Introducing Gemu’s Multifunctional Valve Actuation Automation Module

Gemu has released a new automation module designed to measure and control process fluid flow. The 44A0 combines a control box and a position sensor system into a single package, simplifying wiring and troubleshooting while also reducing the physical footprint as compared to other automated systems.

Process Fluid Control

All refining and other chemical process industries rely on accurate, real-time flow control. Flow control is typically performed in a feedback loop, where flow sensors measure the fluid flow through a pipe. The measurement is compared to a setpoint flow rate, and a control valve is adjusted to change the flow rate to match the setpoint. Developing a mathematical model for this process can be challenging, and it relies on real-time or close-to-real-time measurements for the best results.

The Gemu 44A0 multifunctional valve actuation automation module is built to simplify and enhance process automation. Image used courtesy of Gemu

There are multiple steps. The flow rate is measured, the error signal (difference between flow and setpoint) is calculated, a control signal is sent to the valve, and the valve position is adjusted by hand or machine, measuring the position of the valve to ensure the proper movement is applied. Ideally, this is done continuously.

An automated module like the Gemu 44A0 can simplify this control process. Flow measurements are sent to the control system, and the error signal is sent to a valve controller. Then, the Gemu 44A0 adjusts the position of the valve, measuring how much the valve has moved.

Gemu 44A0 Multifunctional Valve Actuation

The Gemu 44A0 automation module comes in two varieties: one for on/off control and one for precision control. On/off control provides a cost-effective alternative for repetitive operations, but perhaps not as continuous as regular process control. Filling tanks and maintaining the fluid level or constant fluid pressure might require an occasional open/close cycle, but do not require precision control, such as adjusting the flow rate of a process fluid.

Each of these smart modules is designed with retrofitting existing systems in mind. Communication is made possible through IO-Link or ASi-5 and can be accessed via a user-friendly app, reducing integration headaches. It also has built-in diagnostics to let the user know if it is experiencing a problem, which is a major upgrade from less advanced valve controllers.

The Gemu 44A0 features variants for simple open/close applications and precise valve positioning in complex applications. Image used courtesy of Adobe Stock

Another interesting feature of the Gemu 44A0 is its minimal deadleg space. With fluid flow, complicated valve control systems can accidentally isolate fluid volume between valves. This happens frequently when retrofitting an existing valve system with new control, especially when the new control system is physically bulkier and must be placed upstream or downstream from an existing valve. This deadleg space can lead to product spoilage in the food and beverage industry. The Gemu 44A0 cuts down on deadleg space by fitting on existing valve hardware.

Enhancing Process Automation

While the Gemu 44A0 can be used to design new automated flow control systems, its utility lies in retrofitting. Often, control valves are installed in small physical spaces and require separate modules for sensing and physical valve manipulation. The Gemu 44A0 combines both functions into the same compact, physical unit, simplifying installation, operation, and troubleshooting without the need to redesign piping.