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Translation of a Special Print from an Article published by German trade magazine chemie&more, Iss. 03.15. (ACHEMA Special)
The Connection: Pure Stainless SteelSuper Sealing in Most-sensitive Processes chemie&more in an interview with Dietrich Warmbier, ROSS EUROPA®, Langen
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Mr. Warmbier, last fall your compa-ny launched a new stainless steel connection on the market. How did the development of the ZeroCon® product range start off; in particu-lar, against the backdrop of the fact that ROSS EUROPA® is known to focus on pneumatics components and systems?
Being a globally established, widely recognized manufacturer of top qua-lity, innovative and reliable pneumatic products, we considered it a plausible step to introduce the ZeroCon® con-necting system within the framework of our permanent portfolio extensi-on. Also, this move fits the ROSS line perfectly with regard to the up-coming completion of our offering by the addition of SIL- and ATEX-certi-fied valves for sensitive processes. Our customers expect technically ad-vanced, high-quality, robust solutions. Not only are these required to be “sim-ple” in implementation, they need to be reliable in function too. With the introduction of the ZeroCon® con-necting system, ROSS demonstrates once again that innovative technical solutions don’t have to be associated with complicated handling and usage. By the way, we have been demon- strating this over the years in the field of pneumatic safety technology too. Repeatedly, we received enquiries from our customers for a high quality, absolutely leak-tight and elastomer-free connection. Very often these re-quests came in connection with ap-plications involving our DALE-Series valves. We are glad to say that with the introduction of ZeroCon® this re-quest has now been fulfilled.
ZeroCon® is made of high-grade stainless steel. What are the tech-nical features of this connecting element?
I already mentioned that ZeroCon® is absolutely leak-tight. The leak-rate determined by TÜV-SÜD’s laboratory was very near to the detection limit of the measuring device. It is less than 3.0 x 10-10 mbar l/s. Dead spaces <10µm make sure that no viruses or fungi can develop in the ZeroCon® area (by the way, the smallest fungus existing, is sized >=20µm). This analysis has been confirmed by an independent Institute. Due to the aseptic design, its high leak-tightness and the surface quality Ra <= 0,4µm, ZeroCon® is a perfect pharmaceutical barrier designed to be used in a temperature range from -273°C to +450°C and in a pressure range of 450 bar and more. The tube used is the limiting factor. Absolutely flat transition surfaces - even on tube reduction adapters - make sure that neither turbulences nor flow restric-tions occur. After the installation, the integrated leak-test bore checks the
pipe line system for leaks. The mate-rial used in the ZeroCon® production process is marked permanently on all components and can be traced back to the very first step of production. ZeroCon® is made of highest-grade stainless steel (1.4435), all welding ends are prepared for orbital welding. Before packaging, all parts are clea-ned with ultra-pure water in order to eliminate all oil particles, lubricant and loose material residues. Then the components are packaged individu-ally. All components can be supplied electro-polished, on request.
In your documentation you descri-be ZeroCon® as being „leak-tight as a welding seam“. How do you achieve the promised, absolute leak-tightness of the connection?
Absolute leak-tightness is achie-ved through a “lip seal ring” made of highest-grade stainless steel which
Stainless steel connections are essential components in process plants. They must provide installation ease, absolute leak-tightness, and impeccable functionality every day — even in highly sensitive pro-cesses. ROSS EUROPA® recently launched a brand-new stainless steel connecting system which fully meets these criteria and offers a lot more: ZeroCon®. Product manager Dietrich Warmbier highlights this innovation in the following chemie&more-VIP-Interview.
Special Print from chemie&more, Iss. 03.15 Page 2
Dietrich Warmbier in conversation with Ralf W. Dinkel, ROSS EUROPA‘s general manager
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deforms resiliently and plastically du-ring the installation. Due to its smart geometry, leaks and dead spaces are reduced to a minimum. Internal leak testing resulted in <10-14 mbar l/s leakage, which is the detection limit.
What are the benefits for the user of the connecting device, most no-tably with regard to particularly re-levant aspects such as installation, maintenance and process stability?
Anti-rotation as well as front-end fit qualities prevent the influence of external forces and moments. The ZeroCon® system can be installed ea-sily, there is no need to use specific tools as it is block-mounting, being ab-solutely leak-tight from the outset. The ND 20/G1“-connection requires a ma-ximum torque of 90Nm, spanner size 38 mm. All other connecting systems have a much lower tightening torque. It is almost impossible to overtighten the ZeroCon® unit. Due to the fact that no elastomer seals are involved, but exclusively highest-grade stainless steel 1.4435 components are used, ZeroCon® requires no maintenance ef-fort, regardless of how many times the line system is cleaned/sterilized on hot steam or other processes/detergents. High thermal conductivity during hot-steam sterilization causes the com-plete connecting system to heat up strongly; this cannot be guaranteed for elastomeric material which is associ-ated with a much lower thermal con-ductivity. In case of an elastomer seal it may be possible that individual sec-tions do not heat up sufficiently so that a complete sterilization may not hap-pen. Use of highest grade stainless steel ensures that material outgassing will not occur.
You promise superior sealing per-formance in highly sensitive pro-cesses. What industries and what applications do you have in mind?
ZeroCon® with its excellent materi-al qualities (stainless steel 1.4435), outspoken installation ease, mini-mum dead space features, as well as its aseptic design can be put to work wherever connectors are required to
meet highest usability challenges. Just to mention a few examples, the che-mical and pharmaceutical sectors are clearly in focus, but also, the beverage and food industries can profit greatly from this system. Even mechanical engineering offers an interesting ap-plication field when it comes to using costly, sensitive or aggressive media. What are the industrial standards that would apply to ZeroCon®?
For very obvious reasons, no standard can be referred to at this point in time because it is an all new connecting system on the market. We may say, however, that compared to connec-ting systems currently existing in the chemical, pharmaceutical and food segments, ZeroCon® certainly plays in a league of its own. Let me explain these claims a little further, guided by the following examples:
DIN 11864, stainless steel aseptic pipe connections involving O-Ring sealing:
It is very difficult to disinfect the O-Ring properly, and when hot-steam is used, the O-Ring’s life is clearly limited, due to embrittlement. ZeroCon® is made of solid stainless steel which can be disinfected con-veniently without any problems. And when hot-steam comes into play, ZeroCon® sealing components are not subject to aging. Due to the fact that it has no O-Ring and uses a stainless-steel sealing element, ZeroCon® does not fall under DIN 11864, but is doing considerably better. Standard DIN 11851, stainless steel connections for the food and chemical industry with plastic sealing elements:
ZeroCon® can be supplied in identical dimensions, but does not fall under DIN 11851 specifications, as it fea-tures stainless steel seals. I already mentioned embrittlement risks and bad disinfection opportunities for plas-tic seals.
ZeroCon® is 100% conforming to the requirements of EHEDG standard (EHEDG = European Hygienic Engi-neering & Design Group).
Can ZeroCon® be used under clean room conditions, or in connection with ultra-pure media?
As the ZeroCon® connection features highest-grade stainless steel 1.4435, and due to its absolute leak-tightness paired with the zero dead space fea-ture, it can be used under clean room conditions and with ultra-pure media, as long as the media do not attack the 1.4435 stainless steel used.
Dietrich Warmbier, Dipl.-Ing. (BA), studied mechanical engineering (majoring in “Construction”), at Mer-cedes-Benz Lenkungen GmbH, in-terlinked with the University of Co-operative Education in Mannheim. He earned his first laurels during his career at BITO-Lagertechnik, an in-ternationally leading manufacturer of storing systems where he gained high respect for the development of a complex shelf- and storing system. In 2008 he accepted a new professi-onal challenge at ROSS EUROPA®, assuming responsibility for the “home” distribution territory, a task he accom-plished with outspoken zeal and brilli-ance. In April 2014 the ROSS® group of companies appointed him as „Global Safety Specialist“. Soon after, he ad-vanced to become the leader of ROSS EUROPA’s globally acting specialist team. In addition to this double-func-tion, Dietrich Warmbier also oversees as a product manager the international introduction of the innovative stainless-steel connection ZeroCon®, including the coordination of product logistics and sales promotion.
Special Print from chemie&more, Iss. 03.15 Page 3
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Design Schematics and Profile of the ZeroCon® Series
ROSS®
ROSS EUROPA GmbH
Robert-Bosch-Strasse 2, D-63225 Langen
Tel.: +49-6103-7597-0 Fax: +49-6103-74694
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GLOBAL Reach with a LOCAL Touchsm
Premium Pneumatics since 1960.Variety meets Solution Skill.
The ROSS® Line at a Glance:
• Base-mounting valves conforming to all current standards• Line-mounting poppet valves; including ATEX- and SIL • Safety-related pneumatics, according to industrial standards, with BG Certificate• Double valves, press control valves, with BG Certificate• Proportional valves• Cylinders, standard and special versions• Counterbalance cylinders• Pneumatic-hydraulic power cylinders• Pinch valves, vacuum service valves, special valves• System solutions, control cabinet design• ROSS/FLEX® service, customized solutions• Industry-focused pneumatics• Ultra-tight stainless-steel connections• A broad range of accessories• Project planning, comprehensive customer service
Presumably, a high-grade connec-tion like ZeroCon® is much more expensive than a conventional stan-dard-type fitting currently found on the market.
You will be surprised to hear that this is really not the case. By using only few components, and due to high-end pro-duction, ZeroCon® can be offered very competitively, it is absolutely priced at current market levels. Certainly,
ZeroCon® can‘t really be compared with a cutting ring fitting, but — all aspects considered — the ZeroCon® system is much less costly than any connection with welding hub currently on the market.
In addition to the procurement and in-stallation expenses, you should also take into account current costs occur-ring over the full service life. You may find that a connection with elastomer
seal may sell at 10 to 20% less. But, bear in mind that elastomer seals need to be exchanged regularly in order to keep up the standards stipulated for the piping system. This does not only refer to the cost for the elastomer seal, but downtimes and related production losses as well. Metal-to-metal sealing fittings like ZeroCon® do not require an exchange of the sealing elements, which means no equipment standstill and production loss.
You propagate the use of ROSS® DALE poppet valves in combinati-on with the ZeroCon® connection. What are the applications you envi-sage and what are the benefits for your customers?
The DALE valve offering includes de-sign features perfectly suitable for leak-testing. When performing leak-testing, it is absolutely necessary that the re-sults will neither be influenced by the valves in use, nor by the piping system. Easy handling of DALE valves and ZeroCon® and their leak-tight sealing properties make these products an op-timum pairing.
Contact: [email protected]
Special Print from chemie&more, Iss. 03.15 Page 4
