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Hycontrol Foam Detection & Foam Control Systems

South Fork Instruments supplies foam detection systems manufactured by Hycontrol Limited, a UK-based company with more than 40 years of experience in developing industrial level measurement systems. These systems are specifically designed to detect and measure foam and are the most reliable foam detection and control systems in the world. Their benefits include huge reductions in the use of anti-foam products, increased batch sizes, reduced environmental pollution, and significantly improved production efficiency.

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How do Hycontrol’s SureSense+ systems control foam?

The SureSense+ system is specifically designed for measuring foam presence, depth, and thickness, detecting the foam-liquid interface, and accurately measuring liquid level while ignoring any foam present in real time.

The system’s unique level sensor design can be used to control foam in a wide variety of applications across many industries. Reliable measurement leads to real cost reductions and in many cases, increased yield and production efficiency. Some users report a reduction of anti-foam agent of at least 75% after implementing reliable foam measurement solutions.

Hycontrol Suresense Control Unit

Uncontrolled foam generation is a problem for many industries. In addition to the mess “foam over” or “foam out” events can make in and around plant, uncontrolled foam generation can increase processing costs, reduce productivity, cause damage to rotating equipment and create environmental issues.

The installation of reliable foam detection and control instrumentation in the pharmaceutical, wastewater, O&G and food and beverage industries has been extremely effective in reducing defoamer chemical cost while improving productivity/quality, protecting expensive and critical process equipment and removing environmental pollution risk.

How does IMA foam control work? Expand
  1. A foam sensor is fitted through the top (or the side) of a process vessel. The sensor is connected to a foam controller, which in turn is connected to a pump controlling the flow of antifoam into the vessel.
  2. As the process begins, foam starts to form on top of the liquid.
  3. As the foam level increases, the sensor signals back to the controller that foam has been detected. The ‘sense’ light illuminates on the controller to indicate the increasing level of the foam.
  4. When the foam reaches a pre-set level, the sensor signals the controller to start adding antifoam. The ‘activate’ light on the controller illuminates to indicate that action is being taken to reduce the foam.
  5. Because the sensor and controller are very sensitive to foam levels, the antifoam is only added as required, the amount of antifoam used is strictly regulated, producing significant cost savings.
  6. With the level of foam now returned to normal, the antifoam pump stops, leaving the sensor and controller on standby until the cycle starts again.
What have been the shortcomings of alternative foam detection techniques? Expand

A variety of techniques have been applied to the challenge of accurate measurement and reliable control of foam levels:

  • Radar type level systems mounted in the top of a vessel can be tuned to see the topmost layer of a process, but can be fooled if any foam layer becomes lighter or if the process liquid becomes denser or more reflective.
  • Microwave level sensors will more likely than not acquire the level of the liquid below any foam layer.
  • Admittance or capacitance technology probes can be quite successful in detecting the presence of foam as point level devices, but cannot distinguish between foam and liquid and most will be disabled if they become coated with process material, giving continuous false positive indication. In any case, once foam is detected by such systems, and depending upon the height it is set above the process, it can be too late to prevent a “foam-out” situation where vessel overheads are filled with process material, causing blockage of filters and build-up and contamination in vent lines. This is particularly an issue for bioreactor operations where liquid levels can vary through a batch, and foam generation can be rapid and sometimes unexpected.
  • The over-riding problem with these methods is that the instrumentation used is designed to measure liquid level, not foam level. Foam is about 1% liquid, so it’s not surprising that liquid level instruments struggle to reliably measure foam level.
How does SureSense+ deal with probe fouling? Expand

Product fouling and deposits on a measuring probe are common in many foaming applications, and have a serious impact on foam measurement.

Hycontrol’s IMA technology out-performs other detecting techniques, as it operates efficiently and repeatably even when the probe becomes heavily fouled with residual product.

The SureSense+ foam control system uses a special guard electrode which nullifies the desensitizing effect of accumulated fouling on the probe. With the effects of fouling removed, the main foam sensor is able to ignore the product buildup, and only monitor the foam within the process. Regardless of how dense or sticky the fouling on the sensor becomes, the Hycontrol foam sensor continues to function, providing accurate, repeatable, and reliable foam control.

The IMA-equipped Hycontrol SureSense+ sensor shown in the photo below continued to operate as designed, providing accurate foam measurement, despite the severe buildup evident in the photo.

Hycontrol Suresense Rejects Coating and Contamination

How has Hycontrol’s intelligent multi-action (IMA) technology changed foam detection? Expand

Many of the techniques tried up to now to improve visual and manual monitoring of foam level have fallen short. The main issues have been process fouling of single-point systems rendering the detection method non-operable until cleaning can be implemented, and the inability of continuous level systems to distinguish between liquid level and foam layer.

The introduction of intelligent multi-action (IMA) technology by Hycontrol is a major turning point in the ability of foam sensing systems to provide reliable measurement for foam control strategies. Foam detection probes with IMA sensing capability have a separate guard sensor that detects when the probe is coated with process material, essentially nullifying its effect and maintaining the measurement on line. The IMA technique prevents false positives and therefore overdosing of the process with defoaming agent.

What does IMA foam control look like in real-world use? Expand

In food processing, raw materials are processed and prepared for consumers around the world. These photos show how foam can be a real problem in a pea processing plant. The peas are washed and then cooked prior to flash freezing or canning. As peas are cooked, a great deal of foam can be generated, and this gets into the cooker vent pipes and overheads, impeding process efficiency.

Antifoam additives are often used to control “foam-outs”, but without reliable foam measurement, are often ineffective due to overdosing or foam detection errors which arise when foam sensors have been coated. Using a Hycontrol foam sensor with IMA technology allows the addition of just the right amount of antifoam agent to knock down the foam layer and prevent foam from spreading through the plant, cutting costs, cleanup, and downtime.

Before installing IMA-equipped Hycontrol foam control systems:

IMA - Before Foam Control

After installing Hycontrol systems:

IMA - After Foam Control

See the difference for yourself!

Have more questions? Take a quick moment to get in touch with our expert sales engineers and technologists and we'll guide you to a solution.

THE HYCONTROL SURESENSE+ PRODUCT LINE ALLOWS FOR UNPARALLELED RELIABILITY IN DETECTING AND CONTROLLING AQUEOUS FOAM.

SureSense+ systems are designed to operate reliably even with heavy coating and buildup on the sensing elements. SureSense+ units work with up to three sensing points in total, either within a single vessel or spread across three separate vessels. SureSense+ systems are used extensively for the detection and control of foam, reducing the consumption of chemical antifoam additives in a wide variety of processes and industries.

SureSense+ Foam Controller Expand

Hycontrol Suresense Foam Detection and Control SystemThe SureSense+ controller utilizes unique IMA sensing technology to ensure reliable operation even in the presence of severe sensor fouling. To discriminate between the continuous presence of foam and splashing or other spurious triggers, there is an adjustable response time function. When foam is detected, one of three user selectable control methods—off/on dosing, shot and delay dosing, or proportional/integral control—can be used to trigger operation of a pump or valve to start antifoam chemical addition. Liquid level can also be detected and reported via a status output.

Units can be connected to supervisory control systems or other control elements to enable foam control using vacuum valve setting or gas flow regulation. Volt-free contacts can be used for point detection, alarm status or to control dosing pumps and valves directly. An analog output is available for amount of foam present indication. The display on the controller provides at-a-glance status of all inputs and outputs.

  • Power supply: 12 - 30Vdc
  • Response time: 1 - 60 seconds
  • Chemical shot time: 1 - 60 seconds
  • Foam Sensitivity: 0 - 100%
  • Fouling Sensitivity: 0 - 100%
  • Liquid Sensitivity: 0 - 100%
  • Fouling Immunity: 200:1 foam to fouling
  • Outputs: 5 x relay contact output 230Vac/30Vdc/5A
  • 4-20mA analog output
  • Enclosure rating: IP65
  • Dimensions: 235x185x119mm (9.25 x 7.3 x 4.7”)
  • Cable entries: 6 x compression type glands

SureSense+ sensors are built to use Hycontrol’s patented IMA sensing technology, which provides reliable detection of foam, even when coated or fouled with process material. SureSense+ sensors are available with one, two or three sensing points to suit individual process requirements. Mounting is simplified by the wide variety of process connection types available and process compatibility served through different wetted material types. Sensors can be customized for length and shaft diameter or supplied so they can be adjusted for height in-situ. Hygenic SureSense+ sensors are steam sterilizable and autoclavable.

  • Stainless steel/PEEK wetted materials are standard, Hastelloy C-276 and others optional
  • Aluminum, plastic, stainless steel, PEEK (autoclavable) connection head options
  • Ø12mm and Ø20mm shaft options
  • Standard lengths from 150mm to 3m / 6” to 118”. Custom lengths available
  • BSP, NPT, ANSI Flange, DIN Flange, Ingold Port, Triclamp, PG13.5 process connections available
  • pressure: 10 bar / 145 psi
  • temperature: 150°C / 302°F continuous
  • Optional electropolish finish
  • Process seal options of EPDM (FDA / USP VI), Silicon, FPM, FFKM
  • Max cable length: 100m / 328’

View Data Sheet

SmartFoam Sensor Expand

SmartFoam single point detection probes are designed to measure the presence of foam on top of liquids in tanks, pits and vessels. Each SmartFoam probe consists of a sensing element and a head mounted electronics unit. Output is via a simple dry contact relay.  The relay closes whenever foam is detected and can be used to signal an alarm or to trigger the operation of a control actuator such as an antifoam additive pump. Its simple design affords rapid installation at minimal cost.

SmartFoam Sensor

SmartFoam probes utilize Hycontrol’s patented IMA technology that ignores the common problem of process coating on the probe.  The ability to ignore even heavy coatings provides reliable and consistent detection in even the most difficult conditions. Both detection response time and sensitivity are easily adjustable on site.  Sensitivity is adjusted to suit the type of foam (i.e. heavy or light) forming on the process.  Response time prevents false positives from liquid splashes from agitators, falling streams etc., ensuring consistently reliable performance of the instrument.

  • Power supply: 24Vdc
  • Adjustable response time: 1, 6, or 25 seconds
  • Adjustable sensitivity: 0 - 9 (0 = light foam, 9 = heavy foam)
  • Outputs: 1 x dry contact relay output 24Vdc/400mA
  • Enclosure rating: IP66
  • Probe diameter: 20mm
  • Process connection: ¾” BSP (G ¾”) or ¾” NPT
  • Probe material: 316 stainless steel with PVDF insulators
  • Standard probe lengths: 500/750/1000/1500mm (19.7/29.5/39.4/59.1”) probe lengths available
  • Custom probe lengths available
  • Max temperature: 70°C / 158°F
  • Max pressure: 1.5 bar/ 22 psia

Have more questions? Take a quick moment to get in touch with our expert sales engineers and technologists and we'll guide you to a solution.

Why is Hycontrol SureSense+ different from other foam detection solutions?

In so many cases, liquid level systems are press-ganged into service for foam measurement but as foam is only 1% liquid, they really don’t work very well and when coated with process media, quickly become unreliable. Liquid level probes are not designed for continuous foam measurement applications.

SureSense+ is designed specifically to measure foam and provides the ultimate solution for reliably controlling process-generated foam. Using Hycontrol’s unique IMA sensing technology, SureSense+ ignores probe fouling and build up, continuing to operate even in the presence of heavy process coatings on their active elements.

A SureSense+ probe can have one, two or three individual sensing points.  Each control unit can work with up to three sensing points in total, either on the same probe or spread across probes in separate vessels. SureSense+ probes can be mounted either horizontally or vertically, and are pressure resistant to 10 bar, temperature to 150°C.

Each SureSense+ control unit has five relay outputs configurable for a variety of functions including foam detection, dosing control, high level indication and liquid level detection. Its clear display has user friendly menus for ease of programming and use. Each SureSense+ unit is available with a selection of foam probe lengths, mounting/process connections, and materials.

SureSense+ foam detection and control can reduce antifoam chemical use, help protect rotating equipment, improve process quality, and increase productivity through decreased downtime.

SOUTH FORK INSTRUMENTS IS COMMITTED TO SOLVING YOUR FACTORY AND PROCESS AUTOMATION CHALLENGES

Using effective communication and an in-depth understanding of your industry to develop practical solutions for your measurement needs.

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