjust the valve settings accordingly.
• Maintain the valve according to the manufacturer's instructions and replace worn or damaged parts.
• Use a safety relief valve or bypass system to relieve excess pressure and protect the control valve.

By following these measures, industrial control valves can be protected from overloading and failure, ensuring reliable operation and system safety.

6) Excessive Wear

Excessive wear on industrial control valves can significantly impact their performance. The following are some ways excessive wear can affect the performance of control valves:

• Reduced accuracy: Worn components can cause the valve to become misaligned or damaged, affecting its ability to control fluid flow accurately.
• Increased leakage: Worn seals, seats, or other components can cause increased fluid leakage, affecting the overall performance of the valve.
• Decreased flow control: Worn components can alter the flow characteristics of the valve, causing it to become less responsive or to control flow inaccurately.
• Increased pressure drop: Excessive wear can cause an increase in the pressure drop across the valve, reducing system efficiency and increasing energy costs.
• Increased maintenance requirements: Wear and damage to the valve components can result in increased maintenance needs, adding to operational costs and reducing reliability.

Prevent excessive wear of the control valves by regularly inspecting, maintaining, and replacing them as needed to ensure optimal performance and reliability.

7) Improper Maintenance

Improper maintenance of industrial control valves can have a significant impact on their performance, including:

• Reduced accuracy: Neglecting to perform regular calibrations or making incorrect adjustments to the valve can lead to reduced accuracy in flow control.
• Increased leakage: Failure to replace worn or damaged seals and gaskets can result in increased fluid leakage, affecting the valve's overall performance.
• Decreased flow control: Improper cleaning or repairs can alter the flow characteristics of the valve, reducing its ability to control flow accurately.
• Increased pressure drop: Neglecting to clean or replace dirty or clogged components can increase pressure drop across the valve, reducing system efficiency and inflating energy costs.
• Increased downtime: Improper maintenance can lead to valve failure, resulting in increased downtime and decreased productivity.

It is essential to follow the manufacturer's instructions and perform regular, scheduled maintenance to ensure optimal performance and reliability of industrial control valves.

8) Process Contamination

Process contamination in industrial control valves can harm operation by clogging or eroding internal parts, causing valve malfunction or failure. It can also lead to decreased process efficiency and increased maintenance costs. Prevent process contamination by implementing the following steps:

• Proper material selection: Using appropriate materials that are resistant to the specific process fluid and contaminants is vital.
• Regular maintenance: Regular cleaning and replacement of internal components can help prevent a build-up of contaminants.
• Installing filtration systems: Installing filters upstream from control valves can help remove contaminants before they reach the valve.
• Installing protection devices: Installing protective devices, such as strainers or deflectors, can help prevent larger particles from entering the valve and causing harm.
• Implementing best practices: Following best practices, such as avoiding sudden changes in flow rate, can help prevent process contamination and prolong valve life.

9) Aging or Fatigue Failure of Valve Components

Aging or fatigue failure of valve components can have a significant impact on industrial control valves, leading to the following issues:

• Reduced efficiency: Worn-out or degraded components can cause control valves to operate less efficiently, leading to increased energy costs and decreased production.
• Increased downtime: Aging or fatigued components can result in more frequent breakdowns, causing increased downtime and maintenance costs.
• Decreased reliability: Over time, components can weaken and fail, reducing the reliability of control valves and increasing the risk of failure.
• Leakage: Aging or fatigued components can result in leaks, causing loss of process fluid and potentially causing harm to the environment.
• Decreased safety: Worn-out or degraded components can increase the risk of valve failure, which can have profound safety implications in some industrial processes.

It is essential to regularly inspect and maintain control valves to detect and replace aging or fatigued components to prevent these types of failures and maintain efficient, reliable, and safe operation.

Miller Energy, Inc.
800-631-5454
https://millerenergy.com

Back Pressure Regulators

An industrial back pressure regulator is a type of pressure control valve that is used to maintain a consistent pressure downstream of the valve in a process piping system. It is designed to allow fluid to flow in one direction and is typically installed in the outlet of a process unit or a piece of equipment.

The basic design of a back pressure regulator includes a main valve body, a control piston or diaphragm, a spring, and a control mechanism. The control piston or diaphragm is connected to the spring, which is adjustable to set the desired downstream pressure. The control mechanism, which may be a pneumatic or electric actuator, is used to adjust the position of the control piston or diaphragm in response to changes in the downstream pressure.

The main valve body contains an inlet and an outlet, as well as a flow passage that connects them. The flow passage includes an orifice, which serves as the main flow restriction. When the downstream pressure rises above the set point, the control piston or diaphragm moves to close the orifice, reducing the flow and bringing the pressure back down to the set point. When the downstream pressure drops below the set point, the control piston or diaphragm moves to open the orifice, increasing the flow and bringing the pressure back up to the set point.

Back pressure regulators are commonly used in process control applications to maintain a consistent pressure in pipelines and process units. They are used in a variety of industries including chemical, petrochemical, and power generation. They can help maintain safety, improve process efficiency and productivity, and help prevent equipment damage.

Industrial back pressure regulators are commonly used in a variety of process industries, including:

• Oil and gas production: To maintain a constant back pressure on the upstream side of a gas or liquid separator to prevent the flow of liquids into the gas pipeline.
• Chemical processing: To control the pressure of reactants and products in various process vessels, such as reactors and distillation columns.
• Power generation: To regulate the pressure in boiler feedwater systems, turbine bypass systems, and condensate return systems.
• Pharmaceutical and biotechnology: To control the pressure in fermentation vessels and downstream processing equipment.
• Petroleum refining: To maintain a constant back pressure on various process units, such as catalytic crackers and hydrocrackers, to improve process efficiency and product yields.

Miller Energy, Inc.

800-631-5454

https://millerenergy.com

Happy Holidays from Miller Energy

 

Basics of Mass Flow Controllers (MFCs)

MFCs work by measuring the mass of the process fluid flowing through them and using this information to control the flow rate. They typically use a flow sensor to measure the flow rate and a control valve to regulate the flow. The control valve is usually a variable area flow meter or a valve that can be opened or closed to adjust the flow rate.

MFCs are used in a variety of applications, including chemical processing, semiconductor manufacturing, and environmental monitoring. They are often used to control the flow of gases in chemical reactions, to regulate the flow of fluids in manufacturing processes, and to monitor and control the flow of gases in environmental monitoring systems.

MFCs are highly accurate and precise and can maintain a constant flow rate over a wide range of process conditions. They are also relatively easy to install and maintain and can be integrated into various process control systems.

There are many applications for mass flow controllers (MFCs) in process control. Some examples include:

• Chemical processing: MFCs can be used to control the flow of reactants and catalysts in chemical reactions, ensuring consistent product quality and yield.
• Food and beverage processing: MFCs can be used to control the flow of ingredients in the production of beverages, sauces, and other food products.
• Pharmaceutical manufacturing: MFCs can be used to control the flow of active ingredients and excipients in the production of medications.
• Petrochemical processing: MFCs can be used to control the flow of fluids in the refining and processing of oil and natural gas.
• Environmental control: MFCs can be used to control the flow of gases and liquids in air pollution control systems, water treatment plants, and other environmental applications.
• Semiconductor manufacturing: MFCs can be used to control the flow of gases and liquids in the production of semiconductor devices.
• Aerospace and defense: MFCs can be used to control the flow of gases and liquids in a variety of aerospace and defense applications, including propulsion systems, life support systems, and fuel systems.

For more information about mass flow controllers in NY, NJ, PA, DE, MD and OH contact Miller Energy, Inc. Call 800-631-5454 or visit https://millerenergy.com.

Happy Thanksgiving from Miller Energy