Alternative Energy

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www.astsensors.com

Pressure Sensor Capabilities

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TechnologyOverview

“Krystal Bond™ Technology is the latest MEMS (Micro Electro-Mechanical System) pressure sensor technology. Using a single piece of metal and MEMS strain gages, this technology provides accurate, repeatable measurements.” - Karmjit Sidhu, Vice President Business Development, AST Co-Founder, and Material Science PhD candidate at the New Jersey Institute of Technology (NJIT).

The strain gages are molecularly diffused onto the metal diaphragm surface using inorganic materials and high temperatures. As the temperature is reduced, the inorganic bonding material solidifies and secures the silicon strain gauge into position above the center of the sensor, thus creating the one piece sensing element.

Why use Krystal Bond™ Technology?With an operating strain at less than fifteen percent (15%) of the metal’s yield point, the AST pressure sensor cell has less fatigue, higher proof/burst pressure capability, and excellent long term stability. A simple example of this is inflating and deflating a balloon several times. The stretching and distortion depends on the thickness of the balloon. The principles of pressure measurement are the same. As a diaphragm is pressurized closer to the yield point, a transformation in the shape occurs, changing the output over time. Krystal Bond™ Technology would be similar to inflating the tires on a bicycle or car with the same method.

By using inorganic materials in the process bonding the strain gages to the diaphragm, there is virtually an infinite shelf life to the pressure sensing element. AST’s strain gages also yield a high output signal with low thermal errors.

The typical pressure sensor includes a pressure port thread, hex and diaphragm. All three components for AST are a single element. A bar of metal has the outside shape machined and the inside hole bore. The media is completely contained within the sensing element. Other sensor technologies can clamp a ceramic diaphragm with an O-ring, use an oil-filled cavity to transfer pressure, or weld a diaphragm onto the pressure port. Krystal Bond™ simplifies your system with one material and no leak paths. By designing the pressure sensor cell with one piece of material, AST has eliminated weak points and contamination risks.

The AST sensing element provides a high electrical isolation with low leakage rates at 500VAC, making Krystal Bond™ Technology ideal for process control applications, including CSA certification.

Krystal Bond™ Technology can be used on a variety of materials including 17-4PH, 316L, Inconel718, and Titanium, which are designed in different package sizes to meet customer demands. From sour gas in the oil patch to medical pumps in the human body, our MEMS technology can be matched to a variety of media requirements.

Technologyby AST

TMBondKrystal

Krystal™ Bond Technology

Oil Filled

Ceramic

Thin Film / Bonded Foil

Yield Point

STRAINε

STRESSσ

ELASTICREGION

PERMANENTDEFORMATION

X “Fracture”(for metal)

0 275 με 1000 με 2000 με

TM

HISTORICAL

1

Innovator, manufacturer and seller of �

state-of-the-art Pressure, Position and Liquid

Level Sensors.

Over 120 personnel employed � at three

locations: Mount Olive, NJ, Pennsauken, NJ

and Hong Kong, China.

Over 300 years of combined � experience

in engineered sensor products for industrial,

oil & gas, aerospace and military markets.

American Sensor TechnologiesMount Olive, New Jersey USA

Macro SensorsPennsauken, New Jersey USA

Background

TM

Alternative Energy

Alternative Energy

Wind•

Hydrogen•

Solar•

Coal Bed & Methane•

Bio-Fuels & Gases•

Oil & Gas•

Extraction•

Off Shore •

Pipeline Monitoring•

Storage Tank•

Compression•

Fluid Power

Cylinders •

Pumps •

Hydrostatic Transmissions•

Forklifts •

Data-loggers •

Valves•

HVAC / Refrigeration

Freon •

Chilled Water •

Ammonia Systems•

(both stationary and mobile)

Water

Potable and Waste Water Management•

Residential and Commercial Pumps•

Sewage Lift Stations •

Water Wells•

Power Generation

Turbine Valve and Boiler Controls •

Gas Flow Measurements•

Turbine Balancing •

Steam Pressure Measurements•

Micro-Turbines for Standby Power•

2

Markets

TM

Alternative Energy

The windmill is a machine employed to

convert wind energy into electricity.

Due to their remote locations, sensors

are critical components in operation,

maintenance and safety of wind mills,

making their selection important.

Pressure sensors are used to monitor

yaw brake, lubrication oil, cooling

circuit pressure, and level in gear

boxes. Temperature sensors are also

used in the cooling circuits. Differential

pressure sensors are used to monitor the

filter condition. As the hydraulic filter

becomes clogged, the output signal

increases, thus notifying the controller to

replace the filter.

Windmills are located in

deserts, coastal areas and

mountain tops; creating a need for

universal survival of the instrumentation

and equipment installed on them.

Operating temperature for these windmills

can range from -50 to 60°C. For example,

along the coast windmills are subject

to salt mist and fog, a leading form of

corrosion. The instrumentation used to

monitor the operating conditions for the

windmill needs to run in these severe

conditions while offering reliability and

trouble free service.

Pressure sensors, differential pressure

sensors and pressure-temperature

sensors from AST are ideal for

the windmill applications. These

sensors are rugged and can be

operated over wide ranges of temperature

and environments, from deserts to

coastal plains. AST4000 offers high proof

and burst ratings with excellent EMC

protection. AST5400 offers filter condition

monitoring with linear and accurate

readings. AST20HA offers both pressure

and temperature readings from one

device, reducing process penetrations

in the hydraulic system. AST4510

measures the level of the

oil reservoir while offering

temperature output as an option.

Maintaining and monitoring the level

of oil is critical to maintain smooth supply

of power from the windmill.

3

Wind

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Alternative Energy

4

Hydrogen

Due to the small size of hydrogen ions,

the correct material compatibility and

construction of components exposed to

hydrogen media is critical. By using AST’s

proprietary Kystal Bond™ Technology,

leak paths common to other pressure

sensor designs are eliminated. AST is

capable of manufacturing pressure

sensing elements to ultra high pressure

ranges, common to hydrogen storage. By

compressing hydrogen at higher pressures,

hydrogen storage tanks become smaller,

creating a lighter, mobile system. New

materials are also being introduced to

operate in petrochemical processes

requiring hydrogen and hydrogen sulfide

compatibility.

AST sensors are designed for hydrogen

pressure measurement at filling stations.

They are used to monitor storage tank

pressure, compressor controls, as well as

the dispensing pressure. Aside from the

hydrogen media compatibility testing

on the sensing element, UL and CSA

approvals are available to ensure that

the sensor is installed within the electrical

code requirements. Depending on the

proximity to the hazardous area, AST can

offer explosion-proof, intrinsically safe

and non-incendive pressure sensors for

hydrogen filling station systems. Whether

a traditional gas station or a warehouse

using hydrogen fork lifts, the AST pressure

sensor family can support hydrogen filling

station requirements.

Storage Fueling Systems

C US

AP P R O V E D

P R O D U C T

C US

AP P R O V E D

P R O D U C T

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Alternative Energy

5

Hydrogen

Power GenerationVehicles

AST pressure sensors are a great choice

for hydrogen powered vehicles. They are

used for measuring tank pressure and the

pressure of hydrogen before it is released

into the fuel cell. AST pressure sensors

have been independently qualified for

vehicle use by TUV, UL and Detroit Testing

Laboratories. The one-piece 316L sensing

element has passed all standards for

hydrogen pressure cycles and burst

pressure requirements. AST pressure

sensors meet environmental conditions

including high pressure wash-down,

salt water submersion, dust conditions,

shock and vibration. Electrical conditions

were simulated for up to 300V/m of

EMI protection. The latest approval is

EC79 registration for hydrogen vehicle

components in Europe.

With an increased focus on environmentally

friendly products and the risk of theft of

commodity products such as diesel,

hydrogen has become a viable option

for stand-by power generation. These

units can be installed in remote areas

to provide back-up power to systems

such as cell phone towers, guaranteeing

continuous operation. AST pressure

sensors provide the technology to ensure

containment of the hydrogen to the

sensing element as well as the regulatory

approvals to maintain safety. Sensors are

typically installed to measure the manifold

pressure injecting hydrogen, as well as the

on-site storage pressure. Remote monitoring

ensures the hydrogen system is full.

C US

AP P R O V E D

P R O D U C T

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Alternative Energy

6

Solar Power

Solar power by

means of sun

catchers is a new

technique used to

generate electricity.

Each sun catcher

unit employs a highly

reflective parabolic

mirror that tracks the

sun; it concentrates

sun rays on receiver tubes containing

hydrogen gas. The hydrogen gas goes

through an exchanger to heat an internal

fluid that expands and contracts to drive a

four-cylinder Stirling engine. Each engine in

turn drives a generator.

Maintaining the hydrogen pressure is critical

to the operation of the sun catcher. The

pressure of the hydrogen will increase and

decrease as a function of the daily routine

from day to night. Pressure sensors are

employed to maintain the system pressure

and also alert in case of leakage

of hydrogen to the atmosphere. The

hydrogen pressure can range between 2,000

and 4,000 PSI. Since hydrogen corrosion

comes in two forms, permeation and

embrittlement, it is vital that the pressure

sensing elements are made from a thick

piece of 316L stainless steel with no internal

O-rings or fluid cavities. In some cases, the

safety agency approvals such as UL, CSA

and TUV are required due to the presence of

hydrogen.

AST pressure sensors

with one piece thick

316L stainless steel

diaphragms are widely

being used in the

hydrogen applications for

forklifts, buses, cars, fuel cell

stacks, storage, generation

and H2-H2S service. These units have been

tested and certified by TUV, CE, CSA and

UL for safe and demanding operations

worldwide.

TM

Alternative Energy

7

Coal Bed & Land Fill Methane

Coal bed methane (CBM) or coal bed gas

is a form of natural gas extracted from coal

beds. In recent decades it has become

an important source of energy in North

America and other countries. To extract

the gas, a steel-encased hole is

drilled into the coal seam

(100 – 1500 meters below

ground). As the pressure within

the coal seam declines due to natural

production or the pumping of water from the

coal bed, both gas and ‘produced water ’

come to the surface through tubing. Then,

the gas is sent to a compressor station and

into natural gas pipelines. The ‘produced

water ’ is either re-injected into isolated

formations, released into streams, used for

irrigation, or sent to evaporation ponds. The

water typically contains dissolved solids such

as sodium bicarbonate and chloride.

Landfills are the largest source of U.S.

anthropogenic methane emissions.

Landfill methane is produced when

organic materials (such as yard

waste, household waste, food waste, and

paper) are decomposed by bacteria under

anaerobic conditions (i.e., in the absence of

oxygen). Methane production varies greatly

from landfill to landfill depending on site-

specific characteristics such as waste in

place, waste composition, moisture

content, landfill design, operating

practices, and climate. Unless

captured first by a gas recovery

system, methane generated by the

landfill is emitted when it migrates through

the landfill cover. During this process, the soil

oxidizes approximately ten percent of the

methane generated, and the remaining 90

percent is emitted.

AST pressure transmitters, certified and listed

by UL and CSA to Class 1 Div1 and Class 1

Div 2 such as AST4300, AST4400, AST4600

and AST46HA are ideal for use in pipeline,

compressors, plungers, micro-turbines and

storage of methane. For

water level monitoring

and evaporation tanks,

AST4500, AST4510 and AST4520

submersible level sensors are use with

Class 1 Div 1 approvals. Since most of the

applications are outdoors, these units are

sealed against rain ,snow, sleet, dust, wide

range of ambient temperatures and EMC.

TM

Alternative Energy

Bio-fuels are a type of fuel derived from biomass; including solid biomass, liquid fuels and various bio-gases. Bio-fuels are gaining public and scientific attention, driven by factors such as oil price spikes, the need for increased energy security, and concern over greenhouse gas emissions from fossil fuels.

Bio-ethanol is an alcohol made by fermenting the sugar components of plant materials and is made mostly from sugar and starch crops. With advanced technology being developed, cellulosic biomass, such as trees and grasses, are also used as feedstock for ethanol production. Ethanol can be used as a fuel for vehicles in its pure form, but it is usually used as a gasoline additive to increase octane and improve vehicle emissions. Bio-ethanol is widely used in the USA and in Brazil. Bio-diesel is made from vegetable oils, animal fats or recycled greases. Bio-diesel can be used as a fuel for vehicles in its pure form, but it is usually used as a diesel additive to reduce particulate levels, carbon monoxide, and hydrocarbons from diesel-powered vehicles.

Bio-gas is methane produced by the process of anaerobic digestion of organic material by anaerobes. It can be produced either from

biodegradable waste materials or by the use of energy crops fed into anaerobic

digesters to supplement gas yields. The solid by-product, digestate, can be used as a bio-fuel or a fertilizer. Bio-gas

can be recovered from mechanical biological treatment waste processing systems.

Syn-gas, a mixture of carbon monoxide and hydrogen, is produced by partial combustion of biomass, that is, combustion with an amount of oxygen that is not sufficient to convert the biomass completely to carbon dioxide and water. Syn-gas may be burned directly in internal combustion engines or turbines.

AST pressure sensors and transmitters with 316L wetted

parts are ideal when used in bio-fuel and gas applications. Both hazardous

location approved and regular UL listed pressure sensors may be used, subject to the location and close proximity to the gas source.. For low pressures, AST models AST43LP and AST44LP will offer full protection while using corrosion resistance 316L sensing element.

8

Bio Fuels & Gases

TM

SALES

1. Orders must be placed in writing with American Sensor Technologies, Inc. (“AST”) in New Jersey, USA, and may be sent via fax (973) 448-1905 or e-mail (info@astsensors.com). Current manufacturing and shipment lead times apply.

2. All shipments are made F.O.B. Shipping Point via UPS Ground. Other methods of shipment may be requested by the customer. All freight and insurance is prepaid by AST and is added to customer’s invoice. International shipments that are subject to customs charges, duties, bank fees and other such fees are the responsibility of the customer.

3. AST’s prices are subject to change without prior notice. Prices quoted at time of order confirmation will be honored by AST at time of shipment unless written notice is given to customer in advance.

4. Custom Designed Parts may be subject to Non-Recurring Engineering charges (“NRE”), which will be quoted prior to order acceptance. Custom Designed Parts may require cash deposit with order and may not be cancellable.

5. All shipments require payment by either C.O.D., Credit Card or Cash in Advance unless Open Credit Terms are established with AST. International shipments under $2,000 are subject to a $30 payment service fee. To consider Open Credit Terms, AST requires the customer to complete a credit application form.

6. Terms of Payment are Net 30 Days (Strictly enforced to maintain credit privileges). A Service Fee of 1.5% per month (18% annually) will be assessed on all accounts past due terms of payment.

7. Order cancellations and product modifications must be requested in writing at least 3 weeks prior to order shipment due date and must be accepted and acknowledged by AST. A cancellation or modification charge may apply.

8. Returns for warranty service require AST’s issuance of a Return Material Authorization (“RMA”) number. All product must be returned in original factory packaging. Units modified or showing evidence of abuse are not covered by AST’s warranty terms.

9. All other product returns require AST’s issuance of a RMA number and are subject to a 25% restocking charge. Custom, discontinued, used or outdated products cannot be returned.

10. Products purchased through an authorized AST distributor must be serviced through that distributor. AST cannot accept returns or issue credit to distributor ’s accounts.

11. Sales are subject to the Uniform Commercial Code under the jurisdiction of the state of New Jersey, USA.

12. Special Terms and Conditions of Sales may apply to specific customer contracts, stocking arrangements and partnership agreements.

Standard Terms and Conditions

TM

CONTACTPressure & Position Products

www.astsensors.com © 2010 American Sensor Technologies, Inc. BOOKLET_ALTENERGY 12/16/10

All specifications subject to change without notice.

PressureAmerican Sensors Technologies

450 Clark Drive Mount Olive, NJ 07828 USA

Phone: 973-448-1901 / Fax: 973-448-1905

Web: www.astsensors.comEmail: info@astsensors.com

PositionMacro Sensors

7300 US Route 130 North, Building 22Pennsauken, NJ 08110-1541 USA

Phone: 856-662-8000 / Fax: 856-317-1005

Web: www.macrosensors.comEmail: lvdts@macrosensors.com