flowcontrol201106 dl
DESCRIPTION
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JUNE 2011 Vol. XVII, No. 6 • www.FlowControlNetwork.com
Refl ections From a Pioneer of Flow • Pump Guy Goes Sherlock Holmes • Pipe Flow Problems Solved
POSSIBLEMISSION:
®
JUNE 2011 Vol. XVII, No. 6 • www.FlowControlNetwork.com
®
®®
Innovation20112011AWARDS VOTE
NOW!
MASTERING ‘Hot Cutover’ Analog-to-Digital Valve Conversion
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The 2011 Flow Control Innovation Awards nominees
highlight the year’s most compelling
fluid handling technol-ogy advances.
june 2011
features12 Mission Possible
analog-to-digital valve upgrades
20 2011 Flow Control Innovation Awards and the nominees are …
34 Ge F. Fischer Tells It His Wayreflections from a pioneer of flow measurement
37 Flow Problems Solved forum selections from pipeflowcalculations.com
Vol. XVII, No. 6
Flow Control (ISSN #1081-7107) is published 12 times a year by Grand View Media Group, 200 Croft Street, Suite 1, Birmingham, AL 35242.
A controlled circulation publication, Flow Control is distributed without charge to qualified subscribers. Non-qualified subscription rates in the U.S. and Canada: one year, $99; two year, $172. Foreign subscription rates: one year, $150; two year, $262. Wire Transfer: $180. Please call or e-mail the Circulation Manager for more wire transfer information. Single cop-ies $10 per issue in the U.S. and Canada. Single copies $15 per issue in all other countries. All subscription payments are due in U.S. funds.
Canada Post: Publications Mail Agreement #40612608. Canada Returns to be sent to Bleuchip International, P.O. Box 25542, London, ON N6C 6B2.
POSTMASTER: Send address changes to: Flow Control, PO BOX 2174 Skokie, IL 60076-7874. Periodical postage rates paid at Birmingham, AL 35242 and additional mailing offices.
© Entire contents copyright 2011. No portion of this publication may be reproduced in any form without written permission of the publisher.Views expressed by the bylined contributors should not be construed as reflecting the opinion of this publication. Publication of product/service information should not be deemed as a recommendation by the publisher. Editorial contributions are accepted from the fluid handling industry. Contact the editor for details. Product/service information should be submitted in accordance with guidelines available from the editor. Editorial closing date is two months prior to the month of publication. Advertising close is the last working day of the month, two months prior to the month of publication.
plus45 REFERENCE SHELF
46 ADVERTISER INDEX
46 PRODUCT INDEX
Innovation20112011NOMINEENOMINEENOMINEENOMINEENOMINEENOMINEE
®
Transitioning from analog to digital valve positioners is a move more and more end-users are effectively taking on.
20
12
34
columns 4 VIEWPOINT keeping it simple
10 APPLICATIONS CORNER part IV: vortex flowmeter postmortem
40 THE PUMP GUY pump problem solved through observation & deduction
departments 6 NEWS & NOTES the secret behind nist’s gas detector; fieldbus foun-
dation releases flow transducer block; cement plants to spend $2.6 bil. on pollution controls; process automation market to rise through 2011 …
47 THINK TANK pressure regulators
48 QUIZ CORNER measuring fluid viscosity
®
Ge F. Fischer, founder of the Instromet Group, has had a long and storied career in the flow measurement business, and he still may have a trick or two up his sleeve.
2 June 2011 Flow Control
SUbSCRIPTION INFORMATIONToll Free: 866.721.4807Outside US: 847.763.1867Mail: P.O. Box 2174Skokie, IL 60076-7874E-mail: [email protected]
Subscribe/Renew/Change of Address:www.flowcontrolnetwork.com/subscribe
On the Cover: The digital valve positioner shown on the cover is courtesy of GE Energy (ge-energy.com).
FC-0611-TOC.1.indd 2 5/31/11 10:42 AM
Fluid control solutions. Right. Now.For ultra-reliable performance and delivery, turn to ASCO: the world leader in solenoid valve technology. Our fluid automation offerings control flows of air, gas, water, oil, and steam across the globe. Recent innovations include microminiature designs, low-power solenoid valves, and position indicators with network communications capabilities. With tens of thousands of models available, you’ll find just the right solutions for your demanding application. Some last up to 500 million cycles; many are shipped within 1 day with our ASCO Today program. When you must have the highest productivity, lowest cost of ownership, and greatest asset availability. You’re looking at it: ASCO.
I NEED SOLUTIONS, NOT EXCUSES.Your products must perform perfectly, right from the start. And be delivered on time,every time. If those terms don’t work for you.
You won’t work with me. Period.
1-800-972-ASCO (2726) | www.asconumatics.com/RightNow | e-mail: [email protected]
The ASCO trademark is registered in the U.S. and other countries. The Emerson logo is a trademark and service mark of Emerson Electric Co. © 2011 ASCO Valve, Inc.
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4 June 2011 Flow Control
viewpoint
Keeping It Simple® ®
WINNER
PUBLISHERJohn P. harris | (205) 408-3765
ASSocIAtE PUBLISHERMiChaEL C. ChrisTian | (732) 200-5963
EdItoR-In-cHIEfMaTT MiGLiorE | (610) 828-1711
coPyEdItoRsCoTT nEsMiTh
coLUmnIStSLarry BaChus;
DaViD W. sPiTZEr; JEssE yoDEr
ARt dIREctoRJuLiE FLynn
mARkEtIng mAnAgERMary BETh TiMMErMan
SUBScRIPtIon REQUEStS:[email protected]
foR REPRIntS, contAct:[email protected]
Administrative teamgEnERAL mAnAgER
Barry LoVETTE
VIcE PRESIdEnt of oPERAtIonSBrEnT KiZZirE
VIcE PRESIdEnt of mARkEtInghanK BroWn
dIREctoR of cIRcULAtIon & fULfILLmEntDELiCia PooLE
ASSocIAtE dIREctoR of cIRcULAtIonBranDy PaTE
cIRcULAtIon mAnAgER, ELEctRonIc PRodUctS
sTaCiE MurPhrEE
VIcE PRESIdEnt of fInAncEBraD younGBLooD
EdItoRIAL AdVISoRy BoARdLarry Bachus: Bachus Company inc.Gary Cornell: Blacoh Fluid Control
Jeff Jennings: Equilibar LLCPeter Kucmas: Elster instromet
Jim Lauria: amiad Filtration systems James Matson: GE Measurement & ControlJohn Merrill, PE: EagleBurgmann industries
Jerry stevens: Endress+hauser u.s.David W. spitzer, PE: spitzer and Boyes LLC
Tom Tschanz: Mcilvaine CompanyJohn C. Tverberg: Metals and Materials
Consulting EngineersJesse yoder, Ph.D.: Flow research inc.
WINNER
WINNER WINNER
as i sit here on the morn-ing of the u.s. Memorial Day holiday, it occurs
to me that i am truly thank-ful to have the opportunity to address you in this fashion. after what has been a long few years of economic uncer-tainty, there are some positive reports starting to emerge that signal a return to a more stable business climate. For example, a recent report by the american Machine Tool Distributors’ association and the association for Manufacturing Technology showed manufacturing consumption through March is up 118.6 percent over the year prior. and while there are major economic issues that still need to be resolved – such as looming debt crises and unemployment in the united states and Europe – i can feel myself start-ing to breathe a little easier.
as thankful as i am to have been among the lucky ones who emerged from this Great recession with my professional life intact, ialso recognize the quest for survival is not over – it never is. if anything, the recent troubles of the global economy have shown us that we cannot afford to be complacent; we must constantly look for ways to improve. That said, in the complex and ever-changing world in which we operate, it can be difficult to navigate the road toward improvement. My advice is to keep it simple.
in my opinion, our recent economic struggles have a lot to do with making things more complicated than they need to be. For example, let’s consider the mortgage crisis here in the united states. a mortgage, in its most basic sense, is generally a loan designed to enable a person to purchase a house. on the lender’s side, success is deter-mined by the complete repayment of that loan with interest. on the borrower’s side, success is determined by the ability to pur-chase a home that meets the domestic need at a rate of repayment that will be affordable over the life of the loan. somewhere along the line, the parties on both sides of this equation lost their way and rationalized ill-advised strategies that produced loans that,
on the lender’s side, were unlikely to be repaid and, on the borrower’s side, were unlikely to be affordable over their term.
in a world where we are all struggling to find new ways to support our busi-nesses, it is not uncommon for folks to lose sight of their core mission when tempted by the promise of financial benefit. ironically, this is, in my opinion, the point at which
businesses are at the highest risk of financial ruin. This is to say, when a business loses sight of the product or service it is designed to provide and begins to pursue monetary gain without clearly considering how deci-sions along this line will affect the quality of the product or service delivered, then it is compromising its long-term viability.
Going forward, as i look for ways in which i can be better at my job, i’ll keep this “les-son learned” in mind. My job, in its most basic sense, is to provide relevant, informa-tive, and interesting content to professionals involved with fluid handling applications. To do my job better, each decision i make in my professional life should be evaluated based on whether or not it will positively, negatively, or neutrally affect the content we provide.
in my opinion, if we were all to define our jobs in their most basic sense and to evalu-ate the decisions we make based on how they affect the quality of the jobs we do and our organization’s end product or service, our businesses would be stronger and more resilient. on the other hand, if we allow our-selves to be distracted by what some may describe as the “complexities of modern business,” we are entering into a risky area where it is far easier to rationalize ill-advised strategies that may be doomed to failure.
as we kick off the summer months and hopefully continue along a path toward eco-nomic recovery worldwide, here’s to keeping it simple. FC
– Matt Migliore, [email protected]
VGG r a n D V i E W M E D i a G r o u P
WINNER
FC-0611-CA.1.indd 4 5/31/11 10:37 AM
If you’ve paid for automatic control valves,none of your loops should have to be in manual mode.
There must be a better way.
Loops in manual mode due to poor-performing rotary valves require constant operator
attention. And they cost you process effi ciency. You can expect better control from the
new Fisher® Control-Disk™ valve from Emerson. The Control-Disk valve has double the
control range of traditional butterfl y valves to allow control closer to the target set point,
regardless of process disturbances. You can keep your loop in automatic mode. With low
maintenance requirements and availability to ship in two weeks, it’s time to put a
Control-Disk valve in your loop. Visit www.Fisher.com/ControlDisk to watch an
animation video or download a brochure.
The Emerson logo is a trademark and service mark of Emerson Electric Co. © 2011 Fisher Controls International LLC MV20-CD210
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EmersonFisher.indd 5 5/24/11 1:48 PM
Trace gas detection, the ability to detect a scant quantity of a particular molecule — a whiff of formaldehyde
or a hint of acetone — in a vast sea of others, underlies many important applica-tions, from medical tests to air pollution detectors to bomb sniffers. Now, a sen-sor recently developed* at the National Institute of Standards and Technology (NIST, nist.gov) that is hundreds of times faster and more sensitive than other simi-lar technologies may make such detectors portable, economical and fast enough to be used everywhere.
According to NIST investigators, the new sensor overcomes many of the diffi cul-ties associated with trace gas detection, a technique also used widely in industry to measure contaminants and ensure quality in manufacturing. A trace level of a particular
gas can indicate a problem exists nearby, but many sensors are only able to spot a specifi c type of gas, and some only after a long time spent analyzing a sample. The NIST sensor, however, works quickly and effi ciently.
A major hurdle the new technol-ogy overcomes is that it is now possible to look at nearly all pos-sible gas molecules instantly using terahertz frequencies. Previously, it was necessary to expose molecules to a vast range of terahertz frequen-cies — slowly, one after another. Because no technology existed that could run through the entire frequen-cy band quickly and easily, the NIST team had to teach their off-the-shelf equipment to “chirp.”
The NIST team has applied for a patent
on its creation, which can plug into a power outlet and should be robust enough to sur-vive in a real-world working environment.
The Secret Behind NIST’s New Gas Detector
news & notes
Graph shows the NIST detector’s linear increase in frequency as a function of time, sweeping from 550-561 Gigahertz in frequency over 100 nanoseconds.
Image courtesy of Plusquellic, NIST
6 June 2011 Flow Control
New hazardous air-pollution rules for U.S. cement plants will boost the market for air pollution control in the United States, as will infra-structure growth in the develop-ing world, according to market analysis by McIlvaine Company (mcilvainecom pany.com).
Despite the boost from the new U.S. rules, McIlvaine says the U.S. market will be smaller than the Chinese market through 2014. The United States will lead in pur-chases of scrubbers and thermal oxidizers, but fabric fi lters will be the larg-est equipment category.
The cement plants around the world are increasingly utilizing fabric fi lters for cleaning the gas from the kilns. Formerly, electrostatic precipitators were used for this application. For many years, fabric fi l-ters have been used for coal grinding and material-transfer points. McIlvaine says large cement plant suppliers are frequently furnishing fabric fi lters as an integral part of new plants they are building, regardless
of whether they are in a developed or a developing country.
SO2 is of increasing concern in the United States and Europe, and, as a result, McIlvaine says wet limestone scrubbers will be a popular choice in the United States. For Cement MACT rule Relative to NOx control, selective non-catalytic reduc-tion is expected to be the most popular choice. However, the equipment cost is low. The big cost is in the area of ammo-nia injection.
There is also expected to be a signifi -
cant market for activated carbon in the U.S. The EPA expects most U.S. plants to install activated carbon injection systems to remove mercury. This could result in boosting total activated carbon sales in the United States by 5 percent to 10 percent, according to McIlvaine.
Kerogen (organic chemical compounds) in the limestone calcined to make cement is vaporized and, as a result, forms toxic organic air pollutants. The EPA expects many plants to install thermal oxidizers to destroy these emissions.
trendlines
Cement Plants to Spend $2.6 Bil. Per Year On Air Pollution ControlsAvg. Annual Air Filtration Equip. Expen-ditures in Cement Industry, Worldwide
2011-2014 (MILLION $)
Scrubber $350
Thermal Oxidizer $150
Fabric Filter $1,800
Electrostatic Precipitator $105
SCR $120
SNCR $100
Avg. Annual Air Filtration Equip. Expenditures in Cement Industry, Worldwide 2011-2014 (MILLION $)
Air Filtration Equipment
$900
$800
$700
$600
$500
$400
$300
$200
$100
$0
■ US ■ China ■ ROW
Fabric Filter
Mil
$/ye
ar
Electrostatic Precipitator
SCR SNCR Scrubber Thermal Oxidizer
Source: McIlvaine Company
FC-0611-DA.1.indd 6 5/27/11 12:44 PM
Your livelihood runs through it. What’s behind it can make all the difference. If it’s a flowmeter from Hoffer, you can be sure it’s precise, dependable,
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news & notes
Promising signs continue to point toward a sustained process automation mar-ket recovery to continue through 2011, according to a report by ARC Advisory Group (arcweb.com). During 2010, the automation market was at the point where suppliers serving the installed base with MRO activities fared better than those relying heavily on project business. As such, ARC says suppliers ate through a huge chunk of their project backlog and fi nished product inventory while new proj-ects were postponed or cancelled during the recession.
Also, shipments for many new project orders received during 2010 were delayed until 2011. ARC expects the tepid growth seen during 2010 to accelerate in 2011, but remains skeptical about the process automation market reaching pre-recession growth levels. Historically, the process automation market has been characterized by slow yet steady growth, and ARC says it expects the market will return to this pattern with an overall CAGR (compound annual growth rate) of roughly 6 percent over the fi ve-year period of 2009-2014.
Suppliers with quick access to raw mate-rials and components and an effi cient supply chain to enable quick ramp-up of production and inventory will be in the best position to participate in the increase in demand, notes ARC.
Purchasing managers’ indexes (PMIs) provide a good barometer of overall health in the manufacturing and automation markets. PMIs typically include data, such as production level, new orders, supplier deliveries, inventories, and employment level. A PMI reading below 50 indicates a general contraction in the manufacturing economy being measured, while any read-ing over 50 indicates expansion. The J.P. Morgan global manufacturing PMI edged up to 57.8 from 57.1 in January, mark-ing the second-fastest reading ever in the global gauge, which is based on other surveys covering over 7,500 purchasing managers in nearly 30 countries.
Output and new order components accelerated, and the input price gauge rose to 76.7 from 73.3 in January, accord-ing to ARC. The U.S. ISM represents 28.6 percent of the gauge, followed by Japan
at 12.3 percent, China at 7.4 percent, Germany at 5 percent, and the UK at 4.2 percent.
As the economy recovers, ARC says automation suppliers must make plans to make the necessary changes and emerge as stronger organizations that are able to meet renewed demand. However, this con-fi dence will only come if there is a clear understanding in their organizations about the long-term trends that drive demand for automation and develop strategies to satisfy those demands.
The Fieldbus Foundation (fi eldbus.org) released the FOUNDATION fi eldbus Flow Transducer Block Final Specifi cation (FF-908 FS 1.0), which includes a standard-ized fl ow transducer block with a totalizer function. This specifi cation is designed to enable greater consistency in fi eldbus device setup, confi guration and mainte-nance, and to make it easier for end-users to utilize instruments from a range of automation equipment suppliers.
Transducer blocks are an integral part of FOUNDATION technology, providing diagnostic and maintenance data such as calibration dates. They also provide infor-mation regarding the measurement prin-ciple used, such as a Coriolis fl owmeter or a differential-pressure transmitter. The transducer block provides a link between
the local input/output blocks required to read sensors and command output hard-ware from the function blocks.
The Fieldbus Foundation’s Flow Transducer Block Specifi cation includes standard defi nitions for the following fl ow transducer blocks:
• Standard fl ow with calibration for basic device access
• Standard fl ow with calibration for complex device access
• Common practice parameters for extended functionality
In addition, the specifi cation provides a schematic of blocks, parameter access, and details for handling status of input parameters. When used in conjunction with a fl ow transducer block, the new totalizer function block supports the time-
critical procedure of totaling different inputs in order to compute fl ow.
According to the Fieldbus Foundation, fi nalization of the Flow Transducer Block Specifi cation provides greater predict-ability in fi eldbus implementation, while reducing integration risks and simplifying device replacements.
The Fieldbus Foundation has also announced updates to its other transducer block profi les, including temperature and pressure transducer block profi les. The FOUNDATION fi eldbus Device Description (DD) Library has been updated to integrate these new transducer block capabilities. The DD Library includes standardized source code for all FOUNDATION fi eldbus blocks and parameters.
trendlines
best practices & standards
Process Automation Market to Continue Recovery Through 2011
Fieldbus Foundation Releases Flow Transducer Block Specifi cation
ASIA
LATIN AMERICA
Automation Expenditures for Process Industries by Region
NORTHAMERICA
EUROPE, M. EAST, AFRICA
8 June 2011 Flow Control
Source: ARC Advisory Group
FC-0611-DA.1.indd 8 5/27/11 12:45 PM
7641 N. Business Park DriveTucson, AZ 85743Ph: 1.888.290.6060Email: [email protected]: http://www.alicatscientific.com Alicat Scientific, Inc. is a Halma Company ©Alicat Scientific, Inc. 2011
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10 June 2011 Flow Control
applications cornerby David W. Spitzer
For the past few months, I described problems with a new installation of an insertion vortex-shedding fl owmeter. (See “Applications Corner” - Feb., Mar., May.) Not only were the
physical properties of the liquid specifi ed and confi gured incor-rectly, but the fl owmeter was installed in a different size pipe as well. If you have been around for a while, you have undoubtedly seen similar problems where specifi cations are incorrect, confi g-uration is incorrect, and/or the device is not installed as planned.
Looking back, this application and installation had multiple prob-lems, but you might not think that to be the case if you followed the issues in sequence. First, the fl owmeter was reported to be mea-suring low. Apparently nothing else was wrong, but after the fl ow measurement was corrected, the fl ow measurement repeatedly dropped out. My client initially observed both symptoms, but he chose to initially report only the measurement error as a problem.
The second problem (drop out) was not mentioned until the fi rst problem was resolved. Had my client mentioned the second problem in conjunction with the fi rst problem, he would not have had to expend as much time, effort and resources to have a
technician visit the plant to obtain information that was relayed to the representative and, afterwards, to the factory. Similarly, the factory would not have had to diagnose the fi rst problem only to be confronted with a second problem that rendered the fl owmeter
marginally operational in this application. Situations where more than one prob-
lem exists are typically more diffi cult to identify and resolve than their single-problem counterparts. This can be espe-cially frustrating when one of the prob-lems turns out to be fatal to the applica-tion, such that the instrument will not work. Be sure to question people com-pletely and train them to share all of their observations with you – this will allow you to better help them. FC
David W. Spitzer is a regular contributor to Flow Control with more than 35 years of experience in specifying, building, install-ing, startup, troubleshooting, and teach-ing process control instrumentation. Mr. Spitzer has written over 10 books and 150 technical articles about instrumentation and process control, including the popular “Consumer Guide” series that compares fl owmeters by supplier. Mr. Spitzer is a principal in Spitzer and Boyes LLC, offering engineering, expert witness, development, marketing, and distribution consulting for manufacturing and automation companies. He can be reached at 845 623-1830.
www.spitzerandboyes.com
Part IV: Vortex Flowmeter PostmortemTaking Another Look At an Application Gone Wrong
Situations where more than one problem exists are typically more diffi cult to iden-tify and resolve than their single-problem counterparts. This can be especially frustrating when one of the problems turns out to be fatal to the application, such that the instrument will not work.
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The New TA2:The performance you need.The features you want.
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PERFORMANCE:• Faster response to flow changes• Measures higher air and gas velocities• Offers greater measurement stability
CONVENIENCE:• Now PACTware™ compatible• More brightly illuminated display• Housing rotates 270º for convenient viewing
VERSATILITY:• Same unit both AC and DC powered• Pulse and temperature output optionally available
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Magnetrol.indd 11 5/25/11 7:30 AM
12 June 2011 Flow Control
installation guidelines
Mission PossibleAnalog-to-Digital Valve Upgrades
Look around your home or office, and it’s obvious to see the world has become digital. In fact, digital is no longer a “buzz” word, because so many of the things around us have
become digital. Do you refer to the radio in your car as a “digital radio”? No. You simply say “radio.” Why? Because unless it is a classic car, it is assumed that the radio is digital, so the adjective is unnecessary. In fact, you may find yourself having to describe something as “analog” because that is no longer the norm.
A similar transformation is underway in process control, as a wide variety of new digital devices have been introduced in recent years, and a growing number of facilities have installed them. The transition is still a work in progress, however.
Some process control facilities have simply been a bit slower to adopt digital valve positioners, for example, as they seek to become more comfortable with this unfamiliar technology. Others have made the switch to digital devices, but have maintained an “analog mindset” and use the digital positioners as they did their analog predecessors. Returning to the car radio analogy, they have the latest Bluetooth-, satellite- and MP3-enabled system, but only use it to listen to a half-dozen local radio stations.
In either case, the result is the same. The status quo is main-tained and technologies that could help plant operators save time, money and frustration while potentially improving product quality and enhancing safety, are either not adopted or are underutilized.
The first step in making the transition to digital valve position-ers is understanding how they can be easily and cost-effectively implemented in a facility. This article will begin to bridge that gap by reviewing the various technologies available and highlighting the steps that should be taken to help ensure a successful transi-tion. In addition, it will explain how plant operators can achieve what many consider to be a “mission impossible” – i.e., “hot cutover,” or switching to a digital valve positioner while the pro-cess workflow continues uninterrupted.
Why Move to Digital Valve Technology?Moving a process control plant from the world of analog control
technology to that of digital control technology should be con-sidered a permanent move. As this article will highlight, this per-manent transition can provide significant benefits. But, as when considering any permanent move, plant personnel should ensure they have a clear understanding of the advantages and disadvan-tages before proceeding.
There is one very simple reason to consider going digital – to be competitive in today’s completely connected world. Processing plants, whether they produce power, raw materials, or finished products, are under constant pressure to maximize their operation-al excellence – a combination of profitability, plant efficiency, qual-ity, and safety – in a tightly interconnected global economy. Digital valve positioners can help process plants meet these challenges by quickly and precisely giving them the information they need.
A poorly performing $3,000 control valve can cause significant losses because of shutdowns, lost production, reduced efficiency, and unsafe events. Such losses can be reduced with digital valve positioners because they have fewer moving components, are self-calibrating, and can provide diagnostic information that allows plant personnel to monitor valve health more easily. The outcome is improved control valve reliability, repeatable and sus-tainable performance, and detection of valve degradation before it impacts the process and while it is more easily corrected.
Digital Valve Positioning Technologies: The OptionsDigital valve positioners (DVPs) can be divided into two catego-ries: hybrid and fully digital.
Hybrid positioners use an analog signal (current) as a com-mand signal while superimposing over that signal a frequency that allows for bi-directional communications. The HART Protocol is one example of a hybrid protocol.
In fully digital implementations, the command signal is pro-vided in a binary form that is coded and decoded by a com-munication protocol. The FOUNDATION Fieldbus and Profibus PA protocols are examples of fully digital technologies for DVPs.
Hybrid Positioners: The Pros and ConsHybrid DVPs offer several benefits for end-users who want to get their feet wet with digital technology without diving all the way in.
Implementing hybrid positioners is less disruptive than implementing fully digital devices because existing assets and infrastructure, such as the controller, cabinets and wiring, are retained. End-users can quickly benefit from increased uptime and reliability with less engineering effort and a smaller capital investment.
Sustainability is another key advantage of hybrid installa-tions because what controls the valve – the analog signal – is unchanged, and that familiarity means less additional training is required in order to troubleshoot, retrofit or replace the DVP.
Controller
CV with bypass line CV with hand wheel CV without bypass / hand wheel
MARSHALLING RACK
JUNCTION BOX
Bypass valve
TxHW
C.V. C.V. C.V.
Tx Tx
MARSHALLING RACK
JUNCTION BOX
MARSHALLING RACK
JUNCTION BOX
Controller Controller
Figure 1. Three typical control valve installations. The process of moving to digital positioners will be easiest in the scenario on the left and most challeng-ing in the situation on the right.
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www.FlowControlNetwork.com June 2011 13
Along the same lines, unlike an analog positioner, a DVP can guide the end-user in the setup and troubleshooting processes because it provides continuous information about its condition. As a result, less time is spent guessing what could be causing a problem, and the team can more quickly move on to resolving the problem.
On the minus side, hybrid technology will eventually become passé, so it is not a matter of whether the transition to fully digital devices will be made, but when.
Fully Digital: The Advantages and DisadvantagesA fully digital implementation requires a complete replacement of the process controllers because the control signal to the DVP is no longer analog, but strictly digital. Upgrading to fully digital is, therefore, a bigger leap, but can also bring additional benefi ts.
The key advantage of a fully digital DVP implementation is that information moves seamlessly back and forth on the communi-cation bus. In a hybrid system, information only travels between the positioner and the controller. In a fully digital implementation, it also travels between devices. As a result, the information can be used by all assets within the control structure, helping make process control smart and robust.
This complete and unobstructed view of the process and control system assets is one reason that designers of greenfi eld (or new construction) projects consider fully digital systems. In a hybrid installation, each
valve is wired separately and each wire must be individually tested during the commis-sioning process. With potentially hundreds of
valves in a facility, that process can be extremely time-consuming. In a fully digital implementation, however, several control valves can feed off of a main communication trunk, so there is only one test setup required to test several valves. The commissioning pro-cess is streamlined and the facility is up and running sooner.
In addition, a completely digital implementation enables predictive maintenance. According to an ARC Advisory Group (www.arcweb.com) study, “The real value of fi eldbus is Operating Expenditure (OpEx) related rather than Capital Expenditure (CapEx) related. End-users have reported that predictive maintenance is the single largest savings resulting from the use of fi eldbus.” (“Fieldbus Solutions in the Process Industries Worldwide Outlook,” Paula Hollywood, 2007.)
This makes sense when you consider that control valves are a contributor to plant effi ciency and make up a large portion of a
By Sandro Esposito
Control Valve Hot Cutover SetupDVP Setup
DP
V’s
Ava
ilab
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avel
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sor
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alib
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d
Trav
elDVP
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Range
Utilized Travel Sensor
Range
Positionvs
Setpoint
Hot Cutover Feedback Installation
Hot Cutover Feedback
Adjustment
Installation
OffsetInstallation Trimming
100%
50%
Open
Actual
Close
45%
50%
Plug
Seat
0%DVP
ZERO
Util
ized
Sen
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ized
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Figure 2. This chart illustrates the relationship between a DVP’s digital feedback and the true me-chanical position of a valve. A DVP has an available range to measure a displacement of the valve. A portion of that available range will be utilized by the DVP.
Calibration Relationship Between a Digital Valve Positioner and a Control Valve
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14 June 2011 Flow Control
installation guidelines
facility’s maintenance budget. A fully digital DVP can provide alerts and key valve health indicators, allowing plant personnel to plan ahead using actionable information.
These are powerful advan-tages, but they do come with additional challenges. The disadvantage of a fully digital positioner is that it is com-pletely digital. The operator must, therefore, understand the ramifi cations of bytes and bits. He or she does not need to know what “111101010” stands for in order to make a DVP work with the control loop, but does need addi-tional software and computer skills to set up and com-mission a fully digital device because it is software that enables communication between the DVP and the other digital assets. If a digi-tal positioner is not properly set up and integrated with the other assets, it will not be able to respond to a com-mand signal.
As a result, there are more parameters to understand and to set up properly. On average, a fully digital DVP has 500 parameters with an average of four possible set-tings for each parameter – or 2,000 possible combinations. In contrast, a typical hybrid device (with HART communi-cation) has 120 parameters with an average of three choices per parameter – just 360 possible combinations. In other words, setting up a fully digital DVP is a more complex process, and while it is not rocket science, it does require proper training.
Making the Move: Going DigitalWith adequate preparation, the move to digital technology can be completed successfully while the process is running (online) or during a shutdown (offl ine). A hybrid implementation can be done with the existing control system in place, while a fully digital situ-ation requires installation of a completely new control system that is capable of digital communication, such as FOUNDATION Fieldbus or PROFIBUS.
Situation 1: Offl ine – While the Process is Down or the Valve Is IsolatedWhen installing a hybrid DVP (4-20mA with HART), an important consideration is whether or not there is an existing 4-20mA signal available at or near the valve. Very little engineering is required if there is an existing signal going to a current-to-pressure-con-verter (I/P converter) or an electro-pneumatic positioner. In most cases, the engineering involved will be related to management of change (MOC) because the DVP will replace the analog positioner using the existing wiring.
If the process is running but the valve can be isolated (bypassed), it is best to take advantage of remote digital commu-nication. Once the mechanical installation has been completed,
Figure 3. The success of any mission hinges on having the right tools and a solid execu-tion plan. This fl owchart of the “hot cutover” process identifi es the essential questions to be answered, the key steps in the process, and the necessary tools.
Case # Case Type Existing Positioner
Destination Positioner
Handwheel or Position-
blocking Device?
Confi guration and Calibration
Data Avalable for Destination DVP?
1
Migration (Re-instrumentation) Any
DVP
YesYes
2 No
3No
Yes
4 No
5
Replace Existing Positioner DVP
YesYes
6 No
7No
Yes
8 No
Manually confi gure
DVP
DVP’s confi guration information
available?
Handwheel or manual handjack
available?
Based on actuator travel, determine upper and lower calibration stops
Validate upper and lower stop values
Load in DVP upper and lower calibra-
tion stops and other parameters
Lock valve with handwheel or handjack
and read valve position in %
Remove old positioner Install DVP
Adjust feedback mecha-nism so that position
displayed by DVP matches locked position
Apply air supply and set loop
current to match locked position
Slowly disengage handwheel or
handjack device
End
Remove air to valveSet tight shutoff
of 5%
No
No
YES
Yes
Hot Cutover of Digital Valve Positioners (Use Cases and Flowchart)
FC-0611-FB.1.indd 14 5/27/11 9:20 AM
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16 June 2011 Flow Control
installation guidelines
personnel can move to a safe area to carry out the calibration, preventing unnecessary exposure to a potentially hazardous pro-cess environment.
In a fully digital implementation, additional engineering will be required prior to the installation, as the DVP will be digitally integrated with the process control system. This engineering typically consists of:
1 Determining whether there are available addresses for the DVP on the communication segment. Every device on a seg-
ment must have its own digital address so that it can exchange information with each of the other devices on the segment.
2 Quantifying the total execution time of the loop. In most control loops, one second is needed to process the mea-
sured variable and provide a command signal to a fi nal control element. But some loops, such as fl ow and pressure, require quicker execution. In these cases, adding multiple DVPs may not provide for robust control.
3 Identifying the function block within the DVP that will be necessary for each process control loop. For instance, it is
necessary to determine whether the process PID will reside in the DVP or elsewhere on the communication segment. If the PID will reside in the DVP, the parameters for process control must be carefully reviewed and determined in advance.
Situation 2: Online – While the Process is Running (a.k.a. “Hot Cutover”)If the process cannot be shut down, it is still relatively easy to replace an analog positioner with a digital device. This technique is known as “hot cutover” or “online installation.”
Many plant operators still see hot cutover as “mission impos-sible,” and it is indeed so when replacing one traditional analog positioner with another. Several refi neries and petrochemical plants have, however, successfully replaced analog positioners with hybrid devices while the plant was in operation, avoiding signifi cant losses in production that would have resulted from a plant shutdown.
End-users have also successfully completed “mission impossi-ble 2” – migrating from a completely pneumatic control system to a fully digital system while the plant was running. The key to this capability is that, when working with DVPs, little or no mechanical adjustment is necessary and the zero and span can be preset. This allows the replacement of a pneumatic positioner with a DVP without moving the valve for calibration purposes.
In such cases, the valve must be isolated, be locked in its exist-ing position, or remain in its failsafe (open or closed) position. It is, therefore, recommended that the DVP be confi gured and calibrat-ed before work begins at the valve, thus minimizing the amount of time that the valve will be isolated or manually locked in position.
What makes hot cutover possible is that a DVP’s zero and span are not mechanical. There are no screws to turn, beams to bal-ance or springs to adjust when setting the starting and ending points that correspond to 0 percent to 100 percent travel. The zero and span are set digitally and the DVP’s feedback mecha-nism is adjusted to match the actual position of the valve. For example, if the mechanical position of the valve reads 25 percent after the zero and span have been set, the DVP’s feedback sys-
tem can be easily adjusted so that it also reports out 25 percent.
Figure 2 illustrates the relationship between a DVP’s digital feedback and the true mechanical position of a valve. A DVP has an available range to measure a displacement of the valve. A
portion of that available range will be utilized by the DVP.
Of course, the success of any mission also hinges on hav-ing the right tools and a solid execution plan. The fl owchart in Figure 3 identifi es the essential questions to be answered, the key steps in the process, and the tools that will be required to upgrade to digital technology while the process is “live.”
Considerations for a Successful Move to Digital DevicesWhether upgrading to hybrid or fully digital technology, the fol-lowing are some key consider-ations to keep in mind.
✓ Wiring/Power: An analog positioner requires 2-3 Vdc, while a DVP can require up to 12 Vdc. Not all legacy control systems are capable of providing a 4-20mA command signal to a DVP that requires 12 Vdc. This power shortage is even more likely to occur in split-ranged control valve applications in which a DVP is replacing two analog positioners connected in series.
When specifying a DVP, and before removing the old analog posi-tioner, plant personnel should verify the maximum load that the con-troller’s output is capable of and choose the DVP accordingly. If the voltage is still insuffi cient, particularly when installing two positioners in series, a signal conditioner with more voltage will be necessary.
In a fully digital implementation, proper wiring is essential because it greatly affects the quality of the digital signal. If the wir-ing is not properly grounded and terminated, signal quality will be compromised and communication between devices will be slow, affecting every device on the communication bus.✓ Number of DVPs: The greater the number of DVPs that
are installed on the same wire, the greater the risk that multiple control valves will be taken out of service if power is lost to that bus or if the main trunk for that bus is broken. A good rule of thumb is to have no more than three valves per segment and, in key applications and extremely fast process control loops, to have only one valve.✓ Training/Personnel: When planning an upgrade to a fully
digital system, plant personnel must allocate adequate time and resources for training the in-house team. Otherwise, once the installation has been completed and the vendor has moved on to the next project, they may quickly realize that they do not have the knowledge required to support and maintain the new system. It is, therefore, imperative that a detailed training program be included
Figure 4. Digital valve positioners provide reliable process control in severe service applications, such as the installation shown in this photo.
FC-0611-FB.1.indd 16 5/27/11 9:20 AM
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18 June 2011 Flow Control
installation guidelines
in the upgrade plan and that the program include ongoing training until the team is comfortable working with the devices.
Most DVP manufacturers offer product training programs, and excellent courses are available through a variety of colleges and through the Instrument Society of America (ISA, www.isa.org). These programs teach attendees how to mount and set up the DVP, how to commission the DVP using a handheld device, and how to troubleshoot.
The training required to work with hybrid installations is more straightforward, as the command signal is similar to that of an analog device and special system confi gurations are not neces-sary to make the valve work with the control system.✓ Support Tools: A basic 4-20 mA signal generator and volt-
meter are not suffi cient to support a hybrid or fully digital installa-tion with DVPs – particularly a fully digital installation.
While some 4-20mA HART positioners can be set up locally at the device when equipped with an LCD or local buttons for setup and calibration, others require software with a HART modem or a portable handheld calibrator capable of communicating with the DVP. The setup process, thanks to the digital positioners’ user-friendly interfaces and ability to provide troubleshooting informa-tion is signifi cantly streamlined compared to that associated with setting up an analog positioner.
A fully digital DVP will also require a special power supply, a handheld device or computer with digital communication, a modem, software, and communication analyzers. These tools are readily available, and it is only a matter of planning and budgeting for such tools when developing the project scope.✓ Loop Tuning/Control System Adjustments: Imagine a
four-cylinder engine in a midsize car. You have driven this car for years, and you have the habit of putting a certain amount of pres-sure on the gas pedal when passing another car or starting after a complete stop. Now, put a more powerful and effi cient eight-cylinder engine in that same car. There is a good chance that, if you hit the gas pedal the same way, the tires will screech. Worse, you might bump into the car in front of you.
The same theory applies when retrofi tting a DVP on a control valve that is already installed in a plant. The old analog positioner may not respond until the signal changes by 1 percent or 2 per-cent or even more, and it may not be as quick and accurate when positioning the valve. But the loop is tuned and optimized based on those performance characteristics. In contrast, a DVP, with its precise feedback sensor, fewer mechanical moving parts, and fast control algorithm, may respond to a command signal as low as 0.1 percent and move the valve much faster and with greater accuracy. The control valve’s dynamic response has dramatically changed and, as a result, the loop tuning is likely too aggressive for this new control valve behavior.
The worst response to this problem would be to detune the DVP and make it perform like a four-cylinder engine. Doing so would defeat one of the purposes of moving to a digital device – greater plant performance. The best practice is to involve the process control engineer when moving from an analog device to a digital one and work as a team to maximize the control valve’s overall performance.
Putting the DVP’s Data to WorkAs mentioned earlier, end-users have reported that the ability to conduct predictive maintenance is the single biggest con-tributor to the savings that result from the use of fi eldbus. The key is a DVP’s ability to provide easy access to diagnostic information.
In hybrid installations on older control systems, the use of wire-less technology can cost-effectively link the DVP and the asset monitoring tools. Newer controllers can communicate with hybrid DVPs without the intermediary of wireless technology. Fully digital DVPs can literally put terabytes of process information at plant personnel’s fi ngertips.
The data is most valuable, however, when it is delivered with actionable information that is then put to use. When upgrading to digital valve technology, facilities must also invest in the tools – such as plant asset management software and online valve monitoring tools – needed to capture, consolidate and present the information in an actionable format.
Plant personnel must also adapt their workfl ows (and often shift their mindsets) to embrace these new tools. Too often, digi-tal devices are installed and then gather dust as habits remain unchanged and the available data is not accessed and acted upon.
The world around us has become digital. In so many ways, that emigration has made us more productive and effi cient, made our day-to-day lives easier, and made the things we use every day more powerful, reliable and user-friendly. The same thing could happen in the process control world, thanks to today’s digi-tal valve positioning technology. All it takes is a bit of planning and a willingness to start the journey. FC
Sandro Esposito is Global Marketing Manager for digital and SMART products at GE Energy. A 17-year veteran of the control valve and process automation industries, he has extensive experi-ence with control valve diagnostics and system integration. He has been granted several patents related to digital valve posi-tioners. He graduated from Ahuntsic College in Montreal with a degree in instrumentation and process controls. Reach him at [email protected] or +1 281 671-1683.
www.ge-energy.com
As mentioned earlier, end-users have reported that the
Figure 6. The facility shown here features a combination of valves that have been retrofi tted with hybrid positioners and valves that retain the original analog positioners.
FC-0611-FB.1.indd 18 5/27/11 9:21 AM
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And the Nominees Are …Recognizing Fluid Handling Technology Innovation
20 June 2011 Flow Control
2011 fl ow control innovation awards
The following technologies represent the fi nal nominees for the 2011 Flow Control Innovation Awards program. Nominees include novel technology solutions for fl uid handling applications in the categories of fl uid measurement, control and containment. Please review the technology
summaries provided below, and visit FlowControlNetwork.com for more information on how to place your votes for the Innovation Awards nominees. You can vote for up to fi ve products, and all voters will be entered into a random drawing to win an Apple iPhone 4G. Innovation Awards winners will be announced in the September issue of Flow Control, with extended case studies/application stories on each of the winning technologies featured in the October issue. If you have questions and/or require additional information on any of the technologies highlighted below, please contact Matt Migliore at 610.828.1711 or [email protected]. Thanks for supporting the Flow Control Innovation Awards program. Voting Deadline: Noon EST, Aug. 1
Cameron’s differential pressure-based NuFlo Cone Meter is a process control and multi-fl uid meter that is designed to provide accurate, repeatable, and cost-optimized measurements. The meter is able to fi t into small spaces while offering large and stable turn-downs with high levels of accuracy and repeatability. It is designed to work in both unprocessed and processed applications and is a good fi t for upstream, midstream and downstream scenarios that present a wide range of measurement challenges. The device also offers an economic, compact design, low cost of ownership, and,
since there are no moving parts, a long, virtually maintenance-free lifespan.
The NuFlo Cone meter features a hydrody-namic design for easy installation and no moving parts. The design enables a cleaning (or sweep-ing) effect from the velocity increase in the throat and around the differential producer. The cone
meter’s easy installation and compact size is an advantage when used in an offshore platform process, reducing costs and installation time. In addition, the meter is manufactured in a facility that is ISP 9001, API 22.2-certifi ed, and GOST-approved for natural gas custody transfer in the Russian Federation.
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since there are no moving parts, a long, virtually
ing) effect from the velocity increase in the throat and around the differential producer. The cone
COX Flow Measurement’s ALDR is an alu-minum-bodied, dual-rotor turbine fl owme-ter intended for automotive and aerospace applications. Its unique design incorporates an integral ExactComp EC80 fl ow computer and embedded pickoffs, enabling smaller packaging, lighter weight, and greater reli-ability in high-vibration installations.
Aluminum construction creates rotor-blade sensing issues, which are overcome by the use of a high-sensitivity amplifi er with coupling and processing characteristics. Plus, the meter’s smaller packaging, lighter weight, and embedded pickoff coils work well in small areas subject to high vibrations. Combine this with extended-life ceramic bear-
ings and precision primary standard calibrations, and the meter provides top performance for competitive and critical measure-
ment applications.The ALDR design utilizes a 100-ohm RTD to measure
fl uid temperatures and correct for fl uid viscosity variances. The fl ow computer takes full advantage of the capability and
provides a corrected fl ow output, which is enhanced by the dual rotors’ ability to extend the UVC usable fl ow
measurement range. Embedded pickoff coils with-stand vibration typically found in the automotive and aerospace industries by reducing mass and size. This design does not employ fl ow straight-
eners since the dual-rotor cancels out fl uid swirl effects, delivering a fl owmeter package that will fi t in limited-
space scenarios.
’s ALDR is an alu-
ter intended for automotive and aerospace applications. Its unique design incorporates an integral ExactComp EC80 fl ow computer
packaging, lighter weight, and greater reli-
by the use of a high-sensitivity amplifi er with coupling and processing characteristics. Plus, the meter’s smaller packaging, lighter weight, and embedded pickoff coils work well in small areas subject
ings and precision primary standard calibrations, and the meter provides top performance for competitive and critical measure-
ment applications.The ALDR design utilizes a 100-ohm RTD to measure
fl uid temperatures and correct for fl uid viscosity variances. The fl ow computer takes full advantage of the capability and
provides a corrected fl ow output, which is enhanced by the dual rotors’ ability to extend the UVC usable fl ow
measurement range. Embedded pickoff coils with-
eners since the dual-rotor cancels out fl uid swirl effects, delivering a fl owmeter package that will fi t in limited-
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Differential Pressure-Based Multi-Fluid Meter
MEASUREMENT
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FC-0611-FA.1.indd 20 5/26/11 2:11 PM
www.FlowControlNetwork.com June 2011 21
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Emerson Process Management’s Micro Motion Filling Mass Transmitter is specifically designed for high-speed, high-accuracy filling or dosing. Utilizing Micro Motion MVD (multivariable digital) technol-ogy, the transmitter, combined with a Micro Motion Coriolis sensor, is ideally suited for a variety of linear and rotary filling machines across the life sciences, food and beverage, and chemical industries. The transmitter can handle extremely fast fills (less than one second), very small fills (<1ml), and challenging fluids, such as those with entrained air, suspended solids, or high viscosity.
With increasing pressure on production quality efficiency and throughput, traditional volumetric- and meter-based technologies are no longer sufficient. Micro Motion filling meters deliver mass,
density and temperature process data in one device, supporting continuous monitoring of product quality with a complete real-time view of fluid character-istics. Digital communications provide continuous monitoring of density and temperature for real-time
quality control, and enable “on the fly” changes to fill target or recipe.
The transmitter’s Automatic Overshoot Compensation (AOC) feature automatically
adjusts valve management to compensate for changes in process conditions to deliver accuracy and reliability
with minimal setup and maintenance. With direct mass measurement and superior stability (turndown), the Filling Mass Transmitter is suitable for filling a variety of container sizes and products with a single sensor.
Endress+Hauser’s Promass E 200 is a true two-wire, 4-20 mA HART, loop-powered Coriolis meter for mass flow and density measurement. Through the use of patented Adaptive Power Techniques, the Coriolis flow-meter is able to provide continuous, accurate and reliable measurements without the need for convert-ers, custom power supplies, or barriers. The Promass E 200 is the ideal flowmeter for con-tinuous process control, offering a high level of safety and reliability, compliant to SIL-2 and SIL-3, with an intrinsically safe and explosion-proof design approved for Class 1 Division 1 applications. By combining Coriolis technology with the reliability of two-wire integration, a favored cost-effective mea-suring solution now exists that fulfills the high safety standards in addition to the industry-specific requirements.
Coriolis mass flow technology has historically been contained to traditional four-wire power/signal methodologies due to the
need to power the sensor, amplifier, transmitter, and outputs. The Promass E 200 is innovative in that it maintains the highest levels of Coriolis accuracy and reliability while operating under a two-wire, loop-powered concept, which significantly limits the
available power to the Coriolis meter. In addition to the Adaptive Power
Techniques used by the Promass E 200, this product line has set a standard for com-monality across the Endress+Hauser flow and level product lines. The two-wire product lines
from E+H will now share common Human Machine Interface, spare parts, and electronics modules. The new
HistoROM capability provides an onboard nonvolatile device memory that enables data management and automatic data backup for device configuration. The HistoROM offers extended functions for an embedded event logbook, including the data log-ging for over 1,000 points.
Mass Transmitter for High-Speed, High-Accuracy Dosing
Two-Wire, Loop-Powered Coriolis Flowmeter
When placing your votes for the 2011 Flow Control Innovation Awards, you will have the opportunity to automatically enter a random drawing to win a $199 Apple iPhone 4G gift card. The gift card covers the current retail price of an 16GB iPhone 4G, or you can use it for any other product in the Apple Online Store or any Apple Retail Store.
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FC-0611-FA.1.indd 21 6/15/11 1:20 PM
Fluid Components Intl’s ST100 Series is a thermal mass air/gas fl owmeter that provides a graphical user readout, an on-board optically activated keypad, a comprehensive selection of analog outputs and bus communications, a pressure measurement option, dual-element confi gurations, multiple calibrations, 10 user-selectable gas calibrations, a built-in data logger, and a robust transmitter. It also features a selection of fl ow ele-ments matched to a user’s application, temperature service up to 850 F [454 C], can be confi gured with FCI’s VeriCal in-situ calibration verifi cation system, and is available in both integral and remote confi gurations up to 1000 feet (300m).
The typical readout/display in this segment is a small char-acter, two-line LCD. With the ST100, the user gets graphical/digital, backlighted LCD readout, which continuously displays
all measured parameters, fl owrate, total fl ow, temperature and pressure, plus fl owrate in a 0-100 percent bar graph and the active calibration group. For alarms, icons illuminate and fl ash upon a trip condition and will change to steady-state when acknowledged. The display also has an innovative write-
able fi eld in which the user can note gas composition, application name, pipe or process name, or even a tag number for quickly associating the readings with the correct process. Another unique feature of the display is that it is rotatable electronically by the user to ensure the optimum viewing angle.
The meter offers outputs of analog and bus communication, including triple 4-20mA, frequency/pulse, relays, HART (version 7), Foundation Fieldbus, Profi bus-PA, and Modbus.
The meter provides accuracy to 0.75 percent of reading (com-pared to the 1-2 percent typical in this product segment).
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Flow Line Options Corp’s Tracer 1000/2000 Guided-Wave Radar Level Transmitter is designed to provide continuous radar level measurement and point level detection in liquids and solids, with analog and switching output. The Tracer 1000/2000 is well-suited for a range of measurement applications and has almost no installation restrictions. The device can be mounted in small tanks, tall and narrow nozzles, and it measures pre-cisely even with diffi cult tank geometries or close to interfering structures.
Outstanding operating characteristics include:Unstable Process Conditions: Changes in viscosity, density, or acidity do not affect accuracy.Agitated Surfaces: Boiling surfaces, dust, foam, and vapor do
not affect device performance. Suitable for recirculating fl uids, propeller mixers, aeration tanks.Extreme Operating Limits: Performs well under
extreme temperatures up to 600 F (315 C). Capable of withstanding pressures up to 580 PSIG (40 Bar)
Works with Fine Powders & Sticky Fluids: Vacuum tanks with used cooking oil. Paint, latex, animal fat, and soy bean
oil. Saw dust, carbon black, titanium tetrachloride, salt, grain.
Testimonial: “The new radar system works really good; I would like to use it in a few lift stations. The [Tracer 1000/2000] is better than other products used in the past, plus
there is no concern with mist.” – Kevin Smith, Chief Operator at New Philadelphia WWTP.
switching output. The Tracer 1000/2000 is well-suited for a range of measurement applications and has almost no installation restrictions. The device can be mounted in small tanks, tall and narrow nozzles, and it measures pre-cisely even with diffi cult tank geometries or close to interfering
Changes in viscosity, density, or
not affect device performance. Suitable for recirculating fl uids, propeller mixers, aeration tanks.
extreme temperatures up to 600 F (315 C). Capable of withstanding pressures up to 580 PSIG (40 Bar)
Works with Fine Powders & Sticky Fluids: with used cooking oil. Paint, latex, animal fat, and soy bean
oil. Saw dust, carbon black, titanium tetrachloride, salt, grain.
Testimonial: I would like to use it in a few lift stations. The [Tracer 1000/2000] is better than other products used in the past, plus
there is no concern with mist.” – Kevin Smith, Chief Operator at
22 June 2011 Flow Control
2011 fl ow control innovation awards
all measured parameters, fl owrate, total fl ow, temperature
Greyline Instruments’ DLT 2.0 Differential Level Transmitter is a simple solution for barscreen level control at wastewater treatment plants, pump stations, and combined sewer systems. With non-contacting ultrasonic sensors posi-tioned up and downstream from a barscreen, the DLT 2.0 can display and transmit differen-tial level. The downstream sensor can also be installed above a fl ume or weir to measure and totalize open-channel fl ow.
Greyline’s DLT 2.0 reduces costs and simpli-fi es instrumentation at treatment plant headworks. Two sensor differential instruments have been in service for some time, but the DLT 2.0 feature of combining one of the sensors for the dual
function of both downstream level and differ-ential fl ow is a unique, cost-saving design that eliminates the need for a dedicated open-channel fl ow monitor. Until the DLT 2.0 was developed, treatment plants would have to buy two separate instruments to accomplish the same functions.
The DLT 2.0 Differential Level Transmitter mea-sures level and open-channel fl ow with +/-0.25 percent accuracy using two non-contacting ultra-sonic sensors. It is calibrated with a user-friendly keypad/menu system and includes fully program-
mable control relays plus three 4-20mA outputs for upstream level, differential level, and downstream level or open-channel fl ow. Plug-and-play data storage options are available.
Thermal Mass Air/Gas Flowmeter
Radar Level Transmitter for Continuous & Point-Level Measurement
Differential Level Transmitter for Barscreen Level Measurement
FC-0611-FA.1.indd 22 5/31/11 7:40 AM
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INKnet Systems’ INKsmart is a fi lter meter package system. The fi rst in digital “plug-n-work” technology for the printing industry delivers fi ltered ink to the printer with accurate microprocessor-based documentation of ink consumption. A lightweight package with fi lter and meter easily connects to the gear-side of the press without affecting pre-existing plumbing. One of the most impressive features of this 0.1 percent meter is that it requires no calibration out of the box.
The INKsmart unit combines fi ltration & meter-ing weighing approx. 22 lbs. with package dimen-sions of 6.5” deep x 8” high x 9.75” long. All data is captured in real-time with dual outputs both in (network and digital). The instrument is a production tool for monitoring fl ow and consumption rates, time, and temperature.
Aggressive media fi ltration and accurate media consumption documentation is accomplished from the instrument, which is sealless in design, providing quadrature output without breach-ing the mechanism’s integrity. Its fl ow range is from 1cc of ink per minute to a maximum of 15 gallons of ink per minute. It can operate within temperature ranges is from 50 F to 200 F without
compromising its 0.1 percent accuracy, and it operates effec-tively from 5 PSI to 4,000 PSI, producing 40 CC of
measured material at 24 pulses per revolution.The innovative precision meter package with
attached fi lter fi lters media with a high-pressure built-in fi lter system and no fi ltration bypass mechanisms. Filter elements are crush-proof to 4,500 PSI with the fi lter canister pressure-proof up to 12,000 PSI.
Testimonial: “I’ve worked for three different print-ing companies in my 30 years in this industry. I know that old technology was helter-skelter for everybody.
Each of the three companies tried to use the old tech-nology, and each one tossed it out. There was a need for
improvement, but the tools weren’t there. INKnet has bridged that gap, and it’s been a very solid, encouraging improvement in the industry.
Since the original INKnet purchase, I’ve never even looked at any other solutions. They’ve given me exactly what I want.” – Jim Burke, Production Manager, Buffalo Newspress.
24 June 2011 Flow Control
2011 fl ow control innovation awards
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Filter/Meter Package for Ink Filtration/Metering
FC-0611-FA.1.indd 24 5/26/11 2:12 PM
Innovative Sensor Technologies’ MFS02 micro flow sensor is a thin-film thermal mass flow sensor that is a good fit for (low) gas flow and differential-pressure applications. Measuring at just 3.5 x 5.1 mm, the sensor features platinum micro heaters and temperature sensors on an ultra-sensitive polymer membrane. There are four resistance elements on the chip; two high and two low. As flow passes over the sensor, the distribution of heat across the resistors indicates both the magnitude and direc-tion of the flow. An additional pt1000 RTD temperature sensor can be specified on the chip for alternate use as a con-stant temperature anemometer in high flow applications. The MFS02 is capable of measuring gas flow and direction in a range from 0.001 to 2m/s (up to 50m/s), and has a response time of less than 10 milliseconds. The operating temperature range for the sensor element is -40 C to 150 C.
The innovation associated with the MFS02 flow sensor is derived from the polymer membrane technology that it employs. Moving from the traditional ceramic substrates of other flow sensors to the polymer membrane of the MFS02 has allowed the sensor to make extreme improvements in sensitivity and response time. The sensor has a reduced power consumption compared to older sensor models due to its low thermal mass. The MFS02 also impresses when compared to other competitive technologies on the market in regards to increased measur-ing range and operating temperature range, and improved handling, versatility and robustness.
Through thin-film deposition and polymer technology, Innovative Sensor Technology was able to develop the MFS02 with outstanding operating char-acteristics. The first noticeable quality of the sensor is its miniature size. In com-bination with the size of the MFS02, the use of a thin polymer layer exposed to air on both sides of the substrate at the active area has led to an extremely low
thermal mass. This low thermal mass has resulted in additional outstanding operating characteristics, including sensitivity, low power consumption, low weight, and fast response time. The versatility and robustness of the sensor construction also lends itself to both high and low flow ranges, a wide oper-ating temperature range, and a stable zero point at no flow that is resistant to contamination over time.
www.FlowControlNetwork.com June 2011 25
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Nobody knows you like Brooks
When you need flow and level instrumentation for your project, you don’t have time for trial and error. You need the right solution for your exact application and you need it fast. It needs to just flat-out work – now, and for years to come.
That’s why companies across the planet choose Brooks. With over 60 years of process experience – in applications from basic device testing to nuclearprocesses and everything in between – our people have seen it all. You could say we’ve “been there, solved that.”
So bring your biggest challenges to BSo bring your biggest challenges to Brooks for all your toughest applications. Pick our brains and profit from our experience.
Application ExperienceBeyond Measure
Application ExperienceBeyond Measure
1-888-554-FLOW | www.BrooksInstrument.com | [email protected]
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Thin-Film Thermal Mass Flow Sensor for Low-Flow Gas & DP Applications
FC-0611-FA.1.indd 25 5/31/11 7:41 AM
26 June 2011 Flow Control
2011 fl ow control innovation awards
Sage Metering’s Sage Prism is a portable battery-operated thermal mass fl owmeter with extensive data-logging capability. Designed to operate for up to 10 hours on a built-in rechargeable Lithium-ion battery, the insertion-style portable fl owmeter has 16 independent calibration channels, and can measure and log up to 3,800 data points of gas fl ow in pipes one inch and larger. The Prism is ergonomically designed, has an easy-to-read display with navigation buttons, and can log data in Auto Mode or Manual Mode. The data (Log#, Flowrate, Temperature, Calibration Channel, Date, and Time Stamps) is stored within the portable for subsequent uploading
to a PC and saved as an Excel spreadsheet. Software, charger, and carrying case are all included.
The Prism is designed to accurately log the mass fl owrate of gases, such as Natural Gas, Landfi ll Gas, Digester Gas, Compressed Air, and Nitrogen. When commanded, the unit will also output the stored data to a PC. In addition to having 16 Calibration Channels, the Prism also
can be switched to TAG ID Mode, allowing the user to identify 99 different pipes, which require logging of the fl owrate. The unique Tags that the user identifi es for the pipes can be associated with any of the 16 calibrations (or confi gurations).
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LJ Star’s K25-Ex explosion-proof-rated digi-tal video camera is designed for use with a sightglass on a process vessel and for visual inspection of pipes. It is ideal for any hazardous location where operator access to a sightglass is diffi cult or dangerous, as well as for remote locations that require a great deal of time for operators to reach.
The K25-Ex Camera System is smaller than comparable video camera systems that must be mounted inside separate, bulky, explosion-proof housings. It is the most compact camera system in its class that offers high resolution for precise observation and the ability to control and contrast captured images.
Testimonials: A safety-equipment company needed video cameras that were small enough to fi t inside small oil pipelines. Its equipment is used to verify that the pipes are free of resi-due before workers begin to repair the pipes using welders. The cameras that it had been using were installed inside separate housings to assure an explosion-proof rating. The bulky
cameras made it more diffi cult for operators to work around the reactor, which has a lot of other equipment surrounding it. The company solved this problem by switching to the L.J. Star K25-Ex Camera System, which is the only explosion proof-rated camera system small enough to fi t its size requirements that it could fi nd.
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McCrometer’s FPI Mag is a full-profi le insertion electromagnetic fl owmeter with a fully submersible sensor, featuring multiple electrodes measuring fl ow across the entire diameter of the pipe. The meter can be installed in line sizes from four inches to 138 inches and in pressures up to 250 PSI. Each meter comes standard with an L-Series Converter.
Ease of hot-tap installation: The FPI Mag fl owmeter installs without interrupting service, de-watering lines, cutting pipe, or welding fl anges. The easy hot-tap installation makes the FPI Mag particularly cost-effective for retrofi t applications, replacing fl owmeters, or in sites never metered before.
Multi-electrodes deliver accurate full profi le: The FPI Mag’s unique operating principle delivers accuracy unmatched by other
insertion magmeters and rivals the performance of a full-bore mag meter. Continuous measurement across the entire fl ow profi le compensates for vari-able fl ow profi les, including swirls and turbulent conditions.
Robust construction for operational longev-ity: The sensor body is made from heavy-duty 316 stainless steel for maximum structural integrity. An NSF-certifi ed 3M fusion-bonded epoxy coating ensures superior long-term operation.
Virtually no recalibration or maintenance: The FPI Mag’s highly stable fl ow sensor comes pre-calibrated from McCrometer’s NIST-traceable calibration lab and requires no recalibration in the fi eld. With no moving parts, the FPI Mag’s sim-ply designed sensor contains nothing to wear or break.
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Full-Profi le Insertion Magnetic Flowmeter
Digital Video Camera for Hazardous Sight-Flow Applications
Portable Battery-Operated Thermal Mass Flowmeter
FC-0611-FA.1.indd 26 5/26/11 2:12 PM
www.FlowControlNetwork.com June 2011 27
Veris’s Hot Tap Accelabar flowmeter is designed to allow easy retraction of the flow-sensing element located in the throat of the Accelabar nozzle with-out shutting down or depressurizing the pipeline. Its retractable drive rod assembly allows for quick inspection of the sensor in dirty fluids or where periodic inspection is required.
The Hot Tap Accelabar Sensor allows the nozzle and flanges to stay in place while the sensor por-tion is inspected. Prior to its invention, in order for the sensor portion of the Accelabar to be removed for inspection or maintenance, the process would have to be shut down and the pipe depressurized. Bringing a line out of service to inspect a sensor is very costly and time consuming.
The Hot Tap Accelabar allows for sensor inspec-tion over any range of flows and operating condi-tions at 600# ANSI (1,440 PSI @ 100 F or 850 F max) or below.
Testimonial: “The Hot Tap Accelebar has pro-vided more reliable measurement due to its high turndown capability with the added benefit of retracting and inspecting the sensor for periodic buildup common in our process environment. Prior to installation of the Hot Tap Accelebar, we used
orifice plates that did not give us the necessary turndown and they cost us two days of shutdown time for inspection and main-tenance.” – Ops supervisor for oil & natural gas producer.
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Siargo’s MF5700 Series mass flowmeters are designed to provide a digital gas flow control and/or monitor in product process lines where rotameters are currently used do to cost con-siderations.
The meters are manufactured using low-power MEMS thermal mass flow technology that can provide digital (Modbus) interface with a large turndown ratio of 50-to-1 with an accuracy of 2 percent of readings. The meters can also be used as a stand-alone unit pow-ered with four AA batteries. The meter head can be rotated 180 degrees for easy data access at any installation conditions. The meters are sold at below $50 with a volume.
Unlike the volumetric technology, the MF5700 meter provides mass flow (temperature and pressure automatically compensated as per the thermal mass flow principle), and therefore much more precision for the volumetric approaches. In addition to the improved accuracy – particularly during pressure or temperature changes – these meters allow users to remotely monitor the pro-cess and can also control with an optional on-off valve. Further, the user can program the meter so that the data can be stored in the memory inside
the meter head for data download and analysis. The meters also provide a user-defined password for data safety.
Spirax Sarco’s TVA (Target-Variable Area) flowmeter is a mul-tivariable saturated steam meter with minimal straight-run requirements and has a 50-to-1 turndown. The meter features built-in density compensation for accurate mass flow measure-ment. It needs only six upstream and three downstream pipe diameters of straight piping, making it suitable for installation in confined spaces. The wafer is designed to provide lightweight, easy installation. Critical measuring surfaces are resistant to erosion by water droplets present in saturated steam, ensur-ing that accurate measurement is maintained over a long period. No accessories or flow computers are required. Integral keypad/display for easy setup and indication of
flowrate, total flow, pressure, temperature, and power.The TVA incorporates an innovative moving cone design,
which not only provides exceptional flow range capability; but it reshapes the flow profile to allow installation with short pipe runs. The cone’s large surface area disperses the high impact energy of wet steam, making it very resistant to erosion and reliable in the long term.
One application where the TVA is a particularly good fit is for universities that have widely variable flowrates between high winter and low summer steam loads. The TVA is capable of measuring these wide ranges in flow accu-rately with no modifications or required maintenance.
Thermal Mass Flowmeters for Gas Flow Control
Hot-Tap Dual-Technology Flowmeter
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TVA (Target-Variable Area) Steam Flowmeter
FC-0611-FA.1.indd 27 6/15/11 1:20 PM
Burkert’s Type 8691 control head is optimized for inte-grated mounting on linear process valves. The device features bright light LED visual feedback, universal 1/4” & 6mm tube connection, built-in cleanable air fi lter, positive air pressure electronics housing, wash-down environment optimization, and automatic switch position adjustment. An optional integrated pilot valve controls single or double-acting actuators. As an option, a fi eldbus interface (AS-Interface or DeviceNet) can be chosen. The calibration of the valve end position is accomplished through a contact-free analog position sensor, which automatically recognizes and saves the valve end position through the “Teach” function when
starting up. The device is designed to provide enhanced startup and validation time with automatic switch set-ting both for initial system startup and after mainte-nance on the underlying valves. Not subject to variation in target positions due to plant inferences.
Testimonial: “The Type 8691 is ideal to retrofi t any kind of piston operated pneumatic actuator. It is sturdy built and absolutely water and air tight. The Type 8691 can be setup to prevent environmental
air intake with effi cient installation, especially via ASI Fieldbus at an affordable price.” – A leading systems integrator, who has worked with the Type 8691.
28 June 2011 Flow Control
2011 fl ow control innovation awards
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ALMATEC’s FUTUR OMEGA-Series is a line of air-operated double-diaphragm pumps designed for high-end semiconductor applications. The line features a patented cascade sealing system and a patented air-control system for lubrica-tion-free and maintenance-free operation.
Using PTFE or stainless steel for all outside housing parts and nonwetted parts, safety is improved because the pumps are resistant to acid mists and acid leaking. The optimized
PTFE material of the diaphragm has a doubled-strength against fl exural stress compared to standard PTFE, helping to reduce maintenance and production costs.
Solid housing parts are machined on mod-ern CNC-machines, which enable the smallest possible tolerances. The solid housings absorb mechanical vibrations and noise level much bet-ter than thin-walled housings.
Brooks Instrument’s GF Series mass fl ow con-troller is a highly modular, user-programmable, metal-sealed device based on Brooks’ expertise in pressure transient insensitive (PTI) technology that is designed to minimize process gas fl ow variation due to pressure and temperature fl uctuations.
At the heart of the GF Series is Brooks’ MultiFlo, a patented technology that allows users to select new gas calibrations and full-scale ranges without the trouble and cost of removing the mass fl ow controller from the gas line. A major advancement over traditional single-point gas conversion factors, MultiFlo mass fl ow controllers typically deliver a three times improvement in accuracy through advanced gas modeling and compensation for non-ideal/non-linear gases. Selecting a new gas automatically establishes optimized PID settings for dynamic gas control, compensating for the effects of gas density and ensuring smooth overshoot-free transition between fl owrates with steady-state stability. The GF Series fourth-
generation MultiFlo technology continues to lead the market with the most accurate and most range-able performance through extensive refi nement and physical validation on critical process gases.
In 2010, Brooks increased the range of fl ow-rates available on the GF Series from 3 SCCM to 30 SLPM to a new full-scale fl owrate of 55 SLPM. The GF Series is offered with a 300 ms fl ow setting time (GF125) and one-second response (GF100/120). For applications requiring a slower
fl ow response, a user-programmable ramp function linearly transi-tions the fl ow between set points over a period of up to one hour with a resolution of 2 ms.
The GF125 enables users to simplify and reduce the size and cost of gas panels by eliminating the need for point-of-use pres-sure regulators, pressure transducers, and associated hardware.
Additionally, the all-metal fl ow path ensures compatibility with all gas media.
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Air-Operated, Double-Diaphragm Pumps for Semicon Applications
CONTROL
Mass Flow Controller Resistant to Pressure & Temperature Fluctuations
Advanced Control Head for Linear Process Valves
FC-0611-FA.1.indd 28 5/27/11 2:24 PM
Hawk Measurement’s Gladiator Acoustic Switch uses acous-tic wave technology in a new sender/receiver form for blocked chute protection, point-level detection, and anti-collision for heavy machinery. The Gladiator Amplifier powers two AW Transducers, which use special Hawk-developed software in which both units pulse and receive each other’s acoustic echoes. When the path between the transducers is blocked, the units immediately detect the presence/absence change of the return signal and trig-ger a communications relay for indication or control purposes.
The transducers work either together or independently to detect pulse interference, allowing twice the application security.
Hawk’s transducers do not require contact with the product. The switch requires a
simple one-minute setup and allows for remote test function. The acoustic switch supports continuous operation in dusty, wet
environments where other technologies fail. The transducers are used for blocked-chute detection in wet or dry environments.
Emerson Process Management’s Fisher 4320 wireless posi-tion monitor is a noncontacting and linkage-less wireless position transmitter and limit switch. It is a rugged measurement device that provides a precise wireless feedback signal to indicate equipment position with a percent of span plus on/off indication. The 4320 can be used to monitor equipment, such as valves or anything else that has a rotary or linear movement. The wireless position monitor peri-odically reads the position of a measured device and transmits that data over the wireless network.
The 4320 wireless position monitor is battery-powered, eliminating the need to install wires. A recently added
option enables the use of external DC power. These power options make it easier to design new applications or implement into retrofit locations. Instrument calibra-tion and commissioning is performed with a push-but-
ton and liquid crystal display (LCD) interface. The interface is protected from the environment within a sealed enclo-sure and supports multiple languages for ease of use.
www.FlowControlNetwork.com June 2011 29
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Circle 17 or Request Info Instantly at www.FlowControlNetwork.com
SPEC IT AND FORGET IT.Check-All Valve is yourone-stop supplier for thecheck valves you need in the materials you require. Better yet, every valve includes the experience, engineering, and application know-how you need for Òspec-it-and-forget-itÓ reliability. After all, you have better things to do, and check valves are all we do.
Call us at 515-224-2301 or e-mail us at [email protected].
www.checkall.com Since 1958West Des Moines, Iowa, USA
chute protection, point-level detection, and anti-collision for heavy independently to detect pulse interference, allowing twice the application security.
tion monitor is a noncontacting and linkage-less wireless position transmitter and limit switch. It is a rugged measurement device that provides a precise wireless feedback signal to indicate equipment position with a percent of span plus on/off indication. The 4320 can be used to monitor equipment, such as valves or anything else that has a rotary or linear movement. The wireless position monitor peri-odically reads the position of a measured device and transmits that
The 4320 wireless position monitor is battery-powered, eliminating the need to install wires. A recently added
option enables the use of external DC power. These power options make it easier to design new applications or implement into retrofit locations. Instrument calibration and commissioning is performed with a push-but
ton and liquid crystal display (LCD) interface. The interface is protected from the environment within a sealed enclosure and supports multiple languages for ease of use.
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Wireless Position Monitor & Limit Switch
Acoustic Switch for Indication & Control
FC-0611-FA.1.indd 29 5/31/11 7:41 AM
30 June 2011 Flow Control
2011 fl ow control innovation awards
seepex’s Smart Conveying Technology (SCT) is designed to enable more effi cient pump maintenance by making it easier to assem-ble and dismantle the pumps.
SCT is the next logical development after seepex’s Smart Stator Technology. By sepa-rating the stator into two halves, seepex has optimized pumping technology. Since it was
launched, the globally patent-pending innovation has been success-fully installed in thousands of pump installations. Now, with the SCT tech-nology, it is also possible to replace the rotor in just a few easy steps.
Progressive-cavity pumps with SCT no longer have to be removed from the instal-
lation for mainte-nance. Dismantling
and reassembly of piping and the removal of other equipment components are
eliminated. Due to the inte-grated retensioning device, a simple
readjustment of the stator increases the service life of stator and rotor.
Testimonial: “Upgrading to SST has shown real benefi t to the process here at Wargrave. A complete rebuild has been replaced with a simple adjustment to restore fl ow and we have also been able to de-rag and de-ice frozen pumps in a mat-ter of minutes.” – Simon Mattin, Regional Maintenance Manager, Thames Valley East, United Kingdom
www.forcemeter.com
Designed For Force
Measuring fl ow made easy with ForceMeter Technology
FORCEmeter
Circle 18 or Request Info Instantly at www.FlowControlNetwork.com
pending innovation has been success-fully installed in thousands of pump installations. Now, with the SCT tech-nology, it is also possible to replace
nance. Dismantling and reassembly of piping
and the removal of other equipment components are
eliminated. Due to the inte-
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Sierra Instrument’s Smart Trak 2 high-pressure controller features a pat-ented, inherently linear Laminar Flow Element (LFE) design, advanced platinum sensor technology, and a patent-pending notched valve spe-cifi cally designed for high-pressure appli-cations. The device can control fl ow over ranges from 5,000 PSIG in to 0 PSIG out to 5,000 PSIG in and 4,990 PSIG out.
The unit is available with a Pilot Module, which is a front-mounted or hand-held control device that allows users to employ Sierra’s Dial-A-Gas technology to change fl owrate, modify engineering units, or reconfi gure the instrument. With the Pilot Module, the user can set zero, span, and full scale for each of 10 different gases.
With the addition of Sierra’s Compod technology, the Smart Trak 2 transforms into a network-enabled MODBUS RTU with programmable relays and analog inputs.
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Smart Conveying Technology for Pump Maintenance
Mass Flow Controller for High-Pressure Gas Applications
FC-0611-FA.1.indd 30 5/26/11 2:13 PM
www.FlowControlNetwork.com June 2011 31
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AODD pumps with Warren Rupp’s AirVantage Energy Saving Technology are equipped with a microprocessor that is
adaptive and continuously manages the amount of air volume required to operate the pump at desired flowrates.
This adaptive tech-nology determines the optimal diaphragm rod velocity and relays the information to an air-
distribution valve at the air inlet location of the pump. The valve acts as a gated air man-agement system, allowing only enough air to enter each inner-pump chamber. Diaphragms perform at their optimal operating point, with less air consumption. As the pump experienc-es air inlet fluctuations or other changes that affect air flow, the system adapts to optimize
the pump’s performance.
Testimonial: “[Over a 30-day] period of time, AirVantage reduced our air consumption by 23 percent while maintaining our desired flow rates.” – Rick Klok, Plant Manager, Grains and Powders Manufacturing Facility, Saint Gobain
Top Line Process Equipment Company’s E-360 Diaphragm Valve Actuator is designed so that the actuator power unit can be easily maintained and the functions of the unit can be changed without exposing the product process to atmosphere. Thus, the device eliminates product contamination and reduces prod-uct loss, delays and costs incurred restart-ing the system and/or system revalidation. Key features of the device include:• Air inlets are on a 360-degree swivel ring • Bright yellow 360-degree visual indicator • Black Polyamide power unit (stainless steel optional)• Stainless bases for all valve configurations• Power unit can be either normally closed, normally open, or double-acting• Each power unit is head-rated for use with either Teflon-faced or elastomer-type diaphragms• Stainless bases will accommodate either bayonet or threaded-style dia-phragms• Standard North American connections – NPT
• Specifically designed to meet cGMP manufacturing practices
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32 June 2011 Flow Control
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Kuriyama of America’s Piranhaflex Plus 100R7 Hydraulic Hose provides a special low-friction cover to eliminate hose-routing problems between hose sheaves and pulleys when used in Fork Truck hydraulic applications.
Although the Piranhaflex Plus hose provides similar PSI charac-teristics to other hydraulic hoses in the marketplace; its unique, specially engineered low-friction polyurethane cover compound makes it easier to rout the hoses when bundled in fork truck applications. This important characteristic, along with increased flexibility, helps to extend hose service life with less frequent
replacement of hoses required.Use of Piranhaflex Plus hoses
in a fork truck application elimi-nates hose-sticking problems and premature cover wear due to chafing, which requires replacement hoses to be used more frequently.
Even though Piranhaflex Plus hydraulic hose is still a relatively new product in the field, similar uses of this special Piranha-made cover, used in the sewer and jetting hose industries, have already shown to provide increased wear characteristics in very tough application environments.
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Colder Products’ Hybrid Connector combines fluid, air and electrical lines in one easy-to-use connection. Integrating these connections allows clinicians and users to make a single, simple and secure connection between hand pieces and equipment, eliminating multiple connection points and potential misconnections.
The Hybrid Connector includes a panel-mount-ed female socket for use in the device or equip-ment and an integral hose coupling that comes complete with an eight-inch umbilical hose, containing all wiring and fluid tubing. The fluid couplers are made from glass-filled polypropylene with stainless steel valve springs and EPDM o-rings. The external parts, such as housings and rotating collar, are also polypropylene. The hose coupling has an acetal collar that secures the tubing to the coupler. Finally, the external umbilical tubing is flexible and re-enforced PVC with PVC fluid tubes routed through
the umbilical. Operating temperatures range from 40 F (4 C) to 100 F (38 C). Pressure ranges from vacuum to 45 PSI (3.1 bar).
The vast majority of the medical equipment available today has fluid, air and electrical con-nections carefully separated. However, so many different connections on a machine or device can be confusing for clinicians and end-users, leading to potentially fatal consequences. The innovative dry break valved fluid connectors
in the Hybrid Connector have no spillage or inclusion upon dis-connection, allowing fluid lines in the connector to be in close proximity to the multiple electrical contacts. Multiple connections can be made with one simple motion that is easy and intuitive for clinicians and end-users alike.
In addition, design engineers can now directly integrate hand pieces and equipment, streamlining and simplifying their product.
Trelleborg Sealing Solutions’ Turcon M12 is a polytetrafluoroethylene (PTFE)-based sealing material provides key hydraulic sealing char-acteristics, such as friction, wear, and high-pressure operation.
Testing has shown that Turcon M12 is resis-tant to virtually all media, including a broad range of lubricants, and has outstanding wear-resistance and friction characteristics. The cost-effective material also provides customers with extended seal life, as well as a wide operating window in terms of temperature, pressure and velocity
Key to achieving maximum seal life is to make sure that seal-ing compounds match up to application parameters. If a material
can stand up to a greater variety of conditions, this makes the compound more versatile.
Considerable R&D time was devoted to develop a PTFE-based material that is com-patible with a broad range of lubricants. It also had to demonstrate minimal wear with excel-lent friction characteristics at extreme tem-peratures, high pressures, and rapid velocities.
A specification was put together for a “dream” PTFE material, one that could fit virtually all hydraulic applications. This, accord-ing to Trelleborg, was achieved this with Turcon M12, enabling the customers’ products to meet a more universal range of seal-ing applications.
’s Piranhaflex Plus 100R7 replacement of hoses required.
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34 June 2011 Flow Control
fl ow update
Ge F. Fischer Tells It His WayRefl ections From a Pioneer of Flow Measurement
By Jesse Yoder, Ph.D. & Belinda Burum
While at Gastech 2011 in Amsterdam, Flow Research inter-viewed Ge F. Fischer, founder
of the Instromet Group, for its interview series, “Pioneers of Instrumentation.” The story of Instromet is a fascinating one that involves several fl ow companies, including Ruhrgas, E.On, American Meter, and Elster. Today, Instromet has been absorbed by Elster and is part of the Elster Gas North America and Gas International business units. The Elster-Instromet group is a lead-ing supplier of ultrasonic and turbine fl ow-meters. In 2009, the company introduced a bi-directional turbine meter designed to signifi cantly reduce pressure drop while providing a fl ow capacity matching exist-ing ultrasonic gas meters. The company also has developed a gas metering solu-tion that is designed to reduce measure-ment uncertainty by combining turbine and ultrasonic meters in a serial solution.
Measuring Gas As a Hobby“I’m a hobbyist of gas measurement,” says Ge F. Fischer. “Even my wife says the only thing that interests me is gas.” Fischer spent 30 years as a key fi gure at Instromet and built the company into the Instromet Group, one of the largest and most infl uential fl owmeter manufacturers in the world. Fischer is now semi-retired, but he continues his love for turbine fl ow-meters and his distaste for “bean coun-ters” who hamper technology development with their incessant focus on short-term business results.
When Fischer sold Instromet 10 years ago, he started investigating a system for continuous online checking of specifi c turbine meters to eliminate the cumber-some need to pull a meter offl ine except when there is a negative indication. Today, he is still passionate about the need for easier methods of calibration and says he is about to come out with something new involving turbine meters as in-line verifi cation of calibration values. His son, Roger Fischer, works with Elster Amco de Sudamerica in Latin America, promoting the Instromet product line.
‘Rockwell-izing’ the Turbine MeterFischer’s career started as an engineer in the Royal Dutch Navy. In 1968, he began honing his range of professional skills in his fi rst non-military position at Rockwell Manufacturing (now Rockwell International). Over the years, Rockwell gave Fischer a range of business experi-ences, as well as training in the U.S., including a stint at Harvard University. “Being in European Rockwell, one time you had to be an engineer or salesman, anoth-er time the bookkeeper,” explains Fischer.
Rockwell started Fischer off in the Rotterdam and Brussels facilities. Fischer set up a plant for Rockwell in Essen, Belgium, that still stands today as an Elster-Instromet facility.
Rockwell was investigating gas pro-duction, sales, and marketing in The Netherlands and Europe after some gas fi nds a few years earlier in the North Sea near Groningen, The Netherlands. As a result of the gas fi nds, American Meter also developed a presence in The Netherlands.
At that time, Rockwell’s facility in Belgium was designing and constructing skid-mounted measurement and control stations for the European gas industry. One of its main customers was Gasunie, a Dutch natural gas infrastructure and transportation company operating in The Netherlands and Germany. Gasunie was using turbine meters, and at some point had a need for thousands of them. Instromet, which was founded in 1965, had the capability to produce these meters, so they earned the business and started building them.
Meanwhile, the owners of Instromet had a dispute and decided to offer the company for sale in 1971. Rockwell asked Fischer to buy the company.
“As I had set up a plant for Rockwell in Belgium, they instructed me to go and have a look,” says Fischer. “Then, when they bought it, they said, the distance is only 2.5 hours by car, why don’t you do this as well. So they put me in charge of the Instromet operation. On April 26, 1971, they said, ‘Here, Fischer, you have your little toy.’ And they fl ew back to Pittsburgh.
“At that time, the world wasn’t run by the bookkeepers yet. It was not run by the bean counters. So now I had the Belgium plant and a Dutch plant in Silvolde. I split my time between them on a weekly basis.
“We ‘Rockwellized’ the technology of the turbine meter, and we became, suddenly, the number one turbine meter in the world.”
The available European gas turbine meters were not designed for elevated gas pressures, and therefore lacked the accura-cy customers were seeking. Rockwell mod-ernized the turbine meter by stabilizing the
Ge F. Fischer, founder of the Instromet Group, has enjoyed a long and storied career in the fl ow measurement business, and he still may have a trick or two up his sleeve.
FC-0611-FC.1.indd 34 5/27/11 8:46 AM
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36 June 2011 Flow Control
measurement curve at elevated pressures. “Rockwell’s turbine meter made it
possible to measure gas under elevated pressures and at a far advanced accuracy range,” says Fischer. “Today everyone is making copies of those old turbine meters.”
Rockwell Chooses B1 Bomber Over Turbine Meters In the mid 1970s, Rockwell’s focus shifted, which was part of the reason it ended up selling its turbine meter business to Fischer.
“Rockwell had a defense contract for the B1 bomber, so nobody in Pittsburgh was really interested in a $5 million prod-uct when they had a $5 billion product,” Fischer explains. “They made me an offer I couldn’t refuse, I became a minority shareholder in the European Instromet, and Rockwell departed.”
“I started with Rockwell when everybody was driving cars. Then they were in the military and space businesses, and there weren’t any more cars left in Pittsburgh. Everybody was riding in helicopters to the various manufacturing plants.”
Fischer had two backers, banking shareholders who, he says, “had just bought an airplane at 40,000 feet and didn’t know how to fly the plane,” and an outspoken interest serving as a second guarantee from customer Gasunie.
After a year, one of the shareholders wanted out. Fischer and the other partner divided the shares. About six years later, that remaining partner suffered a seizure that left him paralyzed on one side, and he agreed to sell his majority shares to Fischer.
“The funny part was, Rockwell wanted to buy the company back again because things had changed,” says Fischer. “I was handicapped because they were offering real money, and I had to meet their offer. Anyway, that was all said and done, and I became the single majority owner of the group.”
Pitching Turbine Meters to the ‘Bean Counters’One of Fischer’s jobs as the new sole owner of Instromet in the early to mid 1980s was to move the mentality of major gas companies from orifice plates to tur-bine meters to measure large volumes of gas. Ironically, it was Fischer’s strategy of aiming his pitch at the bean counters that
contributed to his early success.“Gas companies are very conservative
and don’t like to change anything unless you can convince them it’s a good move financially,” says Fischer. “They were hold-ing on to the orifice meters. That’s what they learned. I always requested to talk to the CFIO,” he says. “I’d ask, ‘How good are your financial figures? Can we go over the details? How good is your accuracy? Are you plus or minus 0.1 or 0.5? Because, honestly, 0.5 accuracy, when you’re talking about couple of million dollars [of product], is a lot of money. The turbine meter’s accu-racy can’t be beat – you’ll see for yourself.’”
Adding Ultrasonic to the MixLater, Instromet bought an ultrasonic flow-meter line from Stork, a company located in Dordrecht, The Netherlands.
“Stork had been developing an ultra-sonic meter for many years but never had the reputation, so I bought it from them,” explains Fischer. “They had done a good job technically, but the owner wasn’t will-ing to commit sufficient effort. Marketing, developing a reputation, and seeking metrological approvals is expensive. Stork decided it wasn’t in their interest to keep the ultrasonic meter.”
Around that time, Instromet also obtained one of the biggest measure-ment contracts in Russia – $100 million. Instromet also became a 25 percent shareholder in TransCanada Calibrations Ltd. (TCC), not with cash, but with the promise to deliver ultrasonic and turbine flowmeters to serve as calibration instru-ments in the laboratory. TCC, located on the TransCanada Pipeline mainline, today provides turbine and ultrasonic meter repair and refurbishing, high-pressure nat-ural gas flow calibration, and pressure and temperature device calibration services to an international customer base.
The End of an EraAround 1998, Fischer was approached by Ruhrgas, owner of AMCO and Elster. The company started talking about the possi-bility of acquiring the Instromet group.
“First, I started laughing about it,” says Fischer. “I said, ‘Why don’t you invest 10-15 million DM and get yourself up the line?’” To this, Fischer says they respond-
ed, “We would like to, but we don’t have the ideas.”
Ruhrgas ended up buying Instromet in 2001 and internally transferred the essence to Elster. Then E.ON acquired Ruhrgas.
“At the time, Ruhrgas was doing about €16 billion and E.ON was doing€42 billion. Part of E.ON was Elster, which was doing €1.3-1.5 billion,” says Fischer.
Fischer says E.ON was unsure of what to do with Elster and ultimately sold it to CVC Capital Partners. In 2005, CVC Capital Partners acquired Ruhrgas Industries and renamed it the Elster Group.
Turbine Meters Still Shine“Turbine meters are still a ‘new’ technol-ogy,” says Fischer. “Turbine meters have built-in precision and the capability to remain accurate even with flow disturbance.
“Ultrasonic meters are excellent, except you may not know what will deform the flow — you can’t correct for that. You can do the straightening thing [provide a straight run] but once you do that, you’re back to a turbine meter configuration.
“Ultrasonic meters become of interest specifically in larger pipelines where there is no flow perturbation. If you have any flow disturbance up front of the meter, then you really don’t know what’s going to hit your ultrasonic meter, and you can’t com-pletely neutralize or stop that influence.
“In order to be sure of the accuracy of an ultrasonic meter, you really have to calibrate the meter together with the upstream and downstream pipeline. Now you have pipelines you have to transport to TCC or Euroloop system, which are almost their own Bible, and cost becomes a handicap.”
When turbine and ultrasonic flowmeters need to be calibrated, they are often taken out of service and shipped to a calibration facility. Shipping can be costly, especially if the meter is in a remote country or region. TCC and Euroloop are two such calibra-tion facilities. TCC is located in Manitoba, Canada, and was founded in 1999. It has provided ultrasonic and turbine calibra-tion services since 2001. Euroloop is a new flow calibration facility located in Rotterdam, the Netherlands. It provides calibration facilities for both oil and gas flowmeters. Euroloop was established
flow update
FC-0611-FC.1.indd 36 5/27/11 8:46 AM
by the Van Swinden Laboratorium (VSL), which was formerly National Metrology Institute (NMi). It was built with the coop-eration of a number of leading fl owmeter companies, including KROHNE, Elster Instromet, and Endress+Hauser. Euroloop began operations in March 2010.
A Legacy Continues “You know, when Rockwell sold out 40 years ago, they offered me a job in the States,” says Fischer. “I liked the money, but they were going to send me to Anaheim, and it’s a fi nancially oriented company. If someone says – can I inter-est you in something else? My answer is ‘Maybe.’ But I know what I’m doing in gas measurement, because that’s where I’ve devoted my time and my interest.”
Today, the Elster Group is one of the world’s largest electricity, gas, and water measurement and control providers. Its offerings include distribution monitoring and control, advanced smart metering, demand response, networking and soft-
ware solutions, and numerous related communications and services.
Elster has one of the most extensive installed revenue measurement bases in the world, with more than 200 million metering devices deployed over the course of the last 10 years. It sells its products and services in more than 130 countries across electricity, gas, water, and multi-utility applications for residential, commer-cial and industrial, and transmission and distribution applications.
Elster Group operates production facili-ties in Belgium, Denmark, Netherlands, France, Germany, Spain, Italy, United Kingdom, Turkey, Poland, Russia, Slovakia, China, England, Canada, Mexico, Argentina, and the United States. FC
Jesse Yoder, Ph.D., is president of Flow Research Inc. in Wakefi eld, Mass., a com-pany he founded in 1998. He has 23 years of experience as an analyst and writer in process control. Yoder specializes in fl owmeters and other fi eld devices, includ-
ing pressure and temperature products. He has written over 120 journal articles on instrumentation topics. Dr. Yoder can be reached at jesse@fl owre-search.com.
Belinda Burum, editor and writer, has worked in high-tech for 20 years as a technical marketing writer, marketing communications manager, and customer references consultant. She joined Flow Research in 2002, assisting in the devel-opment of market studies and serving as editor of Flow Research’s “Energy Monitor” and “Market Barometer” quar-terly reports. She can be reached at belin-da@fl owre search.com or 781 245-3200.
www.fl owresearch.com
In the July issue of Flow Control magazine, Flow Research will follow up this article with a detailed analysis of the tubine fl owmeter market and the technology trends in this category.
products. He has written over 120 journal
www.FlowControlNetwork.com June 2011 37
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FC-0611-FC.1.indd 37 5/27/11 11:02 AM
38 June 2011 Flow Control
fl uid handling 101By Zoran Savovic
The following Q&As are based on recent forum entries at PipeFlowCalculations.com, a website featuring calculators and a bulletin board for fl uid fl ow applications.
Defi ning Maximum Gas Pipe Velocity Q: What is the typical natural gas pipe velocity, and what is the maximum gas pipe velocity?
A: For underground installations, 20 m/s is normal. Maximum velocity in a pipeline, on the other hand, is defi ned by available pressure, but in control and safety valves, it can be allowed up to 100 m/s.
Q: Thanks for the information. I noticed from the calculator on PipeFlowCalculations.com that for two-inch pipe with 1,500 feet length, 90 PSI in and 10 PSI drop, it gives a result of 337 CFM gas fl ow with a 44 FPS and 50 FPS velocity. Shouldn’t the velocity of this be 257 FPS (based on that 337 CFM fl ow and two-inch pipe).
A: It would only be 257 FPS if pressure is at standard conditions at 1.013 bar, but since the pressure is 90 PSI (cca 6 bar), it is about six times less (257/6 = 44 FPS - approx.)
Q: So it’s acceptable to have a 20,000 CFH gas fl ow in a two-inch pipe with 90 PSI with a drop of 10 PSI? (yielding ~14m/s pipe velocity)?
A: Yes, it is just about perfect.
How to Calculate Gas Consumption Q: We have a batch fryer in our food processing plant. There is a gas fl owmeter to record the fl ow of gas. We use LPG that is stored in a sphere, underground. The gas supplier bills us for LPG in MT (assume in liquid form). How do I calculate consumption and cost of the LPG per pound of cashews/nuts roasted. The fl owmeter readings in cubic M/hr are recorded at the start of fryer and after shut down of fryer, during which time “X” pounds of nuts would have been roasted.
Flow Problems SolvedForum Selections from PipeFlowCalculations.com
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www.FlowControlNetwork.com June 2011 39
Obviously, we have to trace the consumption in vapor form to liquid form, to fi nd out the costs.
A: First you need to know if the fl owrate of the gas mixture is measured on real conditions with some pressure that is above atmospheric. Or is it already converted to standard conditions with volume corrector? If the fl owrate that is measured is already converted to standard condition, calculation of mass fl owrate is straight-forward. You must know the composition of the mixture -- propane butane ratio -- like 30-70 percent or so. Then the density of that mixture can be calculated based on the density of every single component and its participation in mixture. For the theory on how to calculate fl uid mixture density, see:http://fl wctrl.com/iF932N Component density should be used on standard conditions, and you can view the table for it at:http://fl wctrl.com/l0Ni0e When you have the fl uid-mixture density, then the measured fl owrate should be multiplied with the density to determine weight fl owrate:
G=Q x rho
where:G = weight fl owrate -- which is the same for gas and liquidQ = measured fl owrate - volume rho = mixture density
If the measured gas fl owrate is not con-verted to standard conditions, then the density of every single component should be used on the pressure and temperature that is on the point of fl owrate measure-ment. This means you should use compo-nent density on standard conditions using the gas state equation. Calculate density on a given pressure.
p1/rho1=RT1
p1/p2 * rho2/rho1 = T1/T2 if 1 is for standard conditions thenrho2 = rho1 * T1/T2 * p2/p1
Relationship BetweenReynolds Number & Flow Through an Orifi ceQ: Hi, I was wondering about your soft-ware -- I was looking for something like it for years gone by, but it looks wrong that in changing the viscos-ity of the fl uid from a light oil to a thicker one, like from 10 to 100 cSt (or mm^2/S) the fl owing liters pass-ing by the orifi ce increases instead to
decrease. Can you explain if I’m wrong, or not?
A: It may seem incorrect, but if you look at the equation for fl owrate through an orifi ce, you can see that only in terms of discharge coeffi cient C, through Reynolds number, viscosity is treated. Also, in the equation for discharge coeffi cient, Reynolds number is in the denominator, which means if viscosity is higher, Reynolds number is lower, and the coeffi cient of discharge is also higher, which results in higher fl owrate for the same pressure dif-ference in front of and after the orifi ce. That is a mathematical solution and confi rmation for this prob-lem, but what about the physical? I would say that due to higher viscosity, the vena contracta effect is smaller, and the contraction of fl ow stream after the orifi ce is not as big as it is with a less viscous fl uid. As contraction of the fl ow stream after the orifi ce is smaller, the fl ow cross section is bigger and, correspondingly, the fl owrate is also higher. To review the theory from ISO for orifi ce fl ow, see: http://fl wctrl.com/jyqIci FC
Zoran Savovic�is a mechanical engineer with more than 10 years of experience in fl uid transport systems design and engineering. He is also the owner and editor of pipefl owcalculations.com.
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fl uid handling 101
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40 June 2011 Flow Control
the pump guyBy Larry Bachus
The greatest detective in literary history asserted that obser-vation and deduction were a science that could be developed and exercised to remarkable heights. In
“The Greek Interpreter,” Sherlock Holmes and his brother Mycroft (another private-eye, though retired) astound Dr. Watson (Holmes’ assistant) with a superb demonstration of obser-vation and deduction while they sit comfortably in a London pub.
Mycroft spoke fi rst. “This is an excellent place to study mankind. Consider the short, tanned fellow with his hat pushed back, carrying several packages. He’s coming towards us now.” Sherlock, Mycroft and Dr. Watson peered into the street through the window at their booth.
“An old soldier, I perceive,” said Sherlock. “And recently dis-charged from service,” remarked Mycroft.
“I’d say he served in India as a non-commis-sioned offi cer. Royal Artillery, I fancy,” said
Sherlock. “And a widower, with a child.” added Mycroft.
“Children, my dear boy, children,” said Sherlock. Seeing Dr. Watson gap-
ing with astonishment, the two detectives explained.
“Surely,” said Sherlock, “it’s not hard to say that a man with that bearing, expression of authority, and sunbaked
skin is a soldier – more than a pri-vate – and is not long from India.
You see, India is the only sunny place where England currently stations troops.”
Mycroft added, “It’s obvious the man is recently discharged from the service. He still wears his
ammunition boots. He doesn’t have the stride of a cavalry offi cer. Yet, he wears his hat on one side, as is shown by
the lighter skin on that side of his brow. He is in the artillery. His weight doesn’t support work as a trench soldier.”
Sherlock continued the observation. “Then, of course, his com-plete mourning shows that he has lost someone very dear. The fact that he is doing his own shopping looks as though it were his wife who died. He has been buying things for children, I perceive. There is a rattle. One of the children is very young. His wife may have died in childbirth. The fact that he has a picture book under his arm shows that there is another older child to be thought of.”
Amazing? For sure! Impossible? No! Especially when you con-sider that this piece of observation and deduction was actually performed by Dr. Joseph Bell, a professor of surgery at Edinburgh University in Scotland. Dr. Bell inspired Arthur Conan Doyle to cre-ate the fi ctional detective Sherlock Holmes.
These preceding paragraphs illustrate my work as a pump consultant. (I don’t just teach pump courses.) The “Pump Guy” observes and deduces, aided with over 40 years of experience as an industrial maintenance practitioner.
Recently, I had the occasion to address some problematic pumps at an ethanol processing plant in the upper Midwest. I recalled reading Sherlock Holmes. And while my performance did, by no stretch of the imagination, approach the heights that only the inimitable private eye could attain, it was, nonetheless, rewarding. Beginner’s luck, I presume.
Joe F., a supervisor at the ethanol plant, met me at the luggage carousel in the Minneapolis airport. We loaded my stuff into a com-pany pick-up and started a two-hour trek into northern Iowa.
Joe dodged the potholes with his left hand. His right hand was busy shuffl ing two plastic cups. A diet soda was in one cup. The
Observation & DeductionAn Intuitive Investigator Finds a Solution to a Pressing Pump ProblemAn Intuitive Investigator Finds a Solution to a Pressing Pump Problem
he greatest detective in literary history asserted that obser-vation and deduction were a science that could be developed and exercised to remarkable heights. In
“The Greek Interpreter,” Sherlock Holmes and his brother Mycroft (another private-eye, though retired) astound Dr. Watson (Holmes’ assistant) with a superb demonstration of obser-
his hat pushed back, carrying several packages. He’s coming towards us now.” Sherlock, Mycroft and Dr. Watson peered into the street through the
“An old soldier, I perceive,” said Sherlock. “And recently dis-charged from service,” remarked Mycroft.
“I’d say he served in India as a non-commis-sioned offi cer. Royal Artillery, I fancy,” said
Sherlock. “And a widower, with a child.” added Mycroft.
“Children, my dear boy, children,” said Sherlock. Seeing Dr. Watson gap-
ing with astonishment, the two detectives explained.
“Surely,” said Sherlock, “it’s not hard to say that a man with that bearing, expression of authority, and sunbaked
skin is a soldier – more than a pri-vate – and is not long from India.
Mycroft added, “It’s obvious the man is recently discharged from the service. He still wears his
ammunition boots. He doesn’t have the stride of a cavalry offi cer. Yet, he wears his hat on one side, as is shown by
the lighter skin on that side of his brow. He is in the artillery.
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other cup held Joe’s tobacco-chewing spit. Both cups bounced and wobbled in the two console cup holders. I was wor-ried Joe might drink from the wrong cup. I moved my computer bag away from splash range.
Joe signed me in at the guard shack. The afternoon guard bummed a wad off Joe and the two of them talked and spit as I watched the safety video. Then we went to Joe’s office to talk.
Joe said they were beset with mechani-cal seal failures on five sister pumps. They had installed 16 cartridge seals on five
centrifugal pumps in the past year. The pumps were all ANSI spec, same model and brand, moving industrial water with the same suction and discharge pipe diameters. They were not parallel pumps because the discharge pipes went in dif-ferent directions, as the plant was built eight years ago.
Probing a bit, I learned that only one pump was eating seals. The seals on the other four pumps had run for over a year with no leakage. But one pump had eaten 12 cartridge seals in the last year. That accounted for the 16 seals.
It was pretty clear to me that this was a pump problem, especially since the pumps were “identical” and all of them handled cold, relatively clean water.
We walked to the maintenance shop to see the failed seals. Joe offered a wad to the shop foreman. My suspicion was reinforced when I observed that all the failed seals exhibited the same evidence. Considerable chipping on the outside diameter of the carbon face suggested
excessive vibration. I allowed the information to sink in.
As the three of us ruminated (mine was mental), something clicked in my mind as I recalled Sherlock and “The Greek Interpreter.” It was time to visit the five sister water pumps. As we walked through the plant, Joe pointed 40 yards ahead in the distance and said, “Those are the pumps over there.”
“And the fourth pump on the right is the problem!” I commented. Joe’s chew fell to the ground leaving a line of wet, brown drool on his white shirt. Joe stopped walk-
ing and exclaimed, “How the _&#@ do you know that from this distance?”
I responded, “Though the pumps and pipes are ‘identical,’ the motors are not. That fourth pump has a larger motor. It suggests one of two motives. That’s either a two-pole motor (3,500-rpm), or it’s larger because the pump is running on the right extreme of the curve. But, I can’t see that from here.” We walked.
Standing over the noisy pumps, I shouted, “The other pumps are running at 1,750-rpm. This fourth pump is on a 3,500-rpm motor. It’s larger than the oth-ers, and making more noise.”
Joe inserted another wad. With his attention diverted, I touched the offending fourth pump with my right hand and the fifth pump with my left hand. There was a noticeable difference. Joe tugged my shirt sleeve and led me away from the noise toward the shade of a fire-hose shack.
Joe asked, “What do you know about a pump by looking at the electric motor?” I answered, “The Affinity Laws state that
42 June 2011 Flow ControlCircle 26 or Request Info Instantly at www.FlowControlNetwork.com
the pump guy
Recently, I had the occasion to address some problematic pumps at an ethanol processing plant in the upper Midwest. I recalled reading Sherlock Holmes. And while my performance did, by no stretch of the imagination, approach the heights that only the inimitable private eye could attain, it was, nonetheless, rewarding. Beginner’s luck, I presume.
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fl ow changes proportional to the change in speed. Twice the speed generates twice the fl ow. The same laws also state that power changes by the cube of the change in the speed. Twice the speed requires eight times (23) the power to drive the pump. This fourth motor is larger, probably for more fl ow. And this fourth pump and motor are making all the noise.”
Now, any pump or seal manufacturer will tell you that shaft runout should not exceed two thousandths of an inch (0.002”) on a mid-frame ANSI pump. That fi gure includes a safety factor, because they know that in the real world, four and fi ve thousandths runouts are common. At twice the speed and eight times the power, this poor pump shaft is experienc-ing severe runout (maybe 0.040”) and vibrations, which supports the chipped and broken seal carbons.
I led Joe back to the sister water pumps. This time we both put our fi nger-tips onto pumps one, two, three and fi ve, noting the noise, heat and vibrations. A circle of mechanics and workers (the audi-
ence) had gathered around us.Then Joe touched the casing of number
four pump. Although pumping the same cold water, the number four pump was notably hotter. And, sure enough, the vibrations were excessive on number four. And I said so.
An onlooking mechanic raised his eyebrows and commented that the word “excessive” was a relative term. I shot back that he was absolutely right. The vibra-tions on pump number four (with the larger motor) were excessive relative to the level of vibrations in the other sister pumps.
I stretched my novice luck with another deduction. “This pump eats bearings too!” Joe’s eyes fi xed on the ground, in silence. He didn’t deny it.
We returned to Joe’s offi ce and sound insulation. Joe asked, “What can we do?” “There’s a lot we can do,” I said, “but not today. It’s already 5:18.”
Joe took me to the hotel. The next morn-ing, Joe negotiated potholes with his left hand for two hours back to the Minneapolis airport. We scheduled a return visit to the
ethanol plant. As we bounced, the same two cups of diet soda and stale spit wobbled in the console cup-holders. Joe alternately reached for both with his right hand. I slid my computer bag away from splash range. True Story! Thanks Sherlock!
It is always possible to fi nd the answer to a problem if we make a point to dog-gedly search for it and to constantly increase our knowledge. Bad Actor pumps don’t exist. Remove these words from your vocabulary. I wish you all a millionaire’s future and a rewarding professional career with pumps. FC
Larry Bachus, founder of pump services fi rm Bachus Company Inc., is a regular contributor to Flow Control magazine. He is a pump consultant, lecturer, and inven-tor based in Nashville, Tenn. Mr. Bachus is a retired member of ASME and lectures in both English and Spanish. He can be reached at [email protected].
www.bachusinc.com
44 June 2011 Flow Control
the pump guy
ethanol plant. As we bounced, the same two cups of diet soda and stale spit
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think tank
ACCURACY: The variation in outlet pressure that occurs under steady-state conditions within the control range of a regulator.
BACK PRESSURE: A back-pressure regulator is designed to keep an inlet pressure constant and controls this pressure even with varying flow. A back-pressure regulator can either open, in case of excess pressure, or close when the pressure drops below a certain level.
BIAS: The pressure increment that is adjusted or preset into a regulator and is usually held constant during normal functioning (differential pressure).
CAPTURED VENT: A feature incorporated in a self-venting pressure regulator that provides an additional flow path to permit the piping away of expelled fluids from the regulator’s vent valve.
CONTROL: Ability of the regulator to hold a given outlet pressure setpoint.
CRACKING PRESSURE: In back-pressure control, the term used to describe the inlet pressure to the regulator at which flow starts.
CREEP: Any increase in the outlet pressure subsequent to lock up – usually a long-term, slow pressure increase. This indicates a regulator leak and requires service.
DOMELOADING: A method of energizing a pressure regulator using a compressed gas (usually air or nitrogen) in place of a spring.
DROOP: The outlet pressure change from the set pressure, which occurs as flowrate increases.
LOCKUP: The outlet pressure increase that occurs above the set pressure as the flow is decreased to zero.
PILOT REGULATOR: A pressure regulator that feeds gas or hydraulic pressure into the dome of a dome-loaded regulator. The pilot regulator should be self-venting or provide a constant bleed reference in order to permit pressure in the dome to be adjusted to a lower pressure.
POPPET: A sealing mechanism that restricts flow through the orifice between the high- and low-pressure regions of the regulator.
PRESSURE REDUCING: A pressure-reducing regulator is designed to reduce pressure between the inlet and the outlet and control the reduced outlet pressure to a set value.
REGULATOR: A device that controls pressure at a predetermined value or varies it according to a predetermined plan.
REPEATABILITY: The ability of a regulator to return to the same set pressure subse-quent to being subjected to various pressure and flow demands.
RESEAT PRESSURE: The inlet pressure of a back-pressure regulator at which flow stops.
RESOLUTION: Number of handle turns needed to adjust a regulator from its lowest to highest outlet pressure setting.
SELF VENTING: A feature that enables the unit to vent the outlet pressure when the knob handle is adjusted in the “decrease” direction.
SET PRESSURE: The desired outlet pressure of a regulator, normally stated at a single flow condition.
SPRING LOADING: A method of energizing a regulator using spring force.
The terms and definitions for this issue’s Word Search were contributed by Swagelok Company (www.swagelok.com).
ACCURACY
BACK PRESSURE
BIAS
CAPTURED VENT
CONTROL
CRACKING PRESSURE
CREEP
DOMELOADING
DROOP
LOCKUP
PILOT REGULATOR
POPPET
PRESSURE REDUCING
REGULATOR
REPEATABILITY
RESEAT PRESSURE
RESOLUTION
SELF VENTING
SET PRESSURE
SPRING LOADING
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48 June 2011 Flow Control
Which of the following common fluids is most viscous?
A. Water
B. Honey
C. Mustard
D. Peanut Butter
E. Cannot Be Determined
CommentaryViscosity is the ability of a fluid to flow over itself. Viscosity is dependent upon composition, temperature, and the amount of stress applied to the fluid.
The composition of water is well-defined, so its viscosity is also well-defined, likely the lowest among these liquids. The composi-tion of honey, mustard, and peanut butter can vary such that (for
example) “heavier” mustard could be more viscous than honey, while “lighter” mustard could be less viscous. Peanut butter is likely more viscous than either honey or mustard. The correct answer appears to be Answer D.
Additional Complicating FactorsComplicating the above analysis is that temperature also affects viscosity, whereby increasing temperature generally reduces the viscosity of the fluid. Therefore, increasing the temperature of peanut butter will reduce its viscosity. Conversely, decreasing the temperature of honey will increase its viscosity. Therefore, it is conceivable that the viscosity of hot peanut butter could be lower than the viscosity of cold honey.
Without more detailed investigation, Answer E may be the pragmatic choice. FC
David W. Spitzer is a regular contributor to Flow Control with more than 35 years of experience in specifying, building, install-ing, startup, troubleshooting, and teaching process control instru-mentation. Mr. Spitzer has written over 10 books and 150 techni-cal articles about instrumentation and process control, including the popular “Consumer Guide” series that compares flowmeters by supplier. Mr. Spitzer is a principal in Spitzer and Boyes LLC, offering engineering, expert witness, development, marketing, and distribution consulting for manufacturing and automation companies. He can be reached at 845 623-1830.
www.spitzerandboyes.com
think tank
quiz corner: Measuring Fluid Viscosityby David W. Spitzer
MAY SOLUTION: Water Treatment
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