NITRIDING / NITROCARBURIZING CONTROL SOLUTIONS

NITRIDING / NITROCARBURIZING CONTROL SOLUTIONS

Precise Nitriding Control for Retrofits & New Furnaces

Need to be AMS2759/10 or 2759/12 compliant?

UPC nitriding and nitrocarburizing solutions offer:

Compact, fully automatic & cost effective modules or combination of modules

  • Process Atmosphere Analysis
  • Process Control
  • Process Atmosphere Control
  • Ammonia Dissociator
  • Effluent Gas Neutralizer
  • Power Control
  • Pressure Control


MODULAR SOLUTION PACKAGE

United Process Controls'’ Solutions are modular packages customized to significantly improve your nitriding and nitrocarburizing operations, meet industry standards requirements and ultimately provide you with precise and reliable process control. We offer compact, fully automatic modules for new installations or retrofits. Each solution consists of a cost-effective module or combination of modules delivered with state-of-the-art equipment and backed by our extensive technological expertise.

FEATURES:

  • Full compliance with AMS 2750D, 2759/10A, 2759/12 (FNC), NFPA 86-C, CQI-9, Nadcap (depending on hardware purchased)
  • Latest achievements in nitriding & nitrocarburizing process control
  • Cost-effective module configurations for new installations or retrofits

SELECT A MODULE:

MODULES

PROCESS ATMOSPHERE ANALYSIS
Accurate, Continuous, Automatic Measurement

This module is based on the H2Smart™ hydrogen analyzer, an integrated system that measures dissociation with high accuracy in nitriding/nitrocarburizing process atmospheres. Its measuring cell design and advanced electronics eliminate the need for a reference gas cell, thus simplifying the installation. The intelligent sensor calculates: pH2, pNH3, pO2, pCO, pCO2, KN, KC, KO and dissociation (additional hardware or computer interface may be required).

FNC Option: The H2Smart™ used in conjunction with the Nitrocarb™
oxygen probe provides true nitrocarburizing control as well as pre- and post-oxidation.

Features:

  • High accuracy and reliability
  • Compact and robust design
  • Interfaces with SCADA systems
  • Remote configuration possible
  • Controlled sampling flow with warning and alarm
PROCESS CONTROL
Precise Monitoring, Controlling & Recording

The process control module based on the Protherm 500 / 600 or 700 universal programmable controllers for batch, multi-batch and continuous furnaces, is designed to monitor, control and record nitriding and nitrocarburizing processes.

Equipment:

  • Protherm 500, 600 or 700 controller with standard configuration
  • External I/O’s (Protherm 500, 600, 700)
  • High-limit temperature controller
  • Steel plate (mountable) or cabinet (enclosure)
  • Pre-wired with terminal blocks & isolation relays
  • Electrical drawings / user manual
  • Factory assembled and tested

Integration / Connection:

  • Integrated web server (Protherm 500, 600, 700)
  • CANopen interface
  • RS485/422 4 wire Modbus
  • Modbus / TCP interface
  • Optional Profibus slave or master
  • Seamless integration with SCADA

Advantages:

  • Precise atmosphere control (KN, KC, KO or dissociation)
  • Alarm notification and processing
  • Password protected interface
  • Real time and historical paperless chart recorder displaying process variables
  • Recipes and recipe templates can be created and modified
  • Precise temperature control (cascade mode available)
  • Internal data storage
  • PDF reports
  • Data export in CSV format
PROCESS ATMOSPHERE CONTROL
Efficiency with Automated Control

Main Components:

  • N2 emergency flow line
  • Alarm notification and processing
  • Purge flow monitoring device
  • NH3 process line
  • Optional: N2, dNH3, CO2, and others gases
  • Complete set of drawings
  • Factory assembled, prewired and tested


Process gas lines are equipped with solenoid valves, check valves, manual valves, and Waukee Valve-Tronic Plus™™ electronic flow meters.
AMMONIA DISSOCIATOR
Cost-Effective Process Dissociator

The UPC Dissociator produces gases for processes requiring hydrogen by dissociating anhydrous ammonia. When dissociated ammonia is used as an additive gas for nitriding processes or as a principal component for protective and bright atmospheres, the dissociator provides high quality atmospheres at a low cost. Sizes available for a process gas flow output of up to 170 cfh (80 l/min).
EFFLUENT GAS NEUTRALIZER
Pollution-Free Environment

Complete your nitriding or nitrocarburizing system or plant with an effluent gas neutralizer to eliminate pollution, promote environmental friendliness and comply with environmental regulations. The neutralizers are designed to eliminate residual ammonia while achieving low NOx emissions.

Benefits:

  • High efficiency
  • Fully automated operations
  • Low Operating costs
  • Low NOx
  • Compliance with environmental regulations
  • Data recording capability (optional)
POWER CONTROL
Better Temperature Uniformity

Main features:

  • Designed to customer requirements and standards
  • Free standing new cabinets or retrofits
  • Zero crossing burst-fired SCR’s for heating power control to assure highest level of EMC (Electro-magnetic compatibility)
  • High SCCR (short circuit current rating)

Main components:

  • Main disconnect switch
  • Power distribution system
  • Heating power controllers
  • Motor controllers
  • Protection
  • Factory assembled, prewired and tested
  • Complete set of drawings
PRESSURE CONTROL
Safety First

Active Option:

  • Differential pressure transducer
  • Motorized analog valve
  • On/Off solenoid back-up valve
  • Mechanical safety valve
  • Optional pressure switch
  • Complete set of drawings
  • Assembled, prewired & tested

Passive option:

  • Differential pressure transducer
  • Mechanical pressure regulating valve
  • Optional pressure switch
  • Complete set of drawings