Burt Process Equipment engineered and delivered an IPA Transfer System Station to a global leader in performance materials manufacturing. The system was designed to safely and efficiently handle isopropyl alcohol (IPA) transfer operations in compliance with stringent safety and environmental regulations.
Industry
Advanced Materials Manufacturing
Challenge
Safe IPA Handling
Solution
Client Profile
The client is a world-renowned manufacturer specializing in advanced materials used across various industries. Their operations demanded a robust and automated system for transferring IPA, ensuring safety, reliability, and operational efficiency in a highly regulated environment.
Client Requirements
The client required an IPA Transfer System capable of:
- Safely transferring IPA from 330-gallon totes with minimal spillage risk.
- Providing real-time monitoring and control to ensure safe operation.
- Meeting Class 1, Division 2 safety standards for hazardous environments.
- Integrating seamlessly with existing facility systems.
Solution
Burt Process delivered a fully preassembled and tested IPA Transfer System Station featuring advanced automation, monitoring, and safety features.
System Features
Cabinet Construction:
- 304 Stainless Steel Double-Door Enclosure:
- Sized to hold a 330-gallon tote with NFPA hazard and indicator labels.
- Includes self-closing doors with an electronic lock interlock system for enhanced safety.
- Integrated Sprinkler Head Connection:
- Provides additional fire suppression capability.
Pumps and Plumbing:
- ARO Air-Operated Diaphragm Pump:
- Constructed with stainless steel wetted parts, rated at 10 GPM at 55 PSI.
- Includes pulsation dampeners, manual isolation valves, and flexible stainless steel hoses.
- External Air Manifold:
- Equipped with isolation valves, solenoids, and air regulators for pump operation.
Startup and Training:
- Two three-day onsite visits for startup, calibration, and operator training.
Instrumentation and Monitoring:
- LEL Sensor (Q8-GENL-100L-O-X-IPA):
- Monitors lower explosive limits to ensure safe operation.
- Pressure and Level Switches:
- Class 1, Division 2 rated ultrasonic level switch for leak detection.
- Pneumatically actuated feed valve with limit position feedback.
- System Indicators:
- Alarm stack light, fire alarm contact, and exhaust blower operation indicator.
Control Panel:
- NEMA 4X UL-Listed Panel:
- AB Micro820 PLC with Ethernet output for system logic.
- Panel View +4” HMI for level display, valve control, and LEL sensor feedback.
- E-stop relay, alarm relay, and intrinsic barriers for safety compliance.
Engineering and Documentation:
- Comprehensive system layout drawings and P&ID diagrams.
- Operating and maintenance manuals with detailed BOMs, troubleshooting guides, and service manuals.
Implementation
The system was delivered preassembled to minimize onsite installation time. The client was responsible for:
- Offloading and rigging the equipment into position.
- Plumbing influent, effluent, and vent connections.
- Wiring the system to the facility’s power supply and integrating it with existing control systems.
- Preparing the room for Class 1, Division 2 compliance.
Burt Process provided technical documentation and support to ensure smooth installation and integration.
Benefits
- Enhanced Safety:
- Integrated leak detection, LEL monitoring, and interlock systems minimized risks.
- Class 1, Division 2 compliance ensured safe operation in hazardous environments.
- Operational Efficiency:
- Automated controls reduced manual intervention and improved reliability.
- Preassembled design minimized installation time and costs.
- Regulatory Compliance:
- Designed to meet strict environmental and safety standards, including NFPA and UL requirements.
- Scalability and Flexibility:
- Modular components allowed for future upgrades or expansions.
- Compact design facilitated installation in space-constrained areas.
Outcomes
The IPA Transfer System Station enabled the client to:
- Safely and efficiently handle IPA transfer operations while minimizing spillage and environmental risks.
- Improve operational safety and reliability through advanced monitoring and automation.
- Maintain compliance with industry-specific safety and environmental standards.
Conclusion
Burt Process Equipment’s IPA Transfer System Station provided a tailored, efficient, and safe solution for the client’s industrial alcohol handling needs. This project highlights Burt Process Equipment’s expertise in delivering innovative systems that prioritize safety, reliability, and regulatory compliance for demanding industrial applications.
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