Flow, level & control


specification is resilience to the chemicals it comes into contact with in order to achieve the expected lifetime. For this reason, proving origin is also an important factor for customers to validate valve quality. For example, a manufacturer can be asked to provide a 3.1 material certificate, which could trace the composition of a stainless steel valve body to clarify carbon content. Lower quality valves can use stainless steel with a higher carbon content, generally making it more brittle and less robust, so validation is a sensible request. Traceability is vital, but ensuring chemical


compatibility can also be a matter of application experience. For example, in many dairies, nitric acid is used as part of the CIP (clean in place) process. Within a ball valve, typically two carbon graphite seals are used in the end caps, however the material is not suitable for long-term use with nitric acid, which will degrade the seals, reducing the number of cycles the valve can perform in its lifetime. This is a commonly overlooked example and instead Bürkert would use an angled seat valve with a PTFE seal, suitable for use with nitric acid and ensuring that it can achieve its seven million cycle lifetime. It is important to select the body and seal materials most effective for use with the chemicals in each specific application. PTFE is commonly used for seals, diaphragms,


as well as valve bodies. Resistant to nearly all chemicals, including acids and alkalis, PTFE is an ideal choice for CIP applications. Its carbon- fluorine bonds make it inert and therefore ideal for use with reactive and corrosive chemicals. It is, however, susceptible to cold flow, which is distortion under stress of high temperatures or temperature fluctuations. Advanced PTFE can instead be specified if the application includes extreme temperature changes or frequent sterilisation. Alternatively for diaphragm use, GYLON is a


third generation PTFE, which is used across the widest range of applications. With increased resistance to stress, it can be used with greater fluctuations in temperatures as well as higher temperatures, and has a longer lifetime. EPDM is also frequently used for diaphragms and seals because of its resistance to ozone and hot water, as well as FKM which is often selected for its resistance to oil. Valve bodies are frequently brass or stainless


steel, or a suitable hard plastic variant with sufficient impact resistance. Polypropylene and polyethylene are commonly selected for their resistance to various organic solvents, acids, bases and salts while polyamide is appropriate for use with greases, oils, waxes and fuels. Meanwhile, PPS is ideal for use in high temperatures above 200 degrees centigrade. The chemical composition of the valve


components and the media flowing through it are critical factors for a wide range of applications. The challenge can be complex so engaging the right application expertise is well advised.


Bürkert Fluid Control Systems www.burkert.co.uk


Instrumentation Monthly January 2021


Optimising pharmaceutical


prOjects thrOugh partnership Designing and building new pharmaceutical processes is a complex task. New processes or skids can be simplified and made more cost-effective by improving communication and working with an experienced solutions provider. By coordinating the different design groups and optimising the purchasing process, new projects can be delivered with minimal footprints and enhanced performance. Bürkert’s Damien Moran looks at how the design and build of process skids and plants can be improved


Attention also turns to approved suppliers of components and how these will be used to deliver the finished process. Often, this follows a well-trodden path of engaging certain suppliers for specific products, but there is an opportunity to exploit other products from the same suppliers, reducing project complexity. From this point, the process of designing


O


and installing a new pharmaceutical process usually involves three main groups: mechanical engineering dealing with pipework, vessels and valves; electrical and instrumentation engineers taking care of valve control and electrical installation; and the automation engineers responsible for the control concept and implementation. Each group has their own set of goals that,


together with designers and contractors, will deliver the project for the end user. However, these groups will often act independently once the overall concept for the process has been decided. They will proceed with designing and specifying the components they need from approved vendors to deliver their section of the project.


BroaDeNiNg the view For the mechanical section, designers will often use products and layouts from previous projects. For the design stage, this means that they already have the 3D models to use in the ‘virtual layout’, allowing the majority of the design to be delivered relatively quickly. However, this can mean that more compact


designs are ignored or improved functionality is not implemented, even when enhanced components are available and meet all of the build criteria. By taking consideration of a wider range of equipment and addressing potential challenges early in the design phase, many benefits can be achieved. As a long-established manufacturer of control


valves and a designer of flow control systems, Bürkert can offer experienced insight that is supported by cutting-edge technology. Working in partnership with the process designers, it is possible to identify solutions that might


nce the overall concept for a project has been agreed, the process of designing the physical structure begins.


otherwise be overlooked. Furthermore, with considerable experience in designing products for the pharmaceutical sector, Bürkert is well-placed to ensure compliance with industry standards.


iMproviNg DesigNs One of the criteria often raised for a project is to reduce the number of welded joints and minimise the dead space in the system. Bürkert is able to use its design expertise and manufacture a number of specialty distribution valve blocks that achieve this aim while matching all other hygiene standards applied to the rest of the installation. By working across the three major design


groups, Bürkert can deliver a more integrated solution. By working in partnership with OEMs, it is possible to take advantage of additional cost savings as well as reduce the overall time for installation and commissioning.


expertise oN haND Bürkert’s Hygiene Competency Centre (HCC), offers a central pool of expertise that can be targeted at a specific issue or challenge. As the project design progresses, there will often come a point where a number of valves or actuators appear not to fit in the space available. In many cases this can be achieved using a bespoke valve manifold or alternative valve configuration. Taking expert advice on what can be achieved using the latest manufacturing techniques or valve designs can often resolve these issues. HCC contains the resources to allocate


engineers to work with the original project team and provide assistance to all three areas of the design. A local point of contact or project manager is assigned responsibility for coordinating the communication and ensuring all aspects of the project are covered. By taking a more holistic approach, providing


project management support, design expertise, documentation, step files, drawings, 3D models, simulations and sizing tools for control valves, the whole project can become more efficient. Working in partnership with an expert in pharmaceutical design can achieve savings in overall project costs, but more importantly, improved efficiency and process reliability. www.burkert.co.uk


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