Gas Chromatography Calibration
Thursday, September 03, 2009
I'm sorry. I know I'm suppose to share and write a post about having my article printed in the Yellow Pages Energy Guide. But, I think my recent experience during the GC calibration was very worth sharing.
Brief Introduction of our Gas Chromatography
Our research Chemical Reaction Engineering Group (CREG) have 3 Gas Chromatography (GC) Thermal Conductive Detector (TCD). All of them are HP Agilent 6890 model. We have labeled them as GC 1, GC 2 and GC 3. I have personally used 1 of the older GC-TCD (GC 2) when doing my masters degree 9 years ago. GC 2 is the simplest of our GC-TCD. It can only analyze gasses compound and have only 2 columns inside it which are Molecular sieve and Porapak N column.
GC 1 and GC 3 are far advance then GC 2. Both of the GCs are equipped with Flame Ionization Detector (FID) to analyze liquid product, which in our case are hydrocarbons. That means, GC 1 and 3 can analyze both gasses and liquid compound.
GC 2 and GC 3 (Both Agilent 6890 model) are arranged side by side in one of our research rooms.On top of the above mentioned GC-TCD, there is also a unit of Gas Chromatography Mass Spectrometry (GC-MS) to power up our analysis capability. This GC-MS is very useful to identify and analyze liquid compound. GC-MS actually combines the features of gas-liquid chromatography and mass spectrometry to identify different substances within a test sample. In our research group we use it to analyze our pyrolysis, biomass, biodiesel liquid fuel and others. I'm not that familiar with GC-MS, but I plan to learn more about it in future. Now, for my ph.D, I'm more focused on using the GC-TCD.
The molecular sieve packed column and Porapak N column in GC 1Oh yes, we also have one dedicated Perkin Elmer Gas Chromatograph Flame Ionization Detector (GC-FID). This GC-FID is very old, I think it has been around for more than 13 years. It has been used previously to analyze our gas to liquid products. Presently, a master student is using it to analyze her biodiesel from waste vegetable oil research.
Of all the GC brands, we have model from HP and Perkin Elmer but not Shimadzu.
Gas Chromatography Thermal Conductive Detector (GC-TCD) Calibration
All our 3 GC-TCD are in great demand now. The research group population has suddenly increased and all of us need to use this imperative analytical equipment. Unfortunately, the GC-TCDs are not in really good condition. Hence, we've called Agilent engineer to come and help us check on the GCs and calibrate it for us.
I wasn't around on the first part of GC-TCD calibration because I was in Kota Kinabalu with my wife and family for the International Conference on Chemical and Bioprocess Engineering in conjunction with the 23rd Symposium of Malaysian Chemical Engineers (SOMCHE 2009). However, my research colleagues were around for the GC-TCD calibration sessions. Unfortunately, the GC-TCDs could not yet be calibrated due to some problem. It was found that the molecular sieve packed column for GC 1 is not working anymore. So, CREG have to order a new mol sieve column.
Agilent engineer is replacing the mol sieve packed column in GC 1Luckily we managed to order new mol sieve columns and the second GC-TCD calibration session were carried out last week. This time I was around and we work closely with the Agilent engineer. GC 1 has 5 columns inside it and it took some time to work on the valve switching between the valves. The valve switching is an important feature when there are many columns in a GC. This is because a column can only be suitable for certain chemical compound separation, while the others are suitable for other compounds. We calibrated GC 1 with Agilent natural gas standard and successfully managed to get all peaks in the chromatogram at the end of the day.
The engineer is thinking how to solve the mess in GC 3The next day, the engineer continue worked with GC 2 and GC 3. However, he only managed to touch GC 3 after lunch. GC 3 has more chronic problem, it has one of its capillary column torn. He discovered this problem together with a ph.D student doing Plasma Reaction Research. However, the engineer has successfully connect the capillary column again.
HP capillary column is torn.To conclude the GC-TCD calibration session:
GC 1 - Successfully calibrated with Agilent natural gas standard.
GC 2 - Successfully calibrated with Agilent refinery gas standard.
GC 3 - Need to be further calibrated. Probably need 2 days to complete the job. I have contacted Agilent to come and rectify GC 3. We are still waiting the answer from them. I'll follow up with them again tomorrow.
I look forward to conduct my research as soon as possible... :) wish me luck.
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Labels: Experience, Learning Curve, Problem, Research, Technology, Training, Valve
posted by Kipas Repair JB @ 5:07 PM,
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Pinch Valve Sleeves
Saturday, October 18, 2008
Many industries use specific valves, called pinch valves, to control fluids, waste water, slurries, abrasives and corrosive chemicals. Pinch valves are constructed of a heavy-duty, rugged pinch mechanism that positions a sleeve. The valve offers maximum durability and ensures precise flow control in many industrial processes.
Inside every pinch valve is a sleeve that is crucial to the performance success of the valve. This sleeve enables a pinch valve to have a bi-directional, drop tight shut off with which to control flow. Most pinch valve sleeves are made of flexible elastomer compounds, many of which resemble rubber in composition and feel. Because a sleeve's composition is crucial to the success of the valve's application, valve manufacturers offer different elastomer options from which the sleeve can be constructed.
The many uses of the pinch valve
Because pinch valves are useful in a wide range of industries, the ability of a purchaser to choose the desired sleeve composition is paramount. Commonly used in the mining industry, a pinch valve's tough construction makes it ideal for use on harsh and abrasive mining slurries. Pinch valves can also be useful in demanding wastewater treatment applications. For example, a pinch valve's accurate, repeatable linear flow control and drop tight, bi-directional shut off make this valve type a good choice for sludge and raw sewage control.
In the power industry, pinch valves are an important component used in lime and ash handling - two tough services commonly found within a power plant. The abrasion-resistant, self-cleaning, and flexible elastomer sleeve of a pinch valve won't scale, bridge, plug or freeze on slurries. Pinch valves can also work in the treatment and handling of corrosive chemicals. Because there is no packing to maintain and no cavities, seats, or cam action to bind valve operation, pinch valves are often used in corrosive chemical applications.
Pinch valves can also be used in pulp and paper mills. Pulp stock, coating and recycled paper lines are some of the most difficult applications for a valve. The flexible elastomer sleeve of a pinch valve are able to withstand these abrasive services. Pinch valves can also be a great asset in food and beverage plants, cement/sand/silica factories, refineries, pneumatic conveying, and scrubbing.
A sleeve elastomer for every application
The multitude of uses for pinch valves require that purchasers be able to choose specific sleeve compositions and styles for various applications. A pure gum rubber sleeve, for example, is not suitable for the handling of strong acids, but might be appropriate for food manufacture or alcohol distillation. The application of a particular pinch valve, including the temperature range to which it will be exposed, dictates which sleeve elastomer a valve customer should choose.
Pure gum rubber sleeves are resilient and abrasion-resistant. They can handle an incredibly wide temperature range, from -50 F to 180 F, and they are extremely flexible, as well as non-marking. They are composed of natural rubber, and are most suitable for organic (or, carbon-based) acids, and mild chemical compounds, including alcohols. Strong acid and basic solutions, oils, and solvents are some of the chemicals that this type of pinch valve sleeve is ill-equipped to handle.
Neoprene pinch valve sleeves are synthetic rubber sleeves composed of chloroprene polymers. They handle a slightly wider temperature range than pure gum rubber sleeves do, working well with temperatures up to 220 F. Neoprene is chemically inert, and works best in the handling of moderate acids and other chemicals. Unlike pure gum rubber, it is strong and resilient enough to handle products containing ozone, as well as some oils and fats. Neoprene is more resistant to abrasion than is gum rubber; however, it can be eroded or weakened by oxidizing acids, ketone, ester, and chlorinated hydrocarbons.
Sleeves composed of chlorobutyl elastomers, or chlorinated butyl rubber compounds, handle major temperature ranges, from -60 F to 300 F. These sleeves are known for their good abrasion resistance and their ability to handle animal and vegetable fats. However, other types of oils are too heavy for chlorobutyl elastomers to handle -- as are solvents, which can break down the rubber.
The trademarked name of nitrile (a triple-bonded carbon-nitrogen compound), Buna-N can be used to make sleeves suitable for -40F to 240 F temperature ranges. These types of sleeves can be useful in chemical manufacture and chemical engineering because they can handle chemicals and solvents. They are not suitable, however, for ozone, ester, ketone, or nitro/chlorinated hydrocarbons. Meanwhile, Hypalon, a trademarked name for a chlorosulfonated polyethylene compound, is used to construct sleeves suitable for temperature ranges between -60 F and 275 F. This durable compound can handle quite strong acids and bases, as well as freon, ozone, alcohol compounds, and alkalines. This type of pinch valve sleeve should not be used with ketone, ester, or various aromatic and chlorinated hydrocarbons. Hypalon resists weathering quite well, however.
EPDM (or ethylene propylene diene monomer) valve sleeves are excellent for use with fats and oils. These valves -- made of the material used to seal vehicle doors, windows, and the like -- can withstand temperature ranges between -60F and 300F. They should not be used, however, to work with mineral oils or solvents. They also weather well. Viton, a type of synthetic rubber used commonly in O-rings, can also be used with animal and vegetable oils, as well as with acids. Though this type of sleeve performs poorly at temperatures lower than -10 F, it performs quite well at temperatures up to 400 F. Viton sleeves also display excellent tensile strength.
Each of the many uses of pinch valves requires careful consideration of the valve sleeve that is most appropriate to the process for which the valve will be used. With the variety of sleeve elastomer options available, it is no wonder that pinch valves are applicable in so many situations and for so many processes.
Red Valve, in Pittsburgh, Pennsylvania, manufactures custom pinch valves, including air operated, control, and manual pinch valves, along with pinch valve sleeves. For more information, visit Red Valve's Web site.
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Labels: Learning Curve, Valve
posted by Kipas Repair JB @ 12:03 AM,
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How Does Actuators Works?
Wednesday, September 17, 2008
In actuator valve engineering and design, it is essential for engineers, designers, and manufacturers to fully understand the aspects and processes of using this particular product that would eventually help build effective engineering designs in a safe and efficient manner.
One of the most significant products of the company would be the actuators. To make this technical term simpler, an actuator is a device that transforms or converts energy into motion. Also applied as a force, an actuator usually is a mechanical apparatus that takes energy, normally constructed by liquid, air, or electricity, and converts that into a specific kind of motion. This motion can relate to anything from clamping, blocking, to ejecting. These actuators are normally used in industrial applications or in manufacturing, and may also be used in different objects such as motors, switches, valves, and pumps.
From all the actuators available in the market, the most common type would be the ones that are powered by the air, also known as the air cylinder or the pneumatic cylinder. These air cylinders are air tight, usually made out of metal, which uses the energy of compressed air in order to move a piston. In addition, air cylinders are usually used in assembly processes and in manufacturing. On the other hand, grippers, normally used in robotics, use actuators powered by compressed air in order to work similar to the human touch.
Electricity or hydraulics can be a source of power for actuators. Much like there are air cylinders, there are also electric cylinders and hydraulic cylinders where the cylinder converts electricity or hydraulics into motion, and hydraulic cylinders are often used in several types of automobiles. Most of the actuators available have more than one type of power source. For example, solenoid valves can have the ability to be powered by both electricity and air. Electricity powers the solenoid, and the solenoid, powered by air, actuates the valve. Another option for this would be that the solenoid can be powered by both electricity and the hydraulics.
Whether in a linear motion, a rotary motion, or in an oscillatory motion, actuators can still be used, that is if they can create the motion with only one direction, in a circular motion, or in an opposite direction at normal intervals. Hydraulic and air cylinders can also be classified as single acting, which means that the energy source that justifies the movement in one direction, and that a certain spring is used for the other direction. Having these interchanged, these cylinders can act as double as an acting cylinder, which means that the energy is used in two different directions. Even if actuators are usually explained in terms of mechanical implements, muscles are often given as an example of an actuator. Energy, which is created by eating carbohydrates, is converted by the muscle, which in this case would be the actuator, and transform it into motion, such as playing basketball.
The above article was authored by Christel Lumabas who is part of MEA Inc. team. MEA Inc is a world leading organization that is composed of designers, engineers and manufacturers of valves and actuator including butterfly valve, valve actuators, diverter valve, linear actuator, hydraulic check valve and electric actuator for mechanical and electrical automation systems worldwide. For more information check out http://www.meaincorporated.com.
For better comprehension, I include some photos to better illustrate the actuators:
Actuator Diagram - photo adopted from Spirax Sarco
Actuator (topside) connected to one piece ball valve - Image adopted from Randex.
Similar to the latter image, this actuator (topside) is also connected to a one piece ball valve - Image adopted from Ferret.
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Labels: Learning Curve, Process Parameters, Processing., Valve
posted by Kipas Repair JB @ 8:38 PM,
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Some Updates
Saturday, July 28, 2007
I was busy for the past few days. I sincerely apologize for not updating more frequently. By the way, as usual, I experienced a lot of new things at work. Let me share some of them with you .
Between working in the office and at plant-site
I have been an office dweller since a few months back because I was busy doing some paper works, reports, planning, documents/filing 5S, meetings, appointments with
supplier, trainings etc (Once in a while I came out and toured the plant, visited the control room, discussed few things with the supervisors and plant operators). After some time warming up the chair in my cold well air conditioned office, I felt really bored sitting in the office staring at the 15" LCD monitor. The past 3 days, I spent majority of my time in the plant and made my hands dirty. I equipped myself with a meter tape and pens of different coloured ink. Normally, when I walked in the plant, I'll be sweating. Some section in the plant is really hot (like a sauna!!). However, the past few days was luckily colder (thanks to the rainy day...) - So I sweated only a little! We (myself and my senior colleague) planned to install an alternative back-up pipeline for 
some section in the plant where tendency of blockage is most likely to occur. I have to come out with a plan on which route and how to install the pipeline. With that, I also have to calculate how many valves, elbows, flanges incorporated
with the new pipeline.
In addition to that, we're going to install a new plate heat exchanger (PHE). The PHE will arrive somewhere in August. Other materials for the PHE such as piping, valves, elbows, expansion bellows, sockets, metal plates etc have arrived. I have measured and marked the location/position for the PHE installation. It's not a big upgrading project, but surely I learned and experienced a lot through out the process of getting and installing a new PHE. I hope after the installation of this heat exchanger, our heat profile can be improved and the natural gas consumption can be reduced (utility saving means production cost saving).
Process plant - Heat Recovery View
One of our plate heat exchanger has undergone cleaning in place (CIP) for 2 weeks already. We consumed a lot of caustic and decarbonizer in order to thoroughly clean the plate heat
exchanger. Yesterday, we stopped the CIP, flushed the pipeline and heat exchanger with water and air. Then we began using the heat exchanger. Today, I checked the flow rate and outlet temperature. Unfortunately, the temperature is not as high as it is supposed to be. We checked the outlet temperature from the control room (The RTD {resistance temperature detector} installed at the heat exchanger oil outlet sent signal to the PLC and therefore we can see the temperature reading from the Human Machine Interface (HMI)/monitor/PC in the control room).
I was not satisfied with the situation. We consumed a lot of chemicals, water, time, man hour etc to perform this CIP. The temperature should not be like that. It should be good. I personally inspected the pipeline and heat exchanger. My intention was to double check the 
temperature with the temperature gauges installed at the pipeline. There were all together 3 units of temperature gauges that can be referred and the temperature readings are all higher than the RTD reading. I knew it....Earlier, I already suspected that the RTD is not right. The RTD need to be serviced and calibrated. From here, I learned: Never 100% trust your instrument. They can be a good indicator for process control and instrumentation, but we also need alternative/back-up equipment/instrument to counter check the readings. Sometimes we can be deceived and made expansive wrong decision just from a false instrument reading. This will cost money and time which is very precious in this type of industry.
Manpower Issue
I received a resignation letter from one of my sharp and skillful plant operator. I have high hopes and plan to promote him to a higher position next year. Unfortunately, this is a global and universal issue that all private companies encountered. After chatting with him, I realized he has multiple reasons for leaving the company after serving for 9 years. Hence, I accepted his 
resignation and respected his decision. I just wish the very best of luck for him and hope he will be successful in future.
With his departure, I have to recruit a new plant operator and train him. The criterias that we require are very simple - (1) A discipline person which means, will always come on time for work and would not be absent. (2) Willing to learn and work hard. (3) Take care of the cleanliness and smoothness of the plant.
I think those requirement should be ample. We don't need good academic result plant operator. Their attitude is the most important trait. With good attitude, they can climb the ladder of success. Just like my previous senior production executive colleague who started just as a cleaner/sweeper (25 years ago) but ended up now very successful as a factory manager taking care of a number of plants and projects in a foreign country.
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Or you can also Subscribe to CHEMICAL ENGINEERING WORLD by RSS.Labels: Chemical Engineer, Chemical Plant, Equipments, Heat Exchanger, Valve
posted by Kipas Repair JB @ 7:11 PM,
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Butterfly Valve
Friday, February 23, 2007
In a production plant, we need a very good process control equipment and system. We learned the theory in a Chemical Engineering subject called Process Control and Instrumentation. It was hard for me to imagine what process control and instrumentation is all about when I studied the subjects few years back.
When I start working in a plant, then everything becomes clear. One of the most important equipment is valve. There are various types of valve. We have butterfly valve, ball valve, gate valve, globe valve, check valve etc. Each type of valve have their own pros and cons as well as functional area. There are a lot of things to talked about valve. However, in this post, I'm going to cover just a little bit about butterfly valve.
The following photos illustrate a typical butterfly valve. It is a 3" Belgium Ventiel (BV) butterfly valve. This valve have created a very serious contamination and lost earlier because it leaks.
A typical butterfly valve. This is a gear type. The gear is used to open or close the disc. The disc is made of stainless steel.
A closer look to the butterfly valve when it is fully open, allowing liquid to flow passing through it. It is now fully open.
The red arrow shows the seat / liner is damaged and worn out. This is one of the reason leakage can occur from a valve. There are various type of seat / liner to choose for different type liquid and process conditions. The disc is half open.
Another angle of the butterfly valve. Extra photo for you to have better comprehension of this piece of equipment.Labels: Process Parameters, Valve
posted by Kipas Repair JB @ 10:53 AM,
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Checking the Valves
Thursday, February 08, 2007
Before facing the shutdown in 11 days time, I toured my plant another round, just to check all the valves and other parts that need to be replaced. I went from one pump to another pump. There are a lot of pumps. They don't look good. Ugly black dirty oils covered them. I checked the suction and discharge ball valves. Some of the suction valve are 6" and 8" valve and the discharge valve are 4". Well, the sizes of big valves are easier to detect or decide. There's no big problem for me identifying them now. However, that was not the case when I joint the company earlier. It took me some time to get familiar with all types of valves and their brand.
Then I went from one heat exchanger to another heat exchanger. I checked out the drain valves. It's harder for me to estimate the sizes of those drain valves and deciding the brand. There are commonly small varying from 1/2" to 2". In between those sizes, there are also 1.75" 1", 1.5" and others. Deciding the correct size and brand is vital to order and purchase the repair kits/seats. Ordering the wrong spare parts will just be a total waste of money and time and the chance to replace the valve seats which can only be done during plant shutdown.
The darkish, oil layer covering the valves at the pumps and heat exchangers are something that must be improved. It should not be left dirty and uncomfortable for eyes. It should be cleaned and well maintained. I want the valves to be clean and shining like a new piece of metal. Well, We are working on that as well. I'm developing a 5S system (a Japanese Concept of Total Productive Maintenance (TPM)) for maintaining the plant to be a clean healty place and pleasant working environment.
Labels: Heat Exchanger, Plant Shutdown, Problem, Pump, Quality, Valve
posted by Kipas Repair JB @ 11:17 PM,
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Checking Valve Repair Kit
Tuesday, February 06, 2007
The shutdown is just nearby the corner. Early in the morning, I went to the store to check on some ball valve repair kit for the shutdown maintenance job. The repair kit is mostly the internal part of the valve that can be replaced. The valve seat need to be replaced because simple reasons like it has already worn out which resulted to leakage and also because of other reasons like the parts are jammed etc. Many other reason may lead to the valve seat replacement.
Labels: Plant Shutdown, Valve
posted by Kipas Repair JB @ 9:20 PM,
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The Author
I’m Zaki. I used to be a project, process and chemical engineer. Few years ago I successfully became a Chartered Engineer (IChemE) and Professional Engineer (BEM). I'm now employed as a chemical engineering educator/researcher/consultant. Hope you like reading my blog. I welcome any feedback from you. My email: zaki.yz[alias]gmail.com. TQ!
