S O L U T I O N S F O R T H E P R O C E S S I N D U S T R I E S

January 2013

Guided Wave Radar Technology

VEGA introduces the latest innovation

in guided-wave radar technology, the

VEGAFLEX 80 Series. The unit has sensors

specifically designed for measurement of

liquids or solids, as well

as for hygienic and

high temperature/pres-

sure environments. For

liquids measurement,

level and interface mea-

surement are available

from a single sensor.

Perhaps the most inno-

vative feature of the VEGAFLEX 80 Series is

the user interface. Because one of the most

important aspects of providing a reliable

level measurement is ensuring the sensor is

properly configured, VEGA has introduced

a new guided setup procedure that makes

commissioning simple and safe.

VEGA Americas, Inc.www.ohmartvega.comWrite In 503

Bulk Bag Conditioning System

Discharging bulk bags containing material that has

solidified, hardened or agglomerated can cause seri-

ous operational bottlenecks. Conditioning and empty-

ing bulk bags can be dangerous if the right equipment

isn’t used. A new, patented system uses hydraulically

actuated, twin heavy-wall tubular-steel pivoting con-

ditioning arms. Each conditioning arm features “v-shaped” tubular steel

breaker profiles that safely and efficiently return solidified materials to a

free-flowing state. For more information on powder & bulk solids, turn

to page 44.

Material Transfer & Storagewww.materialtransfer.comWrite In 502

Electric Modulating Actuators

Electric modulating actuators in Rotork’s new CMA series are suitably

sized for linear, quarter-turn and rotary control valve and pump applica-

tions requiring precise position control and continuous modulation. They

can be powered by single-phase or direct current supplies, eliminating

the need for the air hoses and compressors used with pneumatic control

valve actuators. Setup and configuration is easy via pushbuttons and

an internal, six-segment LCD display. Resolution is 0.25% on linear and

quarter-turn applications and 2.0 degrees on the multi-turn configuration.

Other features include a permanently lubricated and maintenance-free

drive train; a 4-to-20 mA loop-powered feedback signal; and digital com-

munication options including HART®, Foundation Fieldbus™, Profibus®,

Pakscan™, RIRO and Modbus®. For more information on valves &

actuators, turn to page 34.

Rotork Controls, Inc. www.rotork.comWrite In 500

Large volumes of ethane obtained as

a by-product in shale gas production

have changed the cost position of North

American cracker operations from an infe-

rior rank to second best. Natural gas is

changing the process industry landscape,

leading analysts and consultants to cat-

egorically conclude that the U.S. chemical

industry is “back.” Read more on page 12.

The natural gas being exported from Australia is of the conventional, and not the shale, sort. But transported as liquefied natural gas (LNG), its use is set to transform the regional economy and is already resulting in on-going mega-projects, including the Gorgon project and LNG plants expected to produce 15.6 million metric tons of LNG per year. It’s all about meeting energy demand in Southeast Asia, and for flow-

meter makers the question is, “Who’s gonna measure all that?” To read flowmeter expert Dr. Jesse Yoder’s column, turn to page 28.

www.ProcessingMagazine.com

Weighing Systems Standardize Batching and Filling OperationsIn 2009, Rice Lake Weighing Systems acquired the Santa Rosa,

Calif-based FlexWeigh Div. of Enduro Systems. Since then, Rice

Lake has been busy supporting the brand’s existing product lines

and engineering a new generation of the popular FlexWeigh

DWM-IV. As FlexWeigh’s replacement for the DWM-IV Series,

Rice Lake’s 920i FlexWeigh Systems are pre-engineered and pre-

programmed for many of manufacturing’s most common weighing

tasks. For more information on weighing & feeders, turn to page 40.

Rice Lake Weighing Systemswww.ricelake.com/920iFlexWeigh Write In 501

Featured Article

Featured ColumnistValves & Actuators

Industrial peripherals — the joysticks, mouse pointers and keyboards that act as the interface between humans and processing equipment — are under constant assault in harsh, messy industrial environments.

In processing plants, mines and mills across the country, these peripherals are exposed to extremely high and low temperatures, moisture, high-pres-sure wash downs, dirt, grime and operator abuse — often around the clock.

Unfortunately, many industrial peripherals built to last in these envi-ronments often fail or malfunction within months and are replaced or repaired at considerable ongoing cost.

The problem isn’t always the harsh, abusive environment. Instead, many industrial peripheral manufacturers rely too heavily on ruggedized enclo-sures, while using commercial-grade components and internal designs

adopted from the PC market.

One technician’s take on itFor Robert Johnson, a ser-

vice technician for Bethlehem, Pa.-based Minteq, a supplier

of refractory systems, the steel foundry environment is, “among

the harshest imaginable” and the choice of peripherals used in any

control system is critical to care-free daily operation.Minteq’s LaCam laser profile measur-

ing system for non-contact measurement of refractory linings in metallurgical reac-

tion and transport vessels operates in an environment where tempera-tures can vary from -10 F to more than 2,000 F at the furnace.

“We were using an industrial keyboard/mouse combination unit,” Johnson says. “But it wasn’t reliable. It wasn’t very industrial. It didn’t react to the temperature extremes like we needed. It would lock up from time to time. We were constantly replacing them.”

The keyboard/mouse combination came with a guide rail and roller system, to pull the keyboard out during use. It wasn’t designed to handle dirt or extreme high and low temperatures. The mouse didn’t respond well when operators wore gloves, which in the steel industry is most of the time. Finally, once the membrane that covered the mouse got dirty or roughed up it didn’t work at all. When the mouse began failing the entire unit had to be replaced. Johnson estimates this occurred every couple of months over the span of 10 years.

NEMA designationsBuilt strictly to meet established industry standards, many industrial

peripherals are protected by a NEMA 4X (IP66) enclosure. This desig-nation indicates the enclosure protects internals from dust, dirt, water (including pressure washing) and even external ice formation.

In addition to enclosures, the industry uses several other common tech-niques to keep peripherals sealed and watertight. Industrial keyboards, for example, are commonly covered with a monolithic elastomer cover.

But like the old saying goes, “you can’t judge a peripheral by its cover or enclosure.” A deeper look into the internal components and design separates the “industrial” peripheral from those truly ruggedized devices that survive — and thrive — for many years.

Industrial-grade computer peripherals: more than just a NEMA enclosureRugged internals and components keep joysticks, mouse pointers and keyboards

from breakdown in harsh, messy environments

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A true industrial-grade peripheral entails ruggedized components that can stand a temperature range from -40 C to 80 C, are hardened against wear caused by heavy or rough use and have few moving parts or poten-tial failure points.

Johnson says he spent a considerable amount of time searching for an alternative and tried six or seven different products before discovering the Industrial Mouse from Stratford, Conn.-based CTI Electronics, which designs and manufactures industrial-grade trackballs, joysticks, keyboards and intel-ligent switches for OEMs, system integrators and commercial end-users.

The ‘joy’ of itThe Industrial Mouse is a rugged joystick used as a mouse pointing-

device, with an inductive effect patented by CTI Electronics to deliver the desired control. Unlike most joystick-style devices, there are no physi-cal contacts and only three moving parts, so there is little internal wear despite potentially millions of operations.

“It’s the easiest thing to install, you basically plug it in and it works,” explains Johnson. “There’s no fooling around with it — no drivers, no set-tings, no nothing.”

Today, the devices Johnson installed 18 months ago are still in service.“The most impressive thing is that it’s almost indestructible,” says

Johnson. “It handles everything we throw at it from the extreme heat down south to extreme cold up at the top of Lake Superior. Sometimes, you’ve got to go from the furnace at 2,400 F back to -10 F in about a min-ute. It handles all that without skipping a beat.”

The operators love it, adds Johnson. “It’s a joystick and they can use it while wearing gloves. It’s got a little button on top. Basically, it’s like a video game to them. It’s easy and fast. They can just move, click, move, click, move, click.”

The Industrial Mouse allowed Minteq to eliminate the keyboard compo-nent altogether. Now operators use the joystick along with touch screens.

Eliminating the keyboard also put an end to the difficulties with the guide rail and roller mechanism. That delivered about 1.25 inches of addi-tional room inside the machine for future design elements, says Johnson. “It’s a complete win. We’ve upgraded every keyboard/mouse unit that failed or that we simply wanted to upgrade.”

CTI Electronics Corp.www.ctielectronics.com

Write In 513

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www.ProcessingMagazine.com•January 2013