Manifold to monitor and control electrolyte flow

Burkert has supplied specially designed manifolds and a number of sensors and valves to Doncasters Paralloy to control the delivery of electrolyte to two electro-chemical machining (ECM) units

Burkert Fluid Control Systems has supplied specially designed manifolds and a number of sensors and valves to Doncasters Paralloy to control the delivery of liquid electrolyte to two electro-chemical machining (ECM) units that are used to machine internal bore profiles in cast nickel alloy furnace tubes produced at the company plant at Billingham, in the North East of England.

Doncasters Paralloy, part of the Doncasters Group of Companies manufactures and fabricates centrifugally spun cast alloy tube assemblies for ethylene and reformer furnaces, using a patented profiling process that was developed by the company two years ago.

The pre-mixed electrolyte, which passes through the furnace tubes as part of the machining process, is stored in a tank in the chemical area of the plant.

The computer controlled distribution system, which was designed by Doncasters Paralloy, uses special Burkert-designed manifolds and a combination of Burkert sensors and proportional valves to help monitor and maintain flow, temperature, level, pressure, pH and conductivity.

Commenting for Burkert, Paul Trevitt, Systems Engineering Manager says: "We were consulted at the engineering and design stages and we supplied CAD drawings and visited the site to assist with the commissioning.

The fact that we could supply such a wide range of products for the system was also a key factor in the awarding of the contract".

The installation used products from almost every Burkert fluid control range, including ultrasonic level transmitters and magmeters, stainless steel and plastic manifolds, digital pH controllers and transmitters, flow, pressure and temperature sensors and switches, globe control valves, pressure gauges, diaphragm and solenoid valves, top control valves, and flow controllers housed in a custom-built cabinet.

Commenting on the choice and range of components and the service provided for the fluid control system, Doncasters Paralloy spokesman Mark Glansford says Burkert equipment is used in another Doncasters Paralloy facility, where it has worked very well and proved to be extremely reliable.

"This experience and the wide choice of products, made Burkert the natural choice for this project" he says, adding that "whilst we were working to the Doncasters Paralloy system design it was very much a joint effort".

"Burkert knew what was needed and were therefore able to help us with the detailed design and planning and advise us on what we could sense and control" he says.

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