Flow control is an integral part of all industries, such as in chemical plants, power stations, food factories, dyeing and finishing plants, or other factories, flow control is an essential part of process control. Flow controls meanings to control of the flow rate of the medium in an adjustable range according to the process requirements. For example, flow control may be utilized in the chemical industry to manage the flow of liquids between tanks or reactors during the manufacturing process. In an oil and gas plant, flow control may be used to control the flow of fluids through pipelines or to measure the amount of oil or gas being extracted.
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Usually, this function is required flow control valves, which regulate the capacity of the fluid or gas in the pipeline and ensure smooth and safe operation. In this article, we will explore the different types of flow control valves, their applications, and the common problems associated with their use.
Flow control valves play a key role in regulating the flow of fluids and gases through pipelines, and if you walk into a plant, you can find flow control valves everywhere in the equipment, and they ensure that processes run efficiently and safely. Flow control valves can be found in a variety of industries such as textile mills, water treatment plants, chemical plants, refineries, and power plants. These valves offer several benefits, including improved process efficiency, precise control, reduced energy consumption, and enhanced safety measures.
Globe valves are used for regulating fluid flow and can be found in various configurations, such as on/off globe control valves, single-seated globe control valves, double-seated control globe valves, 3-way globe control valves, and y-type globe valves.
Ball valves offer excellent shut-off capabilities and are commonly used in applications where tight sealing is required.
Butterfly valves are designed for controlling the flow of fluids in pipelines and are known for their compact design and ease of operation.
Check valves prevent fluid flow in the reverse direction, ensuring that processes run smoothly and efficiently.
ARVs protect pumps from damage by maintaining a minimum flow rate even when the demand for fluid decreases.
Diaphragm valves use a flexible diaphragm to control fluid flow, making them suitable for use in sanitary applications or with abrasive and corrosive materials.
Pinch valves are designed to control the flow of fluids or gases in pipelines by pinching a flexible tube or sleeve. They are often used in industries such as wastewater treatment, mining, and food processing.
Pressure reducing valves regulate the pressure of a fluid or gas by reducing it to a specific set point.
Valves such as pneumatic angle type control valves and electric temperature control valves are equipped with actuators to enable remote or automated control of fluid flow.
Flow control valves are used in various industries and applications, including:
To select the right flow control valve for your applications, we need to consider many processing parameters, which include type of fluid or gas, operation temperature, operation pressure, desired flow rate, pressure drop, or differential pressure, control method, mode of operation and the desired level of control accuracy. Correct sizing not only reduces unnecessary downtime for maintenance for the end user, but also greatly accelerates productivity and accuracy. You can ask for a free consultation with THINKTANK to ensure the right selection.
Manual flow control valves require manual adjustment to regulate fluid flow, while automatic valves require the use of actuators such as pneumatic or electric to control fluid flow, via remote signals, or to adjust the valve position according to specific control parameters. You can find these different valves in the following pictures.
Automatic valves are suitable for applications that require precise control, remote operation, or integration with control systems. In modern industry, automatic valves are being used more and more widely in production processes, not only to improve the efficiency of production, precise control, and greater energy savings.
Proper routine maintenance job of flow control valves includes periodic inspections for shell leaks, inner leaks, seals, signals, correct actuator action, and routine valve cleaning and lubrication. In addition, we should replace worn or damaged parts as needed to ensure optimum performance and extend the life of the flow control valve. The end-users need to follow the manufacturer’s guidelines and recommended maintenance schedule, which is essential to maintain valve efficiency and prevent unexpected failures. If you don’t have the manual book or maintenance book in hand, you can contact the equipment factory to ask them to send it again. Every single valve from THINKTANK will have a 100% test and inspection before shipment, ensuring the reliable quality of flow control valves. You can surely no worries about the quality and service.
Flow control valves provide precise control of the flow of fluid or gas in a system. The change of flow or pressure after the valve is controlled by the flow area of the valve core through which the fluid or gas passes. Flow control valves can improve industrial energy efficiency mainly through three aspects.
One is to reduce unnecessary energy consumption due to system pressure drop.
We know that when fluid or gas passes through a pipeline or system without a flow control valve, the flow will pass elbows to change direction in the pipeline, or generate friction with the pipeline wall and other reasons, so it will cause a pressure drop in the entire system, because the loss of fluid energy. The pressure drop not only causes energy loss but also wasted a lot of energy and power.
Flow control valves can help reduce pressure drops by regulating the flow capacity, and make sure fluid or gas passes through the system at a consistent pressure. By maintaining a certain pressure value, no need for much energy is required running the entire processing system.
The second is to improve the control of fluid or gas flow in the system.
Flow control valves can ensure that only the required amount of fluid or gas is used at any given time, precisely controlling the flow parameter value, which prevents overuse and wasted energy, resulting in significant energy savings.
Third, flow control valves can help improve energy efficiency by increasing the overall efficiency of the system.
For example, if a flow control valve works in an HVAC system, it can regulate the flow of water through heating and cooling circuits, maintaining the desired temperature and improving energy efficiency while optimizing heat transfer. It’s more and more important for end-users save costs during production efficiency. Standing for the customer position to thinking of the market is very valve manufacturer need to be consideration.
Flow control is the process of regulating the flow capacity or volume of a fluid, gas, or steam in a piping system. It involves the use of flow control valves and other devices to manage the flow of the medium to achieve the desired output. Welcome to choose THINKTANK as your reliable partner of flow control valves.
We can list 3 types of different valves to achieve flow controls.
Flow control systems are designed to modulate the process flow rate/capacity of fluids or gases in an industrial system. Based on different applications and types of flow control systems on-site, the operating principles may vary in design.
Generally, a standard flow control system consists of 4 key components.
We need to based on a variety of processing parameters to design the best control of flow solution for customers. Deeply knowing the specific requirements of the system running is very important for professional valve manufacturers, like THINKTANK. It will help us to design and provide precision and control systems for the desired levels as users need.
Here we will introduce the most 4 simple control of flow type systems for your reference.
This type of flow control adjusts the flow rate in proportion to changes in the input signal, such as 4-20mA, 0-10V, or 3-15psi signal. For example, if the input signal is 50%, the response flow rate of the control valve is just adjusted to 50% of the maximum capacity. Proportional control is often used for the high level of accuracy of control systems.
In an on/off control system, the flow control valve is either fully open or fully closed based on the input signal. This type of control is less precise than proportional control but can be simpler and less expensive to implement.
PID control is a type of proportional control that also takes into account the integral and derivative components of the input signal. The proportional component adjusts the flow rate in proportion to changes in the input signal, while the integral and derivative components help to reduce the “overshoot” and “undershoot” that can occur with proportional control. PID control can offer a good balance of precision and simplicity.
Flow limiting devices are passive devices (such as orifices, flow nozzles, and ventures) that are designed to limit the flow rate of a fluid or gas. These devices can be effective in applications where a fixed flow rate is required and no active control is necessary.
Ultimately, the best control of flow for a particular application will depend on the unique requirements of the system and will take into account factors such as precision, accuracy, cost, and ease of use. A qualified engineer or technician can help to determine the optimal flow control solution based on these factors.
The three types of control flow in computer programming are:
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This type of control flow is the simplest and most straightforward. Programs with sequential control flow execute one instruction after the next, in the order that they are written. There is no branching or looping, and each instruction is executed exactly once.
In selection control flow, a program chooses between two or more paths based on some condition. This is typically accomplished using if-else statements, which allow the program to execute one block of code if a condition is true, and another block of code if the condition is false. Switch statements are another example of selection control flow, allowing programs to choose between multiple options based on the value of a variable.
Iteration control flow involves repeating a block of code multiple times, either a fixed number of times or until a certain condition is met. This is typically accomplished using loops, such as while loops or for loops, that allow the program to execute a block of code multiple times with different input values.
These three types of control flow are fundamental to most programming languages, and mastering their use is essential to becoming a skilled programmer. By combining sequential, selection, and iteration control flows, programmers can create complex systems that can perform a wide range of tasks.
The two types of flow control are open-loop and closed-loop control. Open-loop control is a non-feedback system where the output is not used to regulate the input, while closed-loop control is a feedback system where the output is used to regulate the input to maintain a desired output.
Flow control should be used when it is necessary to regulate the flow rate or volume of a fluid, gas, or steam to achieve a desired output. It is commonly used in industrial processes, such as chemical and petrochemical plants, food and beverage production, and water treatment facilities. Here are 4 conditions you may consider for using flow control in programming.
Flow control is needed in any application where the flow rate or volume of a fluid, gas, or steam needs to be regulated. It is used in various industries, including oil and gas, power generation, water and wastewater treatment, and food and beverage production.
Flow control is used to prevent a range of issues, such as overpressure, overheating, cavitation, erosion, and water hammer, which can cause damage to piping systems, valves, and other components.
The benefits of flow control include improved efficiency, accuracy, and reliability in controlling the flow rate or volume of a fluid, gas, or steam. It can also reduce operating costs, improve product quality, and enhance safety by preventing damage to piping systems and components.
The reasons for flow control vary depending on the specific application and requirements. Some common reasons include ensuring safety and reliability, improving efficiency and accuracy, meeting regulatory requirements, and enhancing product quality.
Automated fluid management systems have gained a lot of popularity in the recent past. Production processes in biopharma have never been more competitive. New advances and research in gene and antibody therapy have called for more streamlined production steps.
An important factor is safe and efficient fluid handling, which is still often carried out manually. This does not only leave more space for human errors, it can also affect staff and patient safety. Automated fluid management systems, in combination with single-use technologies, help to reduce product loss and rid medical staff of monotonous and laborious tasks like pipetting.
However, as not every fluid management system is the same in terms of production yields and functions, there are several considerations to be taken into account. Here are seven questions you should ask to make the right choice.
A fluid management system (FMS) serves as an automated solution in the handling of sensitive fluids which have to be protected from contamination. FMS are used in different industries and have proven to be especially valuable for aseptic fluid management processes in biopharma production and therapeutic treatments.
The advanced technology automates different steps (or the complete process) of the workflow, which had to be carried out manually by healthcare professionals in the past. Different case studies have shown that automated systems are able to reduce the risk of human errors and, consequently, product loss.
Sterile connectors in automated aliquoting systems ensure that fluids are not exposed to any contaminating factors during filling into containers or fluid controls.1
Due to the specifics of each individual projects, the components needed for a liquid handling can vary. Whereas in antibody production for biopharmaceuticals, freezing and filtration is often part of the process due to transport or conservation purposes, this is seldom the case in diagnostics.
Let us start with a homogenization solution, like RoSS.PADL. This system is able to cool and homogenize substances simultaneously in single-use bags, allowing for optimal temperatures during draining. For aseptic filling in a closed system, the essential components include pumps, valves, and single-use assemblies, seamlessly integrated into a filling system. To achieve the desired storage temperature, freezing solutions like our plate freezer or a cryogenic freezer like RoSS.LN2F are required.
It is also possible to combine several platforms to achieve end-to-end solutions through seamless integration.
There are different fluid handling systems, designed for a variety of volumes. Liquid handling is an important part of life sciences and needed in biotechnological and pharmaceutical production practices, as well as in research and diagnostics. Depending on the subject, such as clinical diagnostics or drug discovery, fluid volumes vary.
Due to an increase in clinical assays for research and diagnostics, not only connected to the recent Covid-19 pandemic, but new advances in antibody research in general, the demand for low-volume technologies has grown rapidly.
Further, especially in larger-scale pharmaceutical companies and contract development and manufacturing organizations (CDMOs) that carry out low-volume and high-volume projects, a need for scalability has sparked. Scalable fluid management systems like RoSS.FILL address this need with a combination of single-use bags in different sizes and automated aseptic filling methods that can easily be adjusted to individual project demands.
Due to the specifics of each individual projects, the components needed for a liquid handling can vary. Whereas in antibody production for biopharmaceuticals, freezing and filtration is often part of the process due to transport or conservation purposes, this is seldom the case in diagnostics.
Let us start with a homogenization solution, like RoSS.PADL. This system is able to cool and homogenize substances simultaneously in single-use bags, allowing for optimal temperatures during draining. For aseptic filling in a closed system, the essential components include pumps, valves, and single-use assemblies, seamlessly integrated into a filling system. To achieve the desired storage temperature, freezing solutions like our plate freezer or a cryogenic freezer like RoSS.LN2F are required.
It is also possible to combine several platforms to achieve end-to-end solutions through seamless integration.
Fluid management requires a lot of staff, especially in laboratory settings. The tasks are rather monotonous and laborious, requiring staff to spend a lot of time hunched over with pipettes and syringes during manual liquid handling. Automating these processes allows workers to spend their time on other tasks and streamlining the overall process in general.
Most important for the production of high-quality drugs and assays is the reduction of human error through automated liquid handling systems. They reduce contamination and deliver consistent results. Additionally, integrated fluid control systems ensure quality and safety against distention during insertion while reducing product loss.
There are also solutions that support staff during procedures in the operating room. For example, fluent fluid management systems with integrated touchscreens, tubes and waste-bags or suction canisters, which are used in hysteroscopic procedures, help health workers monitor fluids when tissue is removed.
Automated systems are designed to be user-friendly, however, it is still necessary to brief staff how to use these systems (i.e. the inserting of tubes), as software and calculation tools need explaining in order to work efficiently. In many cases, there are webinars, on-site trainings, and other instruction materials available.
As mentioned before, there are various systems for different production sizes available. However, project demands might change over time. If an increase in production is needed, as we encountered with fluid management solutions in vaccine production during the recent pandemic, for example, scalability becomes important to prevent bottlenecks.2
In response to this need, Single Use Support's fluid management solutions are designed to be adaptable for both scale-up and scale-out requirements, accommodating various bag sizes.
The concept of "scale-up" is exemplified in scenarios like FDA approval, where there is a need to produce more drug substance efficiently using larger bags. On the other hand, "scale-out" is relevant in applications such as gene therapy and viral vector production, where more liquids are required, leading to the use of multiple bags.
In order to comply with aseptic production regulations, it is necessary to ensure that fluids are not exposed to contamination. The safest way to do so is by linking different process steps with each other. Therefore, it is important that fluid management systems are connectable with cryogenic freezers or homogenizers, for instance, without breaking the cold chain or exposing substances to contamination.
For this reason, solutions by Single Use Support are designed to address the problem of interoperability: Aseptic bag filling machines like RoSS.FILL are compatible with protective cases for all available 2D and 3D single-use bags or bottles. Once bags are filled in their protective shell, the racks can easily be transferred into RoSS.pFTU, a fully scalable and automated plate-freezer and thawing system.
Single Use Support fluid management solutions have been designed to meet the rising standards in biopharma, due to new advances in life sciences and drug manufacturing. As gene and cell therapeutics require special production standards and high adaptability, there is a need for customizable and flexible processing solutions.
Even though it might not seem obvious at first, by optimizing the supply chain with single-use products, sustainability of production processes can be increased, as less energy has to be used for extensive cleaning, and product loss can be minimized.
cGMP compliant filling and draining machines like RoSS.FILL are adjustable for up-and-down-scaling and extremely flexibility. The system is compatible with single-use bags or bottles in different sizes, allowing for seamless aseptic filling and transferring into plate-freezers and transport containers, which keep sensitive substances at the required temperatures. Supporting devices like RoSS.PADL knead single-use bags gently and cool them during homogenization of the processed fluids.
With such solutions, Single Use Support helps biopharmaceutical manufacturers in streamlining their production processes, making them more efficient, sustainable and safe.
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