Case Study by Rotork: Era Polymers is a world-class manufacturer of polyurethane systems, producing a diverse range of cast elastomer prepolymers including spray polyurethane and polyureas, rigid and flexible foam systems, rubber binders and floor coatings.

The company wanted to automate the manually operated temperature control of water supplied to the condenser as part of the water/glycol separation process during the manufacture of polyurethane elastomer. The existing temperature variation of only 1-2ºC resulted in an unacceptable level of wasted product, so the success of the project relied on the achievement of exceptionally accurate temperature control, within +/-0.1ºC. The application also called for full automation, operating from a 4-20mA control signal.

Rotork Australia proposed an all-electric control package, consisting of a V-port ball valve operated by a CVA actuator and, following a product demonstration, this package was selected as the ‘stand-out’ best option. With the equipment now installed, the CVA has successfully and autonomously operated with the sophisticated site control system to maintain the water temperature within the required parameters, delivering a ten-fold improvement in performance. As a result, product waste during manufacture has been greatly reduced

One of the biggest considerations is whether you’re going to use an overhead cable management system, such as basket trays and ladder racks, or an underfloor system. This affects what you buy, how you install it, etc. A number of factors determine which system to choose.

Please click Cable Management to  read in detail.

Combustion flue gas analysis is used by power plants to optimize fuel/air ratio. By measuring the amount of excess oxygen and/or CO in the flue gases resulting from combustion, plants can operate at the best heat-rate efficiency and lowest NOX, and generate the least amount of greenhouse gas. The theoretical ideal, or the stoichiometric point, is where all fuel reacts with available oxygen in the combustion air, and no fuel or O2 is left over.

In actual practice a perfect mix of fuel and air may not be achievable, operation with 1-3% excess O2 and low parts per million of CO may result in the max achievable heat rate.

In addition to achieving the best combustion efficiency, many plants also have other important goals that effective combustion analysis helps to accomplish: minimizing NOX emissions and reducing slag.

Read in Detail 'Combustion Flue Gas Analysis Reduces NOx and Slag'

The Carmel Riviera Mutual Water Company believed it was losing big. Historical estimates indicated that more than 30% of this small, independent water company’s production was going down the drain through leaks, waste, evaporation and other types of loss. The company budgeted almost $60,000 per year in initiatives to reduce these leaks, including labor and materials for surveys and expensive repairs.

Wayne Daniel, head of operations at Carmel Riviera, decided it was time for better measurement and overall operational efficiency. When he contacted us, we recommended our affordable InnovaSonic® 205i, a digital ultrasonic flowmeter with clamp-on versatility that now helps the water company:

• Accurately measure water-loss percentage
• Improve production efficiency
• Improve water quality by reducing backflush
• More accurately bill users by identifying overusers.

Daniel says, “Implementing the InnovaSonic flow meter was not only an important step in making Carmel Riviera a more productive plant, but it’s also helping us drive water conservation.”