Flow Control May 2013

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Considering Thermal Shutoffs • Trends in Membrane Filtration • Pump Terms Gone Wild

InnovationInnovation20132013

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contents

16 Using Interface Level to Optimize Water Dump Control

By William Sholette

The process of removing water from the separation vessel is referred to as a “Water Dump.” The water is “dumped” to a treatment plant for processing, while the oil is removed from the top for further refin-ing. Because of the high cost of treating the water, it is critical to know when the interface between the water and oil reaches a low point to prevent dumping oil to the water treatment facility.

22 2013 Flow Control Innovation Awards Nominees

By Flow Control Staff

The Flow Control Innovation Awards recognize compelling new tech-nology solutions for fluid movement, measurement and contain-ment. The technologies highlighted in this issue represent final nom-inees for this year’s awards program. Reader voting is now open.

32 Part I: Flow Trend WatchBy Jesse Yoder, Ph.D.

Based on results of Flow Research’s new Volume X: The World

Market for Flowmeters, 4th Edition, Part I of this two-part series focuses on important trends, applications, and recent develop-ments in new-technology flowmeters.

36 Considering Thermal Shutoff Valves for Oil & Gas

By Jean Steckler

New technology for thermal shutoffs uses Nitinol shape memory alloy system, originally developed for NASA space station applica-tions. Nitonol’s shape memory effect changes certain metal alloys from one shape to another with temperature changes, a direct result of a transformation of the alloy’s crystal structure.

2 | May 2013 Flow Control Magazine


AWARDSAWARDS®

Flow Control (ISSN #1081-7107) is published 12 times a year by Grand View Media Group, 200 Croft Street, Suite 1, Birming-ham, AL 35242.

A controlled circulation publication, Flow Control is distributed without charge to qualiied subscribers. Non-qualiied subscrip-tion 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 copies $10 per issue in the U.S. and Canada. Single copies $15 per issue in all other coun-tries. All subscription payments are due in U.S. funds.

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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 ofices.

© Entire contents copyright 2013. No portion of this publica-tion may be reproduced in any form without written permission of the publisher. Views expressed by the bylined contributors should not be construed as relecting the opinion of this pub-lication. Publication of product/service information should not be deemed as a recommendation by the publisher. Editorial contributions are accepted from the luid handling industry. Con-tact 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.

®

may 2013 | Vol. XIX, No. 5

16

16

32

22

1616

The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2013 Fisher Controls International LLC. D352200X012 MZ8

You can automate your control signal using the Fisher® Control-Disk™

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contents continued

departments8 NEWS & NOTES membrane filtration outlook; energy

management; fluid treatment trendlines

44 UP CLOSE with Rosemount’s CriticalProcess

Vortex Flowmeter

45 WEB RESOURCE FILE

46 ADVERTISER/ PRODUCT INDEX

47 WORD SEARCH filtration & separation

48 QUIZ CORNERmeasuring the flow of mixed liquids

columns6 VIEWPOINT the future of industrial training

14 APPLICATIONS CORNERhow much straight-run is really enough

40 PUMP GUY making sense of senseless pump terminology


40

A number of methods can be used to measure the interface between

water and oil. These include every-thing from manual sampling to

sophisticated continuous level mea-

surement instruments, such as guided wave radar and gamma radiation transmitters. But for water dump con-trol, an on/off capacitance level switch inserted near the water outlet is almost always the preferred alternative.

“

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In April, I attended Mr. Spitzer’s In-

dustrial Flow Measurement Seminar at

Endress+Hauser’s state-of-the-art Process

Training Unit near Philadelphia. I always

enjoy sitting in on the trainings we present

because they offer me the opportunity to

directly interact with our readers. It’s also

quite informative to hear the exchanges be-

tween attendees and their interactions with

the presenters as they discuss the applica-

tion issues they face in their work. I find I

learn as much, or more, from the tangential

conversations that arise during the semi-

nars than I do from the standard course

material, as it is in these impromptu discus-

sions that very specific, real-world scenarios

are considered.

As I listened to one such exchange dur-

ing the Flow Measurement Seminar, I got to

thinking about the future of industrial train-

ing and the role digital training solutions will

play going forward.

As I see it, here in the United States,

we are facing a triple-threat when it comes

to technical knowhow: 1. A large swath of

highly skilled technical professionals are re-

tiring from the workforce (whether they want

to or not); 2. These skilled professionals are

being replaced with relatively inexperienced

individuals, who lack the critical expertise

you can only gain through hands-on job

experience; and 3. U.S. companies aren’t

spending as much as they used to on con-

tinuing education programs.

I think digital/online training programs

could help bridge the gap between the dire

need for technical knowhow and the ever-

shrinking training budget. Certainly, the price

point for an online training is significantly

lower than that of an in-person training

where travel expenses and time away from

work are usually required. That said, I don’t

see how an online training environment can

enable the sort of information sharing de-

scribed above—where attendees are enter-

ing into detailed sidebar discussions among

themselves and with the presenter to solve

real-world challenges.

As such, while I think digital/online pro-

grams have a role to play in the future of

industrial training, I think they should be

viewed more as a supplement to, rather

than a replacement for, in-person training

programs. At the trainings I’ve attended over

the years, I see how the course material

lights the spark that leads to the discussion

that ultimately results in a breakthrough.

This evolution of a seed of information can

only happen in a face-to-face, in-person

training environment.

Certainly, I acknowledge that since we

offer in-person training, my stance here is a

bit self-serving. That said, just because it’s

self-serving doesn’t mean it’s not rooted in

reality and truth. FC

Thanks for your readership,

— Matt Migliore, Executive Director of Content

[email protected]

VIEWPOINT


The Future of Industrial Training

PUBLISHERJOHN P. HARRIS | (205) 408-3765

[email protected]

ASSOCIATE PUBLISHER

MICHAEL C. CHRISTIAN | (908) [email protected]

EXECUTIVE DIRECTOR OF CONTENT

MATT MIGLIORE | (610) [email protected]

MANAGING EDITOR

AMY W. RICHARDSON | (859) [email protected]

COLUMNISTS

LARRY BACHUS; DAVID W. SPITZER; JESSE YODER

ART DIRECTOR

JULIE [email protected]

MARKETING MANAGERMARY BETH TIMMERMAN

SUBSCRIPTION & REPRINT REQUESTS:

[email protected]

Administrative TeamGENERAL MANAGER

BARRY LOVETTE

VICE PRESIDENT OF OPERATIONSBRENT KIZZIRE

VICE PRESIDENT OF MARKETINGHANK BROWN

DIRECTOR OF CIRCULATION & FULFILLMENT DELICIA POOLE

CIRCULATION ANALYST ANNA HICKS

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: Water Technology ExecutiveJames Matson: GE Measurement & ControlJohn Merrill, PE: EagleBurgmann Industries

Steve Milford: 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

VGG R A N D V I E W M E D I A G R O U P

WINNER

WINNER WINNER

Here at Flow Control, our goal is to help you, our reader, become well-informed and pre-

pared to effectively interface with the applications and technologies you encounter in your job. We do this primarily through the magazine you’re now reading, our website FlowControlNetwork.

com, our various e-newsletters, and our social media programs. In addition, we also present the

Pump Guy and Industrial Flow Measurement seminars, which are led by regular Flow Control contributors Larry Bachus (“The Pump Guy”) and David W. Spitzer, respectively.

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THE OUTLOOK | News & Notes

Researchers say membrane technology is emerging as an increasingly viable solu-

tion for water and wastewater treatment due to its production of high-quality effluent. Intense research and development efforts over the last few years have improved mem-brane technology to make it more efficient, which, in turn, is helping drive down costs and attract new investments.

Frost & Sullivan’s recent analysis (www.environmental.

frost.com), Membrane Technologies Market in Water and

Wastewater Treatment in Southeast Asia, found the market

earned revenues of $249.1 million in 2011 and expects this

to reach $398 million by 2017.

“Earlier, a greater number of membranes were required

to achieve a certain level of quality, but now the improved

efficiency of membranes means that water and wastewater

treatment facilities can lower investments in technologies,”

says Frost & Sullivan Research Associate Prashanth Kay.

“While the effectiveness of membranes is unchallenged, their

compact and scalable features make them ideal for water

and wastewater treatment, especially in desalination.”

Frost & Sullivan chose to study Southeast Asia, Kay says,

because researchers realized this market was growing faster

than expected. Since most Southeast Asian countries are not

as heavily invested in water technologies as water-scarce coun-

tries, they wanted to learn the reason for growth. “I suppose

in terms of trends—the reduction in costs due to increases in

efficiency, and the pure effectiveness of membranes in treating

water—crosses all geographic borders,” Kay says.

The drivers for increased adoption of membrane technol-

ogy in the North American water and wastewater industry are

similar, according to Frost & Sullivan’s North America Energy

and Environment Industry Analyst Eric Meliton. Namely, he says

membrane growth is due to water scarcity issues on a regional

basis, increasing demands on freshwater resources from in-

dustrial manufacturing sectors, and water stress in arid regions

of the U.S. requiring ways to maximize freshwater resources.

“In contrast to Southeast Asia, North American municipali-

ties and industrial participants already use a wide variety of ad-

vanced treatment systems, with membrane technologies being

a major part of that,” Meliton says. “Demand is based on treat-

ment need and procurement budget to implement and operate

the treatment technologies utilized. Many larger municipalities

and Tier I industrial participants have the financial means to

implement advanced systems such as membranes, but smaller

municipalities and Tier II/III participants have difficulties obtain-

ing the funding required to implement these systems, thus rely-

ing on outdated treatment technologies in many cases.”

While drivers may be similar across geographic boundar-

ies, Frost & Sullivan notes that water effluent quality differs

greatly among sectors of the water & wastewater treatment

industry. For this reason, membrane technology companies

are challenged to provide variations in technology to address

Advances in Membrane Technology Greater efficiency leads to wider membrane adoption for water & wastewater treatment


By Amy W. Richardson


these different needs, while keeping efficiency at the highest

level and costs at their lowest.

Membrane vs. ConventionalWhile membrane technology has been around for nearly three

decades, a large segment of the water & wastewater treatment

industry still opts for the less expensive and conventional treat-

ment systems. Conventional water treatment technologies

typically involve a combination of treatment processes such

as coagulation, sedimentation, filtration, and disinfection to

achieve a certain quality of filtered water. While less expensive

technologies and conventional systems are still widely used,

they are slowly being replaced, Meliton says.

“Chemical feed systems come to mind as the technology

being replaced by membrane technology and other advanced

systems; however, outdated systems will still be prevalent in

many municipal facilities that cannot generate the funding re-

quired to replace them outright,” he says. “And in water-rich

countries where water is cheap, the returns on investment from

new technologies such as membranes are still unjustified.”

Membrane technology is generally viewed as part of an

advanced treatment system, used to achieve a higher level

of standardized water & wastewater treatment depending

on application requirements. “In North America, membrane

technology is used as a secondary treatment requirement,

to address tougher contaminant levels in tandem with other

treatment systems,” Meliton explains. “Contaminant type and

level are key factors as to why a membrane system would be

incorporated into existing treatment requirements.”

The Membrane AdvantageChris Stafford, Ph.D., who works in the Material Science and

Engineering Division at the National Institute of Standards and

Technology (NIST, www.nist.gov), explains a key advantage of

membrane technology is the ability to remove contaminants

having a range of sizes from the feed stream. “This is achieved

through a series of membrane elements that successively

remove smaller and smaller solutes from the water, starting

with microfiltration and ending with reverse-osmosis (RO),”

he says. “This will become increasingly important as we begin

to see emerging contaminants entering into previously ‘clean’

water sources, either through run-off/pollution or bioterrorism.”

Stafford says other advantages of membrane technology

are the reduced manufacturing costs of polymeric membranes,

higher efficiency, and less dependence on chemical treatments.

“Membrane filtration is more effective over conventional

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Membrane bioreactors—usually microfiltration (MF)

or ultrafiltration (UF) membranes immersed in aeration

tanks (vacuum system), or implemented in external

pressure-driven membrane units, as a replacement for

secondary clarifiers and tertiary polishing filters.

Low-pressure membranes—usually MF or UF mem-

branes, either as a pressure system or an immersed sys-

tem, providing a higher degree of suspended solids re-

moval following secondary clarification. UF membranes

are effective for virus removal.

High-pressure membranes—nanofiltration or reverse-

osmosis pressure systems for treatment and production

of high-quality product water suitable for indirect potable

reuse and high-purity industrial process water. Also, recent

research has shown that microconstituents, such as phar-

maceuticals and personal care products, can be removed

by high-pressure membranes.

Source: This information was provided by CDM Smith, www.CDMSmith.com, a provider of integrated solutions in water, environment, transportation, energy and facilities.

Membrane Technologies for Wastewater:

treatment systems in that the conven-

tional systems are not able to achieve

100-percent removal of particulate and

dissolved matter, regardless of the perfor-

mance of the filter,” says Kay. “With mem-

brane filters, only particulates that are

smaller than the pore size of the mem-

brane can pass through, meaning the

quality of filtrate can be controlled by the

user. As membrane filters remove most

of the dissolved micro-organisms at the

filtration stage, the use of chemicals for

water treatment is markedly reduced and

sometimes unnecessary, leaving the treat-

ed water more safe for consumption.”

Membrane technology, however, is not

without its disadvantages. First, and per-

haps most notably, membrane technology

carries a higher price point than conven-

tional systems. In addition, Stafford says

nanofiltration (NF) and RO polymeric

membranes are prone to fouling, have a

greater energy footprint, and are pH sen-

sitive. “In particular, membrane fouling

remains a huge problem with NF and RO

membranes, where unlike other mem-

branes, thin-film composite membranes

cannot be cleaned via back-flushing,” he

says. “Thus, we rely on heavy chlorination

to clean the membrane surface, but many

polymers used in RO and NF degrade over

time when exposed to chlorine.”

Technology AdvancementsMembranes have been around for the

past three decades, though use has

mostly been commercial, says Kay. “As

differentiations in membrane technol-

ogy have come about (Microfiltration,

Reverse Osmosis, etc.), the use of

these membranes has been able to

reach the regular household due to

increased efficiency and hence, scal-

ability,” he says. “What is meant by

this is that membranes are now able

to filter water at a faster rate over a

set area of filtrant. So basically, it takes

less surface area of a membrane now

to filter a certain amount of water over

a certain period of time, making mem-

brane systems more compact and eas-

ily integrated to any size of application.”

Stafford says one promising area of

research underway centers on “self-heal-

ing” and “self-cleaning” membranes.

“Self-healing and self-cleaning mem-

branes are currently being researched

and would represent a huge technologi-

cal breakthrough for membrane design,”

he says. “There are various strategies

being taken, including tuning the hydro-

philicity and roughness of the membrane

surface to control what deposits on the

surface, as well as constructing mem-

brane surfaces that can slough off its

outer-most layer or ‘skin,’ taking with it

whatever is attached to the membrane

surface as well.” Currently, Stafford says

NIST does not have any projects in the

pipeline associated with these areas.

Meliton says advances in operational

efficiency; lowered cost of technology ac-

quisition and implementation; and com-

plexity and dynamic design have all been

factors leading to more effective use of

membranes in wastewater treatment ap-






plications. He says, “This is especially true

in regional applications in which treatment

requirements (more challenging contami-

nant levels) are being addressed and in

applications where membrane technol-

ogy is used to enhance existing treatment

systems to further strengthen the overall

treatment capabilities of the plant design.”

Room for ImprovementWhen it comes to manufacturing and

implementing new membrane technol-

ogy for water & wastewater treatment

purposes, manufacturers and end-users

both see reducing energy consumption

as a necessary goal.

“A key challenge for both sides is re-

ducing the energy consumption from a

membrane system,” Kay says. “Manu-

facturers find this an important area

they need to improve upon, which will

drive higher sales. Another challenge for

the end-user side is the recovery factors

from membranes in desalination and

how to dispose of brine.”

Meliton says, in the short-term, cost

of acquisition and design implemen-

tation are key factors that limit wide-

spread acceptance. “Operational costs

related to energy levels, requirements

of tandem systems (e.g., reverse-osmo-

sis), and high costs of acquisition/pro-

curement reduce the appeal to smaller

municipalities,” he says. “Long-term,

the stigma to change existing systems

is still a key factor, since many opera-

tors rely heavily on the performance of

existing systems and there is a lack of

a regional need to enhance or improve

existing operational efficiency. This is a

factor that is prevalent in this industry

segment in North America and will con-

tinue to be a limiting factor for any ad-

vanced treatment technology, including

membrane technologies.”

On the Horizon Going forward, challenges will continue

to be the need for highly skilled human

capital, as well as the financial capital

needed to operate membrane-based

water treatment systems.

“The demand for purer potable water

and the increase in regulations for the

industrial sector will ensure this mar-

ket continues to grow,” Kay says. “Par-

ticipants can make the most of these

opportunities by focusing on using the

different forms of membrane technology

to provide the best combinations at the

most cost-effective prices.”

Amy W. Richardson is the manag-

ing editor of Flow Control magazine.

She can be reached at ARichardson@

GrandViewMedia.com.

trendlines

Industrial Energy Mgmt. Revenue to Double by 2020

Annual revenue from industrial energy

management systems will reach

$22.5 billion in 2020, essentially dou-

bling their 2013 level, according to

a new report from Navigant Research

(www.navigantresearch.com).

Growth is expected to be driven by

the evolution of Industrial Energy Man-

agement Systems (IEMSs) to enable

industrial facilities to minimize energy

use and waste while still meeting the

demands of production, Navigant Re-

search says. With their global pres-

ence, extensive domain expertise, and

established infrastructure to support

long-term engagements, large original

equipment manufacturers (OEMs) have

long been the leaders in this market.

However, the market is changing rapid-

ly, the report says. Major IT companies

with expertise in handling large data

sets and sophisticated real-time busi-

ness analytics applications are making

inroads, as are smaller players.

Mergers & Acquisitions Shuffle Leaderboard in Fluid Treatment & Control Market

Pentair has emerged as the new

leader in the market that treats and

controls liquids and gases (including

air), driven in part by the addition of the

revenues it added through its recent

acquisition of Tyco Valve, according to a

new report from the McIlvaine Company

(www.mcilvainecompany.com). With

Tyco Valve, McIlvaine says Pentair pump

and filtration revenues generated a

combined $7 billion in sales in 2012,

and a 3.5 percent increase is antici-

pated in 2013. This will create revenues

of $7.2 billion in the treatment and

control sector.

The total market for treatment and

control is forecast to rise 5 percent to

$340 billion in 2013, but the leader will

only garner 2 percent of the market, so

the market will remain quite fractured.

The treatment and control market is

increasingly being recognized as a dis-

crete market, according to McIlvaine.

Various players, however, view the mar-

ket slightly differently. Parker Hannifin

sees a $100 billion market in which it

is the largest player at $13 billion. With

its filtration, hydraulics and pneumat-

ics products, it is a major participant in

treatment and control, but is not among

the top five, according to McIlvaine’s

rankings.

For more information on this report,

visit www.mcilvainecompany.com.




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Flow Control Innovation

Award Nominee

Air/Gas/Water/Fluids Treatment and Control Markets

Ranking Company2012 Sales $ Millions

2013 % Increase

2013 Projected Sales $ Millions

1 Pentair 7,000 3.5% 7,420

2 Ecolab/Nalco 5,000 5.00% 5,250

3 Flowserve 4,400 7.19% 4,654

4 Xylem 4,000 5.79% 4,230

5 GE 3,800 4.83% 3,983

trendlines

Source: McIlvaine Company

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I recently read an interesting email exchange that was

originated by a person who was involved with a large (over

30-inch) orifice-plate flowmeter. He stated that ISO 5167

required 20 diameters of straight run upstream, but that the

installation only allowed for 10 diameters.

Approximately 5 percent accuracy was

required, and the writer wanted to know

how much the shortened straight run

would affect the flow measurement and if

repeatability would be good.

The first response to the inquiry was

that an insertion flowmeter might be more

economical and still produce the desired

accuracy. The responder also wanted to

know if the fluid was a liquid or gas, lead-

ing me to believe that the orifice-plate flowmeter was in the

process of design and had not yet been installed.

The originator responded by saying that this was a liquid

application and that he could not change the technology

because the flowmeter had already been purchased. In ad-

dition, the originator repeated that accuracy was not a big

deal because the flowmeter would be used for “minimum

flow control,” and reiterated wanting to know if the measure-

ment would be repeatable and reliable with the shortened

straight run.

I interpret “flow control” to mean that the flowmeter is

one component in a flow control loop that includes a flowme-

ter, controller, and control valve. “Minimal” could mean either

that the purpose of the control loop is to maintain a minimum

operating flowrate, or that maintaining tight flow control is not

really that important to the process. Given the relatively wide

accuracy requirement, I suspect that the latter is more likely.

More next month … FC

APPLICATIONS CORNER | Flow Measurement

Part I: Considering a Large-Line Orifice-Plate FlowmeterHow Much Straight-Run Pipe Is Really Needed to Produce the Desired Results?


David W. Spitzer

Approximately 5 percent accuracy was

required, and the writer wanted to know how much the shortened straight run would affect the flow measurement and if repeatability would be good.

“”

David W. Spitzer | Insertion Flowmeter | Flow Mea-surement | Orifice-Plate Flowmeter | Straight Run

FLOWSTREAM Find related content @ flowcontrolnetwork.com

David W. Spitzer is a regular contributor to Flow

Control magazine and a principal in Spitzer and Boyes,

LLC, offering engineering, seminars, strategic marketing

consulting, distribution consulting, and expert witness

services for manufacturing and automation companies.

Mr. Spitzer has more than 35 years of experience and has

written over 10 books and 250 articles about flow mea-

surement, instrumentation and process control.

Mr. Spitzer can be reached at 845 623-1830 or spitzer

andboyes.com. Click on the “Products” tab to find his

Consumer Guides to various flow and level measurement

technologies.

© 2011 FMC Technologies. All rights reserved.

www.fmctechnologies.com

We put you first.And keep you ahead.

FMC’s Flow Research and

Calibration Lab is accredited

through NVLAP (NVLAP

Laboratory Code 200939-0) to

ISO/IEC 17025:2005 and meets

all OIML standards.

We are not the only

ISO 17025calibration lab.

Today’s challenging hydrocarbon custody transfer environment demands

precise and reliable metering. That means equipment, like Smith Meter® brand

products, must exceed design specs and prove dependable against a wide range

of flow conditions. FMC Technologies’ accredited Flow Research and Calibration

Lab puts every meter through the paces, giving you confidence that the volume

delivered is accurate, time after time. Experienced technicians can apply dynamic

testing of flow rates between 30 to 6,670 m3h (200 to 42,000 bph) and viscosi-

ties of between 2 to 250 cSt making it the widest test range available, anywhere.

Whether it’s a custom ultrasonic or a specialized turbine meter, you know that

Smith Meter products from FMC will perform in the real world just as they did in

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Just the one that ensures

ultimate accuracy.


Fracking is becoming widely used in

the oil and gas industry, and as it grows

in popularity, treating produced water

coming from wells is becoming a major

challenge, especially because the cost

of cleaning produced water is about

300 times that of cleaning municipal

wastewater.

A similar problem exists at oil refiner-

ies, where incoming crude oil contains

water that must be removed prior to refin-

ing. At refineries, crude may contain any-

where from 3 percent to 5 percent water.

The volume of water produced is de-

pendent on a number of factors, includ-

ing source of the oil, age of the well,

type of separator, and location in the

refining process. Volumes ranging from

several hundred to millions of gallons a

day are possible.

Whether the separation is done at

the well site or at the refinery, one of

the most critical parts of the process is

measuring the level of the interface be-

tween oil and water in the separation

vessel. A correct measurement ensures

the maximum amount of oil is drawn off

for refining purposes, and a minimum

amount of oil and hydrocarbons are

sent to the water treatment process.

Water Separation ProcessesOil in production fields contains varying

amounts of water depending on the

specific oil reservoir, the age of the well,

and the methods used in extracting the

oil from the ground. Some separation

of water from the oil is done in the field

to reduce the amount of water that is

transported to the refinery.

At a well site, especially one that

uses fracking, the separated water must

be treated on site or at a nearby water

treatment facility before the water can

be returned to the environment.

Refineries take in crude oil from

production fields with varying levels

of Basic Sediment & Water (BS&W)

measurements. The higher the BS&W

measurement, the more water is in the

crude. The refineries separate the wa-

ter and other impurities through various

separation processes, including, but not

limited to, gravity separation, desalter

vessels, and skim tanks.

In all these processes, water sepa-

rates from the oil and must be evacuat-

ed from the bottom of the vessel, while

the hydrocarbons typically are removed

on a continuous basis by flowing over a

baffle at one end of the separation ves-

sel (Figure 1).

Essentially, all the various separation

processes involve a tank where oil and

water coexist, with oil on top and water

on the bottom. As the separation process

continues, the water must be removed.

Water DumpingThe process of removing water from

the separation vessel is referred to as a

“Water Dump.” The water is “dumped”

SYSTEMS DESIGN | Level Measurement


Figure 1. In a separation vessel, oil and water separate, with oil moving to the top and water to the bottom. Capacitance level switches are used to detect the oil/water interface.

A SOLUTION for Separation SuccessInterface Level Sensing for Water Dump Control in Oil & Gas Applications

In hydraulic fracturing (fracking) operations at oil and gas wells, water and oil both come to the surface and must be

separated. Oil and gas can be filtered from the water fairly easily, but the remaining water—called “produced water”—is contaminated and must be treated before being released into the environment.

By William Sholette


to a treatment plant for processing,

while the oil is removed from the top

for further refining. Because of the high

cost of treating the water, it is critical

to know when the interface between

the water and oil reaches a low point to

prevent dumping oil to the water treat-

ment facility.

The main purpose of water dump

control is to prevent excess hydrocar-

bons from being sent to the water treat-

ment facility. There are two reasons for

this: First, in some cases there are fines

for dumping hydrocarbons to the water

treatment plant; second, the idea is to

maximize the hydrocarbon throughput

to the refining process, not dump it

down the sewer.

A number of methods can be used

to measure the interface between water

and oil. These include everything from

manual sampling to sophisticated con-

tinuous level measurement instruments

such as guided wave radar and gamma

radiation transmitters. But for water

dump control, an on/off capacitance

level switch inserted near the water

outlet is almost always the preferred al-

ternative, for reasons delineated below.

Inside Capacitance Level SwitchesA capacitor is made up of two con-

ductive plates separated by a non-

conductive “dielectric” material (Figure

2). Dielectric materials are categorized

by their “Dielectric Constant” or “DK”,

which is a number that is related to the

material’s ability to store a capacitive

charge. The higher the dielectric num-

ber, the more capacitance it can store.

Capacitance is equal to the DK

times the Area of the conductive plates,

divided by the Distance between the

two plates, or:

C = (DK * A) / D

Capacitance sensors for level mea-

surement use these basic capacitance

concepts, with the vessel becoming one

plate of the capacitor (Figure 3) in point

level applications. That is, the probe

becomes one conductive plate, the

vessel or a ground reference becomes

the second conductive plate, and the

material being measured is the dielec-

tric material. In the case of conductive

materials such as ground water, the

Figure 2. A capacitance sensor can be used to detect the presence of conductive fluids.

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plates are essentially shorted out, pro-

viding a large change in capacitance.

A bridge circuit in the sensor’s elec-

tronic unit is balanced to null out the

capacitance generated by an uncovered

sensing element. As material covers the

probe, an increase in capacitance is gen-

erated on the probe side of the bridge,

which causes the bridge to become un-

balanced. This change is converted to

a switch command to allow a relay or

other output to indicate the status of the

switch, either covered or uncovered.

In the case of materials that leave a

coating on the probe, active buildup com-

pensation in the electronic unit provides a

means to compensate for the coating and

continue to provide reliable measurement.

Capacitance Level Switches for Interface DetectionKnowing where the interface between

the water and oil occurs is important to

prevent dumping oil to the water treat-

ment plant, resulting in loss of product,

extra cost for treatment, and potential

environmental fines.

Using a capacitance switch to iden-

tify the interface between the oil and

water is very effective because of the

dramatically different electrical proper-

ties of the two fluids. Ground water is

very conductive and acts to short the

two plates of the capacitor, causing an

almost infinite change in the measured

capacitance. The oil phase is not con-

ductive, and the low dielectric constant

of oil (around 2DK) causes a small

change in the measured capacitance.

This results in a very clear electrical defi-

nition between the two phases.

In a water dump tank, the sensor is

covered with a mixture of oil and water

until the separation process proceeds,

when oil moves to the top and relatively

clean water moves to the bottom. The

separated water will still contain some

oil, grease, iron, polymer additives,

paraffin wax, and other contaminants

that will be removed in the ensuing wa-

ter treatment process. The sensor will

probably never see pure water. However,

even with the contaminants, the water

phase will be conductive making it elec-

trically different then the oil phase.

The capacitance switch is mounted

at a point where the low interface be-

tween the oil and the water needs to

be detected. This could be a horizontal

installation just above the water dump

outlet line (Figure 4). The capacitance

switch could also be mounted directly

into the water outlet piping.

In some cases, the vessel has no

openings to mount the sensor horizon-

tally at the required point of control. In

these cases, a capacitance sensor can

be mounted from the top of the ves-

sel extended down to the control point.

Since the capacitance sensor will see a

large change between the water and the

hydrocarbon, vertical mounting is often

feasible, but a horizontal installation at

the control point is preferred.

The capacitance switch is set with

a large preload on the bridge circuit to

make it less sensitive. This allows the

switch to detect the water because of

the large change in capacitance due to

water’s conductive electrical properties.

The low dielectric constant and non-

conductive properties of the oil phase

will not generate a large enough change

in capacitance to exceed the large pre-

load on the bridge circuit.

The result is that the switch will

change states as soon as the water

drops below the tip of the probe. This

provides an extremely reliable indication

of the water/oil interface that can be

used to stop dumping.

Other Point Level Methods for Detecting InterfaceSeveral other methods are available to

detect the water/oil interface, but all

have significant disadvantages as com-

pared to capacitance level sensors:

Manual Sampling: The manual sam-

pling method is somewhat archaic, but

is still used in many facilities. A number

of valves are spaced vertically on the

side of the vessel. An operator opens

the valve briefly and pulls a sample.

By observing the sample visually, it can

be determined which valve yields water

and the next closest valve where oil is

present, thereby identifying the inter-

face as between the two valves.

Manual sampling has a number of

flaws. First, it only gives an idea of where

the interface is located—that is, some-

where between two valves. Since the

samples are taken manually, the location

of the interface is only as accurate as the

last sample. It also relies on a manual

visual interpretation of what is water and

what is oil. This interpretation is arbitrary



Figure 3. In a capacitance level sensor, the vessel itself becomes one plate of the capacitor, and the oil/wa-ter mixture is the dielectric material.

Figure 4. A capacitance level switch mounted just above the water dump outlet line can detect the presence of oil and send a signal to shut off the pump, thus preventing oil from reach-ing the water treatment process.

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and inconsistent with different operators.

Last, it is an operator’s judgment to de-

cide when to stop dumping, which adds

to the human error factor.

Sight Glass: A sight glass located in

the water dump outlet line can be used

to visually discern the change from the

water phase to the oil phase. As in the

manual sampling method, it relies on a

visual interpretation of what is water and

what is oil. Also, because the sight glass

is in the outlet line, some oil will inad-

vertently be dumped. As this is a manual

function, human error is introduced.

Conductivity Switch: Conductivity

switches operate by passing an electrical

current from one electrode to a second

electrode through a conductive liquid.

In an oil/water interface application, the

current passes through when water is

present. When the liquid changes to

non-conductive oil, the current no longer

passes between the electrodes and the

switch indicates a change of state.

Conductivity switches can and do pro-

vide reliable interface detection in many

installations. However, if the electrodes

become coated with a non-conductive

material such as heavy crude oil or paraf-

fin wax, the electrode will no longer be

able to pass current. This will indicate a

false reading until the electrodes have

been cleaned. For this reason, conductiv-

ity switches should only be used in sepa-

ration processes where the phases are

free of heavy material or contaminants.

Float Switch: Float switches can be

used for measuring the interface between

water and oil. The float is calibrated for

the specific gravity of water, which is 1.0

or slightly higher. The oil has a lower spe-

cific gravity, generally between 0.7 and

0.9. As the water level drops the float

arm moves down, providing an indication

of the low water control point.

Floats can be problematic in wa-

ter dumping applications for several

reasons. The moving parts of the float

switch are susceptible to wear and

damage. The float can be compromised

causing it to sink. Heavy crude and wax

can build up on the float and float arm,

causing hang-up and failures. Finally,

the specific gravities of both the ground

water and the oil are variable, requiring

calibration “tweaks” on a regular basis.

Keys to SuccessThere are a number of point level

approaches to measure the interface

between water and oil for water dump

control. Manual methods, such as sam-

pling valves and sight glasses are still

widely used in these applications. Using

level instrumentation to determine the

interface removes both the manual aspect

and human error from the procedure.

When comparing point level instru-

ments that can detect the water/oil in-

terface, the capacitance sensor stands

out as the best choice. Capacitance

level switches are simple to calibrate and

can be installed horizontally or vertically.

There are no moving parts to wear out or

hang up. Because capacitance has the

advantage of active build-up compensa-

tion, materials that coat, such as heavy

crude or paraffin, are not a problem.

Capacitance level switches provide

reliable water oil interface detection,

and help to automate the water dump

control process. FC

William Sholette is Level

Products Business Manager for

Endress+Hauser, Inc. Mr. Sholette

has been involved in level mea-

surement for the past 33 years in

virtually all aspects of process level

measurement instrumentation from

the manufacturing and sales, to his

present position in product manage-

ment. He can be reached at Bill.

[email protected].

www.us.endress.com



Level Measurement | Oil & Gas |

Separation | Water & Wastewater

Find related content @ flowcontrolnetwork.com…Search on:

FLOWSTREAM

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MODBUS Multiple Register Version

Coming Soon!


Rotork has announced the CMA range of compact, modulating actuators to complement its existing line of CVA electric actuators for control-valve, pump, damper, and other continuous-modulation applications.

CMA actuators offer an economical way for common, everyday process control applications to gain the benefits of accurate and repeatable position control as well as superior robustness – features associated with Rotork CVA electric actuators, which were introduced in 2008 and have proven highly successful in thousands of process control applications throughout the world.

Compact, accurate, lightweight CMA actuators operate on single-phase or DC power supplies without the need for air compressors and hoses. They are available in rotary, linear, and quarter-turn actions; have permanently lubricated and maintenance-free drive trains; and can be mounted in any orientation.

Redefining Flow Control

Rotork Process Controls5607 West Douglas Ave. Milwaukee, WI 53218

phone: 414 461 9200email: [email protected]

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Rotork CMA ac tuators increase scopeof elec tric control-valve technology.

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Redefining Flow Control Write in 18 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo

ASCO’s new 212 Series Solenoid Valves are made out

of a highly engineered composite body, which is a

good fit for use in water purification and water

treatment markets, specifically in the mem-

brane-based filtration system markets.

The new 212 series solenoid valve is

also ideal for use in Reverse-Osmo-

sis (RO) systems applications where

lead-free, NSF-approved constructions

are required. The composite series 212 valves are available in

½-inch and ¾-inch pipe size and are designed with the new

FasN connection system, the world’s first universal connec-

tion system. FasN enables an NPT thread connection, turn

& lock, and solvent bond fitting possibilities. The composite

valves handle water pressure up to 150 PSI and operate up

to 180 F. Low power coils come in 6.3 W in AC and 6.9 W in

DC normally closed versions.

In a high-production OEM environment, cost differ-

ences can be substantial when using newer tech-

nology versus conventional solutions. ASCO com-

posite valves with FasN connections demonstrate

a measured labor savings of 35 seconds per valve,

plus much greater materials savings depending on

which type of extra fitting or adapter would otherwise

be required. Assuming 1,000 RO units turned out per year,

with three valves per unit, a study comparing FasN connec-

tion to NPT-threaded valves on PVC piping calculated savings

of $15,790 per year. Another, versus NPT-threaded valves on

PEX tubing, showed savings of $40,930 per year.

What’s Innovative? 1) FasN technology can be used

for all threaded pipe types with NPT threads; and 2) NSF

certification to accommodate new regulations in many

parts of the world.

2013 FLOW CONTROL INNOVATION AWARDS


And the Nominees Are...Recognizing Outstanding Technologies for Fluid Movement, Measurement & Containment

The Flow Control Innovation Awards have showcased compelling new technology solutions for

fluid movement, measurement and containment for more than 15 years. The following rep-

resent final nominees for our 2013 program. Now we’re asking you, our readers, to vote for the

technologies you believe are most worthy of being named this year’s Innovation Awards winners.

Review the technology summaries provided below, and visit FlowControlNetwork.com to place your

vote. Winners will be announced in the August 2013 issue of Flow Control magazine.

Alicat Scientific developed its new Whisper

Series of mass flowmeters and controllers

with pressure drops as low as 4 mbar (0.058

PSID) for use in systems with very low pres-

sure sources or very low differential-pressure

availability. Beyond low pressure drops, the

Whisper series offers all of the same features

and benefits as Alicat’s standard line of flow

devices, including fast response (10 ms for

meters, 50 ms for controllers), a 200-to-1 turndown ratio, high

accuracy (0.8 percent of the reading plus 0.2 percent of the

full-scale flow), 30 field-selectable gases and gas mixes and

real-time monitoring of mass flow, volumetric flow, pressure and

temperature, all on one device.

The Alicat Whisper couples a very low differential-pressure

sensor with a redesigned flow body utilizing

Alicat’s patented laminar flow technology to

reduce the minimum pressure requirement

for applications needing flow measurement or

control. Together, these innovations result in

a device that requires almost no differential

pressure for full scale flow.

What’s Innovative? The extraordinari-

ly low pressure drops of Alicat’s Whisper Series distinguish it

from any other mass flowmeter or controller on the market.

For most meters and controllers of the Whisper series, the

full-scale pressure drop is less than 10 mbar (.145 PSID).

Yet even at 500 SLPM, the Whisper mass flow controller

requires only 1.74 PSID.

vote for this technology @ www.flowcontrolnetwork.com


Whisper Series Mass Flowmeters & Controllers

ASCO 212 Composite Valve

Ashcroft Inc.’s DG25 general-purpose digital pres-

sure gauge adopts the basic form and fit of a

standard 2.5-inch (dial diameter) pressure gauge

with a water-tight enclosure that provides IP67

ingress protection, making it suitable for wash-

down. A black or orange rubber boot is also avail-

able to further protect the gauge while installed

or carried portably as a test device. All-welded

stainless steel wetted parts also serve to protect the

gauge from adverse environmental conditions, as well

as ensure compatibility to many corrosive media. Ranges

from vacuum to 25,000 PSI are available and can be read

to accuracies of +/-0.5 and +/-0.25 percent full scale. Two

standard alkaline AA batteries power the DG25 for more than

2,000 hours. A five full-digit, .48-inch high LCD includes a bar

graph to show the pressure status relative to the full scale of

the gauge. When equipped with the optional backlight feature,

the DG25 can be easily read despite poor lighting conditions.

With the push of a button, the display can report the maximum

and minimum readings since last cleared, reset the

zero, tare a pressure preload, and read in a choice

of nine pre-programmed engineering units and

one that is user programmable.

Operating characteristics include:

• Range from vacuum to 0/25,000 PSIG• 5 full-digit LCD with optional backlight

• Battery life exceeds 2,000 hours• Accuracy to +/-0.25 percent full scale.

• 9ine engineering units, including user programmable• LCD includes bar graph indicator

• IP67 (water-resistant) enclosure

What’s Innovative? The DG25 digital pressure gauge

can be used in place of a traditional dial-mechanical pres-

sure gauge with many advantages, including easier readabil-

ity, greater accuracy and resolution, improved resistance to

shock and vibration, the ability to record max/min readings,

multiple units of measure, and more.



DG25 Digital Pressure Gauge

When voting for the 2013 Flow Control Innovation Awards, you will have the option to enter a random drawing to win a Kindle Fire HD. The advanced Kindle Fire HD 8.9-inch tablet delivers rich color and deep contrast from every angle. Featuring exclusive, custom Dolby audio, dual-driver stereo speakers, and auto-optimiza-tion software, the Kindle delivers clear, crisp, balanced sound. State-of-the-art dual-band, dual-antenna Wi-Fi (MIMO) technology enables fast streaming and download speeds. Place your votes now at FlowControlNetwork.com for a chance to win the Kindle.

VOTE to WIN a Kindle Fire HD

Image courtesy of Amazon.comInnovationInnovation20132013

AWARDSAWARDS®

Burkert presents a flexible solution for integration

of actuators in hygienic processes with AirLINE

Quick. The diverse areas of application for

Burkert’s valve terminals in the food and beverage and biopharma industries are

expanded by AirLINE Quick, a stainless

steel adapter plate and stainless steel

push-in connectors. Installation and com-

missioning are reduced to a minimum. End-users de-

termine the installation location of the valve terminal or valve

block: on the wall or floor of the control cabinet. AirLINE Quick

supports both options. It is reliable, compact, and saves time.

AirLINE Quick significantly reduces the number of compo-

nents in the control cabinet. Fewer pneumatic hoses and ca-

bles are needed, and AirLINE Quick can be integrated directly

in the floor or wall of the control cabinet, eliminating the need

for bulkhead connections on the cabinet. A unique feature of

Burkert’s Type 8640 and Type 8644 automation system is

the combination of the pneumatic connec-

tions, fieldbus interface, and I/O modules

directly on the floor or wall of the control

cabinet, which means the control cabi-

net can be generally smaller than in the

past. Some operating characteristics for

AirLINE Quick are:

• Reduced number of components• Fast installation

• In stainless steel for hygienic applications• In anodized aluminum for general purpose• Fully assembled control cabinet from one source

What’s Innovative?AirLINE Quick significantly reduces the number of components

in the control cabinet. Fewer pneumatic hoses and cables are

needed, and AirLINE Quick can be integrated directly in the floor

or wall of the control cabinet.


AirLINE Quick Stainless Steel Adapter Plate & Push-In Connectors



The Vertex mercury-free pressure sensor from

Dynisco sets a new, higher standard of monitor-

ing and control for plastics extruders.

Patent-pending capacitance tech-

nology is used to register pressure

directly at the tip of the sensor, with

no mercury or other fill medium. This

direct approach is more reflective of the

true process pressure and provides faster

response for better control in precision extru-

sion systems. The solid-state design means that

end-product quality cannot be compromised by

mercury or other liquid-fill contamination if the sensor is

damaged during production. Toxic waste management issues

are eliminated for both the manufacturer and the user. Other

improvements include rugged construction features—like

a thicker, abrasion-resistant diaphragm and fortified side-

walls—that minimize maintenance requirements,

extend the working life of the sensor, and

reduce the overall cost of ownership.

What’s Innovative? The Vertex pressure sensor employs

patent-pending capacitance technology

to register pressure directly for readings that

more accurately reflect true process pressure, as well

as faster response for better control of polymer flow in

precision extrusion systems. There is no chance of mercury

contamination, and toxic waste management issues are

eliminated for both the manufacturer and the user.

Cameron’s NUFLO Scanner 2000 is a

field-mounted flow computer available with

the FOUNDATION Fieldbus H1 interface. It

is able to sense and compute flows from

integral DP, pressure and temperature sen-

sors. Additionally or alternatively, the DP

measurement can be a pulse input device

such as a PD, vortex, Coriolis, ultrasonic or

turbine flowmeter. When measuring gases

or steam, the computed values are typically volume, mass and

energy. Liquid hydrocarbon measurements result in volume

and mass computations. Many installations can also simulta-

neously measure another uncorrected liquid volume.

To support regulatory and standards-based require-

ments, data logging, user change logs, tamper indication

devices and multilevel password security

are essential. The Scanner 2000 is the

first field-mounted custody-transfer flow

computer to act like a multivariable trans-

mitter and serve this data by FOUNDA-

TION™ Fieldbus H1 protocol. Simultane-

ously, fiscal record sets can be extracted

using Modbus RTU protocol. Data can be

captured via remote connection (wired or

wireless) or directly from the device itself.

What’s Innovative? The Scanner 2000 is an H1 FISCO device on the

FOUNDATION Fieldbus network. It is the only field-mounted

flow computer listed on the fieldbus.org registry.

Emerson Process Management’s Rosemount

8800 Vortex Severe Service Sensor uses premium

nickel alloy material. The non-wetted severe service

sensor is only exposed to the ambient environment.

With the new piezo crystal design, the severe service sen-

sor provides stable performance at high temperatures up

to 850 F. Designed with the customer’s needs in mind,

the Rosemount 8800 Vortex flowmeter system with

the new severe service sensor is a good fit for harsh

environments in chemical, power and refining.

The unmatched reliability at high temperatures

makes it a good choice for solar power and high-

temp hydrocarbon applications. Offshore and near-

shore applications specify nickel alloy sensors be-

cause of corrosive environmental concerns, and high

temperature will often further magnify the corrosion-

resistant needs. A major up-

stream oil and gas producer

has adopted the Rosemount

vortex severe service sensor

to avoid issues with marine

environment chloride stress

corrosion cracking on the

vortex sensor in high temperature process lines.

What’s Innovative? Rosemount 8800 Vortex severe service sensor

provides stable performance at high temperatures

up to 850 F, exceeding the 750 F high-temperature

thresholds of competitive devices.



Vertex Mercury-Free Pressure Sensor

NUFLO Scanner 2000 With FOUNDATION Fieldbus H1


Rosemount 8800 Vortex Severe Service Sensor



AWARDSAWARDS®

Endress+Hauser’s Promass 100 Heartbeat Technology

(HBT) provides on-board diagnostics, monitoring and

traceable verification to ensure product and process

safety with or without manual intervention and without

interrupting the process. The HBT monitor-

ing system is continuously online and guar-

antees the process is safe by ensuring the

meter is in good operating condition. In the

case of a sensor or electronic problem, real

text remedy instructions are provided for a fast and safe trouble-

shooting per NAMUR standards. The Proline Promass 100 is

an industry-optimized Coriolis flowmeter that offers fewer mea-

suring points in a compact, hygienic design. With one single

device for multivariable measurements, the Proline Promass

100 measures mass flow, volume flow, density, temperature,

and with the Promass I, viscosity with accuracy up to +/-0.05

percent—even with immunity from process and environmental

influences. With its compact and hygienic design, the Proline

Promass 100 is ideal for modular skid-mounted process facili-

ties looking for full functionality in the smallest footprint. Thanks

to its new circuit board design and low-mass components, the

Promass 100 has a 30 percent smaller footprint than typical

flow transmitters, and this compact design helps it meet hy-

giene and sterility requirements by offering 316L stainless steel

enclosures. The Promass 100 allows for seam-

less integrations into a variety of digital com-

munication protocols such as, EtherNet/IP,

Modbus RS485, and 4-20mA HART.

The Proline Promass 100 with Heartbeat

Technology includes three key features:

• Continuous self-checking with

Heartbeat Diagnostics—qualitative information and

device status from the sensor to the output is displayed in a

clear, concise way—based on NAMUR standards.

• Device measurement values through Heartbeat

Monitoring—continuous quantitative data can be used to

enhance process operations and allow proactive reaction.

• Seamless and traceable with Heartbeat Verification—

seamless and traceable verification results permanently stored

and can be retrieved immediately during recurring test.

What’s Innovative?Now with Heartbeat Technology, it is possible for the Proline

Promass 100 to monitor, diagnose and produce verifications

in its capabilities to ensure proper operating process func-

tion, and satisfy reporting requirements demanded in process

applications.

Equilibar has introduced its ZF Series back pressure regulator

to extend its uniquely high-precision performance down into

the nano-flow range. Traditional back pressure regu-

lators (BPRs) have limited precision across widely

varying flowrates. Many traditional BPRs incorporate

a pressure offset of several percent between their

steady state flowrate and their shut-off (zero

flowrate) condition. The new Equilibar ZF

regulator holds the inlet pressure within 0.5

percent from full flowrate down to an absolute zero

flow condition. Like Equilibar’s existing products, the ZF

is dome-loaded, sealing directly on the diaphragm. However, the

patent-pending ZF uses a rubber o-ring with a special floating

hub support (pictured top right here) to accommodate pres-

sures up to 3,000 PSIG. Incumbent products have a variety of

limitations. Traditional spring-adjusted back pressure regulators

are frequently used in lab settings, but often operate in a binary

(on/off) manner at very low flowrates (for example below 100

ml/min). These devices are useful in many research applica-

tions, but suffer from temperature limitations, modest precision,

and thermal cycle leakage. Equilibar’s back pressure regulators

address many of the issues mentioned above.

Operating characteristics of the new ZF Series include:

• Can be used up to 3000 PSI

• Can be used up to about 250 C• Has steady state (non-pulsing) low

down into the nano-flow range (<0.01

ml/min gas)

• Pressure control down to true zero low (hours or days with valved-off inlet condition;

stable pressure)

• Upper low limit recommended up to about 2,000 ml/minute

• Precision of 0.5 percent range through more than eight orders of flow magnitude

• Agreement between parallel units at similar lowrates is approximately 0.2 percent.

• FFKM o-rings to allow for repeated thermal cycles with-

out maintenance

• SS316L or Hastelloy diaphragms can be used for sensi-tive Helium or Hydrogen applications

• Stability of pressure across about 10 orders of low mag-

nitude is about 0.5 percent.

What’s Innovative? The new Equilibar ZF regulator

(originally nicknamed “Zero Flow” regulator) holds the inlet

pressure within 0.5 percent from full flowrate down to an

absolute zero flow condition—a vast improvement over typi-

cal BPRs that have pressure offsets of several percent.



Proline Promass 100 with Heartbeat Technology

ZF Nano-Flow Back Pressure Regulator



Fox Thermal Instruments’ Fox Model

FT3 thermal mass flowmeter and tem-

perature transmitter was designed to help

plant operators improve process efficiency,

comply with environmental mandates, and elimi-

nate the cost of annual factory calibration.

Of the many new design features of the Model

FT3, Calibration Validation is the most compel-

ling. It has optimized the way operators interface

with flowmeters by allowing the calibration of the meter to be

validated in-situ (without the need to remove the meter from

the pipe or send to the factory for re-calibration). Using CAL-

V, the test may be performed in the pipe, at process condi-

tions, with just a push of a button. The test takes about four

minutes to complete and a “Pass/Fail” result is given at the

conclusion of the test. Zero CAL-CHECK is a com-

panion test to the CAL-V Calibration Validation

feature, which tests the functionality of the sen-

sor and its associated signal processing circuitry. It

checks for build-up on sensor, validates the

zero stability of the meter, and checks ther-

mal conductivity.

What’s Innovative? The meter’s calibration can be checked with-

out sending it back to the factory. Without CAL-V and Zero

CAL-CHECK Calibration Validation, the meter must be returned

to the manufacturer annually in order to check its functionality

and for recalibration. With a “Pass” result from the CAL-V and

Zero CAL-CHECK tests, these tasks are no longer necessary.


Fox Model FT3 Thermal Mass Flowmeter and Temperature Transmitter

GF Piping Systems’ Signet 9900 Smart-

Pro Transmitter provides a single-channel

interface for multiple parameters includ-

ing flow, pH, ORP, conductivity/resistivity,

pressure, temperature, level, salinity, and

more. Designed for complete flexibility,

plug-in modules enable the unit to be eas-

ily adapted to meet changing customer

needs. The device has improved visibility over previous units.

A key feature of the device is its extra large (3.90 inches by

3.90 inches) backlit display that allows visibility at four to five

times the distance of other transmitters. This highly illuminat-

ed display and large characters reduce the risk of misreading

or misinterpreting the displayed values. The display shows

separate lines for units, main and secondary measurements,

as well as a dial-type digital bar graph.

Other capabilities include relay and warn-

ing LEDs and an intuitive menu for easy

programming. Older units were limited in

visibility to 3 feet, while the newer 9900s

are visible up to 30 feet away.

Optional plug-in modules include relay,

direct conductivity/resistivity, HART Com-

munications, and a PC configuration tool.

What’s Innovative? The single-channel, multi-parameter capability and field-

upgradable modularity enables increased service levels while

maintaining reduced inventories. Plug-in modules allow for

complete flexibility. Improved visibility over previous units.


Signet 9900 SmartPro Transmitter

The EXAIR USB Data Logger is a com-

pact device, which connects directly to any

EXAIR Digital Flowmeter to log and record

the compressed air flowrate through the

pipe on which the flowmeter is installed. It

can be set up to log the flowrate at intervals

ranging from once a second (covering a pe-

riod of about nine hours), up to once every

12 hours (over two years’ worth of data.)

When it is removed from the digital flowme-

ter and plugged into any available USB port on a computer, the

data can be viewed using the included EasyLog USB software,

or it can be exported directly into Microsoft Excel. The USB Data

Logger can be easily installed on an existing digital flowmeter, or

it can be ordered pre-installed on a new digital flowmeter.

EXAIR digital flowmeters have always

had the capability to provide an output

signal (4-20 Milliamp, Pulse, or RS-

485). These, however, can be limited by

the maximum functional cable length.

The USB Data Logger, however, can be

quickly and easily removed from its host

flowmeter for data transfer to the com-

puter, and just as quickly and easily re-

attached to begin gathering data again.

What’s Innovative? When the data logger is plugged into a computer, the data

can be viewed in the included software or exported to Excel.

This allows end-users to track flowrate easily on a computer.


USB Data Logger for Digital Flowmeter


In March 2013, Max Machinery’s Model P001

flowmeter hit the market. Designed to eclipse

the low-end capabilities found in other low-

flowmeters, the new P001 ultra-low flowmeter

offers capabilities of reporting flow volumes

down to 0.005 cc/min (for fluid viscosities

above 100 CPS).

The solution, which supports flowrates from

0.005 to 200 cc/min, is the world’s small-

est radial piston flowmeter. The P001 is at

the limits of what can be achieved in positive-

displacement resolution and offers the ability to

accurately measure in the sub 1 cc/min range of flow.

Meeting this challenge was achieved through a combination

of precision miniature machining, and advanced heat treating

technologies in conjunction with corrosion-resistant materials.

The positive-displacement flowmeter provides an answer

for start/stop flow applications, does not suffer from zero

drift, and is insensitive to flow turbulence. The P001 offers

4,000 pulses per meter revolution and k-factors as high

as 24,000 pulses per cc. It comes in at half the cost of

an ultra-low flow Coriolis meter, provides accuracy in in-

termittent applications, and offers enhanced output resolu-

tion with innovative, linearized transmitters with adjustable

dampening and anti-dither functionality.

What’s Innovative?Compared to other micro flow options, the P001 gives high

accuracy, immediate response and exceptionally low pres-

sure drop with thicker fluids.

Nanjing Youyang Control Technology Co.,

Ltd.’s SPINDLE is a new differential-pres-

sure flowmeter that generates the pres-

sure drop required to measure flow via a

spindle-like central body as the primary

flow element. The flowrate is determined

from the difference of the pressure mea-

sured at the pressure taps located in the

wall of the pipe in front of the SPINDLE and

at the annular channel between the central body

and the wall of the pipe. Providing optimized conditioning of

the flow inside the flowmeter is an important feature of the

SPINDLE meter, as accurate flow measurements require

the same flow conditions (same velocity profile, same Reynolds

number, same turbulence level, and same geometry of pipe-

line, etc.) when the flowmeter is calibrated in the laboratory

and when it is operated in industry. As the SPINDLE is

forcing an annular channel flow through a well-designed

central body, it is able to modify the dif-

ferent flow characteristics upstream of

the flowmeter into a very stable, repeat-

able and well characterized flow.

What’s Innovative?The SPINDLE minimizes the drag of the

central body (throttle), as the shapes

of the central body and the fins have

been carefully optimized so that no flow

separation occurs while keeping the pressure drop as high as

possible, hence, most of the pressure drop can be recovered.



SPINDLE Differential-Pressure Flowmeter

Model P001 Radial Piston Flowmeter

Magnetrol International’s ECLIPSE Model 706

is 2-wire, loop-powered, 4-20 mA level transmitter

that leverages the principle of Guided Wave Radar

(GWR) technology. High frequency electromagnetic

energy is sent down a probe that is contacting the

medium to be measured. A reflection occurs at

the product surface, and high-speed circuitry mea-

sures the time of flight and translates it into a level

measurement.

Key Advantages of the ECLIPSE MODEL 706

Include:

• Improved signal strength and a first-in-class signal-to-noise ratio enables use in very difficult high-pressure, high-temper-

ature, low-dielectric industrial applications.

• A broad overfill-capable probe line allows for accurate measurement all the way up to the top

of the probe.

• Advanced diagnostics allow the transmitter to automatically save pertinent troubleshooting

information and waveforms during an upset.

• Intuitive Local User Interface with graphical LCD display offers simple, easy-to-use configuration.

What’s Innovative?With an accuracy of up to +/-0.1 percent of

probe length or 0.1 inch (whichever is greater); and operat-

ing pressures and temperature up to 6,250 PSI and 850 F,

the transmitter is becoming a standard in the industrial liquid

level market.

ECLIPSE Model 706 Level Transmitter



AWARDSAWARDS®



Sage Metering’s Sage Rio Thermal Mass Flowmeter pro-

vides the performance, reliability, and accuracy of the Sage

Prime series of products, while meeting

requirements for hazardous areas Class 1,

Division 1, Groups B, C, D and ATEX Zone

1 approval (II 2G Ex d IIB+H2 T6 Gb). In

addition to the expanded hazardous area ap-

provals the Rio comes standard with HART in

addition to the 4-20 mA and pulse output

signals.

Class 1, Division 1 hazardous area

approval on the Sage Rio Thermal Mass

Flowmeter complements the Class 1 Division 2

approval of the Sage Prime. ATEX Flameproof ap-

provals combined with HART allows the Rio to be

used in Europe and other locations that prefer

ATEX safety ratings. One distinct feature of the Rio

is the low power consumption and heat input, which permits

the use of the product in some hazardous areas where other

thermal mass flowmeters cannot be used due to the need for

higher energy input.

What’s Innovative?Sage thermal mass flowmeters have demonstrated the capa-

bility for measuring the mass flowrate and utilization of gases.

They measure very low flowrates of gases with high turndown

capabilities and negligible pressure drop. Best accuracy is

obtained using actual gas calibrations. The reproducibility of

the instrument is excellent permitting the use of the unique

in-situ calibration verification, which confirms that the instru-

ment operates the same as the original NIST traceable

calibration.

Sage Rio Thermal Mass Flowmeter


Flow Problems?We Can Help>> Troubleshoot Problem Flow Measurements

>> Assess Billing Flowmeter Accuracy

>> Close Plant and Water Balances

>> Improve Flowmeter Accuracy

>> Select and Specify Flowmeters

>> Train Your People

WE KNOW FLOW!

www.spitzerandboyes.com • 1.845.623.1830Write in 31 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo

The Parker Veriflo HCV Cylinder Valve provides

maximum safety in oxygen delivery systems for

medical, laboratory, industrial, aviation, space, and

mining applications. Tested at pressures up to 6,000

PSI, the HCV Cylinder Valve maximizes product safe-

ty even in extreme conditions, including high-pres-

sure oxygen. All oxygen-wetted metal components

are constructed of burn-resistant alloys. The seat

is protected against particle impact, which reduces

the chance of ignition. The non-rotating seat design

reduces the potential for seat wear and damage that

can increase the risk of flow friction ignition and rotating

threads are outside the oxygen-wetted region, reducing par-

ticulate that could be generated and become an ignition risk

or contribute to seat damage.

What’s Innovative?The HCV valve’s unique combination of materials and design

features address historical cylinder valve ignition risks and

ensures maximum product safety.

1. Flow Friction: The HCV’s patent-pending design

includes several major innovations to the cylinder

valve’s seat. Most importantly, the seat is out of

the direct flow path, greatly reducing flow impinge-

ment/friction and adiabatic compression.

2. Adiabatic Compression: The valve seat is behind

a burn-resistant Monel keeper, reducing its exposed

surface area and protecting it from ignition. The seat

moves straight up-and-down (instead of rotating) and

has a metal-to-metal stop to prevent over-torqueing.

Both features greatly reduce wear and damage (extru-

sion) to the seat that can increase the risk of ignition from

either flow friction or particle generation/impact.

3. Particle Impact: Threads on traditional cylinder valves are

in the direct flow path, potentially creating particles that

can become an ignition risk. By contrast, the HCV’s rotating

threads are outside the oxygen-wetted area, limiting their

potential for particle generation.


Parker Veriflo HCV Cylinder Valve



AWARDSAWARDS®

Sierra Instruments’ QuadraTherm

640i/780i Series flowmeters offers

accuracy of 0.5 percent of reading

above 50 percent of full scale flow,

which is the highest accuracy specifi-

cation in the thermal dispersion flow

measurement market. High accuracy

is important for users because it im-

proves the quality of product and, in

the case of custody-transfer, saves

money. According to Sierra, the QuadraTherm 640i/780i can

compete with the accuracy of Coriolis meters, but at a frac-

tion of the installed cost.

QuadraTherm’s innovative sensor design accounts for all

the heat transfer variables that can skew thermal mass flow

readings. The innovation in the patented four-sensor technol-

ogy on which the QuadraTherm is based provides the critical

inputs to achieve +/- 0.5 percent

accuracy. In traditional “two-sensor”

flowmeters, the heat lost via stem

conduction is not accounted for. This

can introduce errors as high as 20

percent, depending on the gradient

between the gas temperature and

the temperature outside of the pipe.

What’s Innovative?As shown in the Figure here, two new temperature sensors

(T4 and T2) are added to the two-sensor design (T3 tempera-

ture and T1 velocity) used in traditional flowmeters. T4 and

T2 provide real-time measurement of stem conduction and

the heat lost to the outside environment. This innovation,

from two to four sensors, is the foundation for the shift in

accuracy offered by Sierra’s QuadraTherm 640i/780i.

seepex’s Pre-Engineered Skid System supports a wide vari-

ety of liquid chemical dosing applications, primarily in the dis-

infection processes of water and wastewater treatment

facilities. The customizable skid system comes com-

plete with all the components necessary for chemi-

cal dosing packaged into a single unit with (or

without) controls and framework. Compo-

nents include calibration column, pressure

gauge, pressure switches, dry-run protec-

tion, and flowmeters. Also included are supe-

rior quality seepex Progressive-Cavity Pumps. Com-

ponents of the pumps, such as valves, pressure switches,

and flowmeters, as well as materials of construction of pumps,

such as elastomers, exotic metals, and plastics, are custom

designed to the application. An integrated vector drive with au-

tomatic (4-20mA) or manual speed control also comes stan-

dard, eliminating the need for a local interface/control panel.

What’s Innovative?seepex packaged skid systems are designed to

eliminate the valuable time and costs associ-

ated with engineering, procuring, assembling, and

commissioning flow control systems. Systems are

commissioned at the factory according to the appli-

cation’s flow ranges and then calibrated according

to the flow control loop. The skids can deliver mild

to aggressive, thin to highly viscous liquids, as well as

corrosive and solid-laden chemicals. With chemical-resistant

materials, all skid components will hold up in harsh acidic

and caustic chemical environments.

Siemens’ SITRANS FC430 Coriolis Flow Sensor is

a compact, in-line mass flow sensor for liquids and

gases that provides high levels of accuracy and re-

peatability. The sensors can also measure the den-

sity and the temperature of the fluid in the flow

stream, and when the mass flow is combined

with the process density, volumetric flow can

also be measured.

Key features include:

• Small footprint low sensor for easy handling• SIL 3 certiication designed in from concept to production for safety and redundancy

• +100Hz signal processing for fast data delivery• Easily assessable internal back-up of all perfor-mance and certification data

• High immunity to external and process noise• QR code readable data onboard for easy ac-

cess of key equipment data, FAQs, and support

What’s Innovative? The SITRANS

FC430 flow sensor supports data update rates of

100Hz, and its small footprint makes it easy to handle

and a good fit for retro-fitting. Robust construction protects

against process noise. An online GUI with wizards makes

the device easy to set up and secure configuration.

QuadraTherm 640i/780i High Performance Thermal Mass Flowmeter

Pre-Engineered Skid System for Chemical Dosing




Coriolis SITRANS FC430 Flow Sensor



Spire Metering Technology’s RH40 Handheld Clamp-

On Ultrasonic Flowmeter is designed for convenience

is mobility. The meter weighs about 1 lb. and can be

operated with one hand. It is the smallest flowmeter

on the market, and its performance matches a fully

featured wall-mount flowmeter.

The RH40 relies on clamp-on ultrasonic trans-

ducers to effectively perform both flow and BTU en-

ergy measurements from outside of a pipe. It requires

no pipe-working and no process shutdown. With the

unique built-in Quick Start guide, one can conduct the

measurement within 10 minutes.

The RH40 combines several frequency systems into one

unit. This allows it to measure not only regular size pipes,

but also small and large pipes with excellent accuracy and

stability. With its Bluetooth interface, the RH40 can be

easily linked to a computer for data management. It

also offers 4-20mA and digital output for real-time

flow and BTU monitoring. Its data logger can log up

to 2GB data on velocity, flow, energy, temperature

and events.

What’s Innovative?The RH40 employs a patented signal processing

technology to maximally extract information from

received signal and to reduce statistic variants.

This technology has been implemented in a low-

cost microprocessor without using an expensive DSP chip,

resulting in increased accuracy at lower cost (30–50 percent

less) compared to similar performing ultrasonic meters.

RH40 Handheld Clamp-On Ultrasonic Flowmeter



AWARDSAWARDS®

Warren Rupp’s mobile applications for SANDPIPER and

Versa-Matic pump models are designed to help

pump owners at the distribution and end-user

level quickly and easily find the tools needed to

support their pump. With the mobile apps, cus-

tomers can quickly locate information related to

a specific pump using the “My Pump Details”

feature; can review the SANDPIPER and Versa-

Matic “Chemical Compatibility Guide,” browse

the latest full-line product catalogs, or watch

service and training videos. Pump owners can scan the

QR code located on the pump tag or manually enter a pump

serial number to get started.

Before the app was developed, customers had to either

call the manufacturer or visit the website and search for the

information needed to support their pumps. Customers

also had to reactively ask us for the information

they thought they needed. Now, the mobile app

proactively and comprehensively provides the

technical information any time of day, any day

of the week. In addition, the mobile app al-

lows the user to instantly submit a request for

quotation (RFQ) for SANDPIPER or Versa-Matic

products, right from their smart phone or tablet.

What’s Innovative?The mobile app is a first in the world of air-operated double-

diaphragm pumps. Pump owners can scan the QR code

located on the pump tag or manually enter a pump serial

number to get started.

Mobile Applications for SANDPIPER & Versa-Matic Pump Models


Singer Valve’s Model 106-SPI-MV is a single-point insertion

electromagnetic flowmeter installed and calibrated in con-

junction with a Singer valve to provide an accurate flowrate

that can be utilized with the metering valve as a stand-

alone option or built into a 106-2SC-PCO pilot sys-

tem to provide complete flow-based valve control.

The sensor is available for 1-inch taps, depend-

ing on valve size and application. The compact

insertion design fits in confined spaces and offers

complete accessibility. The flowmeter can be re-

moved for easy inspection, cleaning, calibrating or verification.

The flowmeter is available for valve sizes from 4 inches

(100mm) to 36 inches (900mm). The flow sensor comes

pre-calibrated and requires no recalibration in the field, and

is accurate at 2 percent of reading, not full scale like existing

in-valve meters. With no moving parts and a single-piece

design, the SPI Mag’s sensor contains nothing to wear

or break, and it is generally immune to clogging by

sand, grit or other debris.

The 106-SPI-MV Magnetic Flowmeter is pro-

filed for the valve body, further enhancing its

measurement accuracy by allowing precise de-

termination of mean velocities.

What’s Innovative?This is the first time a magnetic flowmeter has been coupled

with a control valve. Singer says in-valve metering has been

limited to turbine meters, vortex meters, or calculated flow

using position transmitters and differential-pressure transmit-

ters. The new insertion meter option provides better accuracy.

Singer Model 106-SPI-MV Metering Valve



Defining New-Technology FlowmetersNew-technology flowmeters are defined

by the following characteristics:

1 The core technology was introduced

after the end of World War II. 2 They incorporate technological ad-

vances that avoid some of the problems

in earlier flowmeters.3 They receive more focus in terms of

new product development than older

technologies.4 Their performance, including criteria

such as accuracy, is at a higher level

than that of traditional technology flow-

meters.5 They are quicker to incorporate

recent advances in communication

protocols such as HART, Foundation

Fieldbus, and Profibus than traditional

technology meters.

Generally, flowmeters that fit in the

“new technology” category include

Coriolis, magnetic, ultrasonic, vortex,

and thermal.

CoriolisCoriolis is the fastest growing flowmeter

market, and there are a number of rea-

sons for this. One is that Coriolis flow-

meters remain the most accurate flow-

meter, and they are highly reliable with

little need for maintenance. Coriolis

meters do not place any obstruction

in the flowstream, although bent-tube

meters can slow down flow veloc-

ity. Straight-tube meters have been

developed to address this effect and

to suit the needs of sanitary applica-

tions, which pose an issue for bent-tube

meters, which can accumulate material

building at their bending points.

The most important recent advance

in the Coriolis market is the develop-

ment of Coriolis meters for line sizes

above 6 inches. Rheonik, now part of

GE Measurement, used to be the only

company offering large line-size Co-

riolis meters. In the past five years,

Micro Motion, Endress+Hauser, and

KROHNE have all entered this market.

Many of these meters sell in the range

of $75,000. They are primarily targeting

oil & gas applications. Many of them,

though not all, are designed for custo-

dy-transfer applications.

Coriolis meters, along with ultra-

sonic, are getting a substantial portion

of the research & development dollars

from the major flowmeter companies.

As a result, a steady stream of new

products and new features for existing

products is entering the market. This is

clearly one of the driving forces behind

the rapid growth in the Coriolis flowme-

ter market.

MagneticThe growth rate of the magnetic flow-

meter market is not as great as that

of Coriolis, but the magnetic flowmeter

market is already one of the largest of

any flowmeter type. This is true despite

the fact that magnetic flowmeters can

only measure conductive liquids. This

means they cannot measure steam,

gas, or hydrocarbon liquids. However,

suppliers have made some progress in

enabling magnetic flowmeters to mea-

sure low conductivity liquids.

Magnetic flowmeters are widely

used in the chemical, food & beverage,

FLOW UPDATE | Flow Measurement


Inline ultrasonic meters have two or more transducers embedded into the flow-meter (sensor tube) body. They are installed by cutting into a pipe and having either wafer or flange style fittings. (Photo courtesy of Flow Research)

Part I: Flow Trend WatchA look at recent developments in new-technology flowmeters

The following is the first in a two-part series on broad-based trends in flowmeter technology and applications

based on results of Flow Research’s new Volume X: The

World Market for Flowmeters, 4th Edition. The focus of Part I will be on new-technology flowmeters. Part II will focus on trends in traditional-technology flowmeters.

By Jesse Yoder, Ph.D.


and pharmaceutical industries. There is

a wide variety of linings used for sanitary

applications. PFA and PTFE are the two

most popular types of liners. PTFE is a

combination of fluorine and carbon that

is also known as Teflon. Other popular

types of liners are hard rubber, ceramic,

and polyurethane. A significant per-

centage of magnetic flowmeters come

in sizes of 1 inch or less, and they can

measure very low flows.

The most popular industry for mag-

netic flowmeters is the water & waste-

water industry. They excel at measur-

ing any kind of water, whether clean or

dirty, and can measure slurries that few

other flowmeters can tolerate. For clean

water, they are relatively inexpensive,

although inline magnetic flowmeters

can fit line sizes of 108 inches or more.

These meters are quite expensive. As a

result, a number of suppliers have in-

troduced insertion meters that are not

as accurate, but are significantly less

expensive than their inline counterparts.

UltrasonicIt used to be conventional to segment

the ultrasonic market into transit time,

Doppler, and hybrid. While this is still

valid, transit-time meters have become

capable of measuring many of the fluids

that formerly only Doppler meters could

measure, and they have cut signifi-

cantly into the market share of Doppler

meters. As a result, it is now more

useful now to segment the ultrasonic

market into inline (spoolpiece), clamp-

on, and insertion.

Inline ultrasonic meters have two or

more transducers embedded into the

flowmeter (sensor tube) body. They are

installed by cutting into a pipe and hav-

ing either wafer or flange style fittings.

Inline ultrasonic meters are distin-

guished according to whether they have

single-path, dual-path, or multipath

configurations, meaning three or more

paths. Custody-transfer applications re-

quire three or more paths.

Ultrasonic meters for liquids are built

differently than ultrasonic meters for

gas. The market for inline ultrasonic me-

ters for custody transfer of natural gas is

one of the fastest growing niches in the

entire flowmeter market. Companies

such as Caldon (now part of Cameron)

and KROHNE have also introduced ul-

trasonic flowmeters for custody transfer

of petroleum liquids.

Clamp-on meters have the advan-

tage of portability (though some are

fixed), and are widely used for check

metering. However, they cannot achieve

the same accuracy levels as inline me-

ters for several reasons. One is that they

are mounted outside of a pipe and the

ultrasonic signals have to go through

the pipe wall. This can attenuate the

signal. The amount of attenuation de-

pends on the type of material the pipe

wall is made from. Build-up on the side

of the pipe wall can also have an effect

on the ultrasonic signal, introducing an-

other level of uncertainty.

Insertion ultrasonic meters are

mounted in a pipe by cutting a hole

in the pipe and inserting the flowme-

ter into the pipe. Insertion meters are

significantly less expensive than inline

meters because the cost of the meter

body is eliminated. However, they can-

not achieve the same levels of accuracy

as inline meters. One of the chief ap-

plications for insertion ultrasonic me-

ters is for measurement of stack gas

and exhaust gas emissions. Here they

compete with averaging Pitot tubes and

thermal flowmeters.

VortexIn many ways, vortex meters are the

most versatile type of meter. They can

reliably measure all types of fluids,

including liquid, steam, and gas. They

are somewhat more intrusive than ultra-

sonic meters since they require insert-

ing a bluff body into the flowstream.

This bluff body is required so that the

meter can generate the required vor-

tices whose frequency is proportional

to flowrate. While the bluff body can

get knocked out of position, vortex

meters are far less intrusive than tur-

bine meters or positive displacement

meters.

For many years, vortex meters did

not have the same types of industry

approvals as differential-pressure, tur-

bine, ultrasonic, and Coriolis meters.

This changed in 2007, when the Ameri-

can Petroleum Institute (API) approved

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FLOW UPDATE continued

a draft standard for the use of vortex

flowmeters for custody-transfer applica-

tions. This approval was reaffirmed in

2010. However, up to this point it does

not seem to have had much impact on

the measurement of petroleum liquids

or gases for custody-transfer purposes.

However, the draft standard has been

used in the custody transfer of steam.

Vortex flowmeters offer accurate and

reliable flow measurement at a com-

petitive price. Even though vortex me-

ters are not as accurate as Coriolis me-

ters, many vortex meters offer accuracy

readings of better than one percent, de-

pending on fluid and application. While

vortex meters are somewhat intrusive

compared to magnetic and ultrasonic

meters, they are much less intrusive

than the orifice plates used with DP

transmitters to measure flow. Pressure

drop from vortex meters is minimal,

since most shedder bars are relatively

small in size. Vortex meters are less

widely used than magnetic flowmeters,

due, in part, to the fact that they were

introduced nearly 20 years after mag-

meters.

ThermalThermal flowmeters are used almost

exclusively for gas. For many years,

they have been associated with envi-

ronmental applications. In the early

1990s, multipoint thermal flowmeters

were developed to handle continuous

emissions monitoring (CEM). At that

time, the Environmental Protection

Agency (EPA) developed regulations

designed to reduce the amount of sul-

furic oxide (SOX) and nitrous oxide (NOX)

in the air. Multipoint thermal flowmeters

were developed for these applications.

Multipoint averaging Pitot tubes and

ultrasonic flowmeters were also used

for this purpose.

While thermal flowmeters are still

used today for CEM applications, they

are also used for a variety of other en-

vironmental applications. Under the

Obama administration, their use for

flare gas, biogas, biomass, coalbed

methane, and landfill gas has become

more prominent. Other popular appli-

cations for thermal flowmeters include

submetering, compressed air, boiler in-

let, and wastewater treatment.

Many of the environmental applica-

tions for thermal meters involve inser-

tion meters. However, inline thermal

meters are also widely used for a variety

of gas applications. One disadvantage

of thermal flowmeters is that it is nec-

essary to know what type of gas is be-

ing measured. Thermal flowmeters have

also not achieved the accuracy levels of

Coriolis or ultrasonic meters, and their

accuracy is typically less than 1 per-

cent. However, suppliers have made

important strides in the areas of ther-

mal flowmeter accuracy and reliability.

Expect to see continued developments

and improvements in this area for ther-

mal flowmeters. FC

www.flowresearch.com


FLOW UPDATE | Flow Measurement

Jesse Yoder,

Ph.D., is president

of Flow Research Inc.

in Wakefield, Mass.,

a company he found-

ed in 1998. He has

25 years of experi-

ence as an analyst

and writer in process

control. Dr. Yoder specializes in flowme-

ters and other field devices, including

pressure and temperature products.

Dr. Yoder can be reached at jesse@

flowresearch.com.

For more information on Flow

Research’s Volume X: The World

Market for Flowmeters, 4th Edition

study, visit www.floweverything.com.

Jesse Yoder

Coriolis Flowmeter | Flow Mea-

surement | Flow Research | Jes-

se Yoder | Magnetic Flowmeter |

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With so much domestic growth in

LNG, LPG (liquid petroleum gas), and

oil—as well as alternative energy sourc-

es such as ethanol—worker, facility and

regional safety will be a top priority to

help assure secure fuel storage and dis-

tribution. And though each new facility

designs its own safety systems, guid-

ance is available from standards bodies

and insurers.

The Role of Thermally Activated Emergency Isolation ValvesThermally activated Emergency Isolation

Valves (EIVs) are critical components in

refinery, terminal and distribution safety

systems. Thermal activated shutoffs

work like fuses in the piping that carry

extracted fuels. When a fire occurs, the

fuel flow is shut down, preventing the

fuel from feeding the fire.

Historically, thermal shutoffs relied

on fusible links made of metal alloy.

Once the alloy melts, a spring-armed

plug is released, which stops the flow

of fuel. The problem with the fusible

link design is that once triggered, the

unit needs to be replaced and, likewise,

cannot be field-tested.

However, new technology for thermal

shutoffs uses a Nitinol shape memory

alloy system, originally developed for

NASA space station applications. Ni-

tonol’s shape memory effect changes

certain metal alloys from one shape to

another with temperature changes—

a direct result of a transformation of

the alloy’s crystal structure. The shape

memory element senses the ambient

temperature and, through a phase in-

duction change, rapidly produces the

force and motion to operate the shutoff.

When the thermal shutoff senses

temperatures above the shape memory

alloy’s actuation level, the shape mem-

ory element simultaneously vents pneu-

matic actuator air pressure and closes

upstream supply pressure. A manual re-

set allows routine performance testing

for safety maintenance programs.

Hydrocarbon Processing Plants“The standard insurance recommenda-

tion report for a gas processing facil-

ity includes a request for a Process

Hazards Analysis and an Emergency

Shutdown System with multiple emer-

gency isolation valves,” says Jesse

Wilson, president of Allrisk Engineering

STANDARDS & REGULATIONS | Thermal Shutoffs


Emergency isolation valve with local (thermal) and remote shutoff. (Photo courtesy of Assured Automation)

Safety MeasuresThermally Activated Emergency Isolation Valves for Oil & Gas Applications

The recent annual World Energy Outlook report from the Paris-based International Energy Agency (IEA, www.iea.

org) predicts the United States will displace Saudi Arabia as the world’s largest oil producer by 2020. Meanwhile, the ExxonMobil 2013 Outlook for Energy report forecasts:

• The United States will become the world energy leader by the end of the decade.• Liquid Natural Gas (LNG) will surpass coal as a fuel source globally by 2025.• North America will become a net exporter of all sources of energy by 2035.

By Jean Steckler


Inc. (www.allriskengineering.com) in Auburn,

Wash. “Emergency isolation valves are the risk

mitigation ‘bread and butter’ for most Compressed

Natural Gas (CNG) and Liquid Natural Gas (LNG)

facilities.”

The entire gas plant, as well as many of its

processing subsystems, are mechanically isolated

and de-energized by the Emergency Shutdown

(ESD) System. ESD systems are independent of

the basic process control system; however, they

can be triggered by critical process control vari-

ables, such as product flow and pressure. ESD systems can

also be initiated manually by operators located in the field or

in the control room.

ESD systems typically include gas detectors and heat de-

tectors interlocked with Emergency Isolation Valves (EIVs).

EIVs are failsafe, on/off type valves used for emergencies

only. Most insurers recommend that each EIV be provided

with some type of local thermal actuation device.

Factory Mutual publishes data sheets to assist in designs

for emergency isolation and shutdown. The FM Global Prop-

erty Loss Prevention Data Sheet, titled “Fire and Explosion

Protection for Process Structures 7-14,” includes a Piping

and Instrumentation Diagram (P&ID), which identifies where

in the process automatic and remote manual valves are rec-

ommended. The Ignitable Liquid Operations 7-32 data sheet

also includes a P&ID, outlining where Safety/Emergency Shut-

off Valves are recommended for inert-gas transfer systems.

Joseph Looney of FM Global says safety shutoff valves with

pneumatic or electric actuators are used for the startup and

routine shutdown of systems, while emergency shutoffs are

one-time operated shutoff valves used in emergency scenar-

ios, such as a fire.

The following list of recent fires reinforces the neces-

sity and value of emergency shutdown procedures and

technologies:

Jan. 13, 2013 fire at Chevron’s El Segundo

refinery, south of Los Angeles. The refinery can pro-

cess 279,000 barrels of feedstock a day, and supplies

40 percent of the jet fuel to Los Angeles International

Airport and 20 percent of the region’s gasoline.

August 6, 2012 Chevron Refinery Fire in Richmond,

Calif., which processes 245,000 barrels of crude oil a day.

Oct. 2, 2012 Exxon Mobil’s Baytown, Texas, refinery

fire in the diesel hydrotreater unit. The refinery has a capac-

ity of 584,000 barrels a day, making it the largest operating

refinery in the U.S. and one of the largest in the world.

Dec. 11, 2012 natural gas pipeline explosion near

Sissonville, W. Va., owned by the NiSource subsidiary

Columbia Gas Transmissions. It took about an hour after

the initial rupture for officials to stop the flow of gas and

shut off the line. The pipeline was not equipped with auto-

matic or remote shutoff valves.

Sept. 9, 2010 natural gas pipeline explosion in

a residential area of San Bruno, Calif., owned by

Pacific Gas & Electric. It took 60 to 90 minutes to shut

off the gas after the explosion, according to San Bruno

Fire Chief, Dennis Haag. The tragedy reached a death

toll of eight people and 38 homes destroyed. The U.S.

Geological Survey registered the explosion and resulting

shock wave as a magnitude 1.1 earthquake. Eye wit-

nesses reported the initial blast “had a wall of fire more

than 1,000 feet high.” On Jan. 13, 2012, an indepen-

dent audit from the State of California issued a report

stating that PG&E had illegally diverted over $100 mil-

lion from a fund used for safety operations, and instead

used it for executive compensation, bonuses, and PG&E

shareholders.

Lessons Learned


New technology for thermal shutoffs uses a

Nitinol shape memory alloy system, origi-

nally developed for NASA space station

applications. Nitonol’s shape memory

effect changes certain metal alloys from

one shape to another with temperature.

“”

FLOW UPDATE continued

Large Propane Storage FacilitiesSince Liquid Petroleum Gas (LPG),

commonly known as propane, is stored

and transported under high pres-

sure, this fuel requires its own set

of safety systems. The NFPA 58—

Liquefied Petroleum Gas Code requires

Emergency Shutoff Valves have all of

the following means of closing:1 Automatic shutoff through ther-

mal (fire) actuation;2 Manual shutoff from a remote

location; and 3 Manual shutoff at the installed

location.

Before the shape memory thermal

actuators described above were widely

available, LPG storage facilities relied

on fusible-link thermal shutoffs to au-

tomatically shut down LPG flow when

a fire occurred. Ted Lemoff, of TLemoff

Engineering, says he has never had any

issues or problems with fusible link-

based thermal shutoffs in his 25 years

of experience. Lemoff has written ex-

tensively on the NFPA 58 LPG Standard

during his tenure at the National Fire

Protection Association (NFPA).

Fuel TransportOnce processed, fuel is distributed

to local markets by pipeline, rail car,

and trucks. Each transport method

requires its own set of safety systems,

including automatic thermal shutoffs.

Alloy Custom Products (www.alloycu-

stomproducts.com), a manufacturer of

cryogenic semi-trailers, uses automatic

thermal shutoffs for LNG, oxygen, and

mixed-use vessels. The company uses

shape memory thermal (fire) actuators

to automatically shutdown the flow of

fuel in the event of fire. These air-oper-

ated, self-closing thermal shutoffs are

housed in a rear cabinet of the trailer

and are used for fire protection in both

the loading and offloading of LNG.

The Promise of Safe and Secure Domestic Oil & Gas

Safety in the refinery, delivery and ter-

minal business continues to improve

based on lessons learned from experi-

ence (see sidebar on page 37).

With increasing reductions in staff-

ing, refinery and terminal facilities are

more reliant on automation. However,

if a fire damages the control system,

an electronic remote shutoff no longer

works. These type of systems need:

Failsafe designs to close valves in

the event of power loses; or

Automated valves with motorized

assembles including spring return and

battery backup.

To prevent the escape of fuel during a

fire, thermally activated shutoffs are

also needed, such as the shape mem-

ory thermal actuators or fusible link-

based systems detailed in this article.

A complete Emergency Isolation Valve

assembly provides:

Local thermal shutdown for auto-

matic shutdown in the event of fire

Remote shutdown to isolate sub-

systems

Local manual shutdown (optional)

Optional limit switch and lock-out

device FC

Note: The online edition of this article

at FlowControlNetwork.com will include

a bonus sidebar on Regulations &

Standards for Thermal Shutoffs.

Jean Steckler is a fire protec-

tion and safety code team leader at

Assured Automation, an assembler of

automated valves and flowmeters. She

has submitted code modifications to

the ICC on gas safety and consulted

with the NFPA and FM Mutual. Ms.

Steckler can be reached at jeans@

aa-fs.com.



STANDARDS & REGULATIONS | Thermal Shutoffs

America Petroleum Institute |

FM Global | NFPA | Oil & Gas |

Safety Valve | Thermal Shutoff


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CORE STUDY


Mr. Bachus,

I am a project engineer for a Midwest municipality waste-

water authority. I’d like your opinion on some recent events

with a pump.

In 2010, we installed a new variable-speed pump at the

final collecting station at the treatment plant. The pump oper-

ates between 500 RPM and 600 RPM. The speed varies to

maintain a constant water level in the wet well 7 feet over the

pump centerline.

Since 2010, we have documented the following issue:

The pump starts and runs up to 600 RPM (25,000 GPM)

when the high level sensor trips in the wet well. The pump

speed slowly reduces, sometimes to 500 RPM (20,850 GPM)

as the level drops in the well. If incoming flow increases into

the well, the pump speed reaccelerates.

However, after the pump speed reaccelerates to 600 RPM,

the flow peaks at about 22,000 GPM rather than 25,000

GPM. Sometimes the level in the well continues to rise even

with the pump at 600 RPM. The only way to return to 25,000

GPM and control the level in the well is to stop and restart

the pump. As we stop the pump, we lose the discharge water

column back into the well and this further exaggerates the

problem and the anxiety.

We called the pump manufacturer. The engineer referred

to a “time dependent steady state capacity drift” issue. After

the engineer repeated the term a couple of times, he reduced

it to “TDSSCD.” I have never heard of this term.

We will remove the pump from service and inspect it for

signs of air entrainment or a suction recirculation problem. Is

there any sign or indicator that might identify or support suc-

tion recirculation?

Also, what do you know about TDSSCD?

Regards,

Harry R.

Hello Harry,

Three points come to mind that might affect the flow through

your pump.1 Consider air/gas entrainment: Remember you’re

pumping intestinal waste (methane gas) and air from every

commode flush that feeds the lift station. Air and gas can col-

lect at the impeller eye and block flow into the pump, which

will reduce the discharge flow.2 Consider air vortices: Vessels tend to form vortices (air

tornadoes) when filled and drained at the same time. The vortex

is attracted to the tank exit nozzle and the pump. The air can fill

the pump and displace the liquid leading to reduced flow.3 Consider the foot valve: In your message, you said

you lose your liquid column back into the well when the pump

is turned off. If the flapper is stuck and won’t actuate properly,

it can either starve the pump or cause excess turbulence that

releases air and gas into the pump.

An impeller suffering suction recirculation normally shows dam-

age on the leading edge (the high pressure side) of each impel-

ler blade close to the eye of the impeller. You will see this on

examining the impeller blades when the pump is disassembled.

An impeller suffering air or gas entrainment normally

shows damage on the trailing edge (the low pressure side) of

each blade close to the eye of the impeller. We cover these

issues with plenty of pictures in my Pump Guy Seminar se-

ries. (For more information on upcoming Pump Guy trainings

in Chicago and Philadelphia and a full course outline, visit

FlowControlNetwork.com/PumpGuy.)

Some Thoughts on Acronyms in GeneralIn the 1980s, our society became aware of an illness that

was called the “Auto-Immune Deficiency Syndrome.” This long

phrase began consuming a lot of time and energy in spoken

conversation and medical conferences. The term consumed a

lot of paper and ink in newspapers and press releases, eventu-

ally being reduced to the acronym AIDS.

Many years ago, the French marine explorer Jacques Cous-

teau perfected a device that allowed humans to stay under wa-

ter for long periods. Cousteau called his device the “Self-Con-

tained Underwater Breathing Apparatus.” After repeating this

phrase many times in conversation and print, self-contained

underwater breathing apparatus became the acronym scuba.

In the Second World War, there was a small military util-

ity vehicle that any soldier could start and drive without a

key if one were available. The vehicle was labeled “Govern-

ment Property.” Eventually the Government Property became

known as a G.P. This is the vehicle we know today as the Jeep.

TV will always be short for television. And PC will always be

THE PUMP GUY | Pumping Systems

mailbag: TDSSCD ... OMGMaking sense of senseless pump terminologyLarry Bachus


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short for personal computer. But scuba is in a family of acronyms

like Jeep, laser, radar, aids and sonar that have become their

own words. Many people don’t even know they are acronyms.

Your industry uses the common acronym WWTP meaning

Waste Water Treatment Plant. The pump industry has a few ac-

ronyms like GPM, PD, API, AODD and NPSH. Acronyms, whether

justified or not, often lend credibility to the terms they describe.

Now, Let’s Consider TDSSCD Years ago, you could call a pump manufacturer and speak

with the senior design engineer. The pump engineer’s voice

would ooze and drip with useful knowledge.

If you call a pump manufacturer today, you are likely to

get lost in a NEAM. What is a NEAM? It’s an acronym I just

invented for “Never-Ending Answering Machine.”

Today, pump companies are managed by accountants and

‘bean counters.’ They can tell you which parts are cast in

China and which parts are assembled in India. The only way

they can feign product knowledge is to spout acronyms and a

few buzzwords like “Proactive,” “Win-Win,” “Stretch the Enve-

lope,” “MTBF,” “Bad Actor,” etc.

If somebody uses “TDSSCD” in an email or phone conver-

sation, the other party might assume this acronym is a real

term or phrase because it is reduced to an acronym. After

writing or saying “Time Dependent Steady State Capacity Drift”

8,326 times, it becomes necessary to reduce the phrase into

its acronym TDSSCD. Obviously, you must be “OIL” (Outside the

Information Loop) if you are unfamiliar with TDSSCD.

Personally, I don’t think TDSSCD exists. I believe the phrase

“Time Dependency” exists in many communications. I believe

the term “Steady State” is a rather popular term in some circles.

And “Drift” is a term used by instrumentation technicians. But

TDSSCD doesn’t, in my opinion, exist. This seems like some-

one’s attempt to appear IIL (Inside the Info Loop). FC

LOL,

Larry Bachus

www.bachusinc.com

THE PUMP GUY | Pumping Systems


Air Entrainment | Cavitation | Larry Bachus | Pump Guy | Pump Guy Seminar | Recirculation

Find related content @ flowcontrolnetwork.com ... Search on:FLOWSTREAM

Larry Bachus, founder of pump services firm Bachus

Company Inc., is a regular contributor to Flow Control

magazine. He is a pump consultant, lecturer, and inventor

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].

Do YouKnow & Understand

Your Pumps?Larry Bachus ("The Pump Guy") is theco-author of Everything You Need toKnow About Pumps, one of the bestselling technical books on pump systems inthe world. This book is written exclusively forpeople who must maintain pumps. Whereasother pump books are written from a designpoint of view, this book is written withmaintenance in mind. While most technicalbooks sit on a reference shelf gathering dust,this book gathers dirt smudges. Its pages getcreased and folded when mashed by the lidof a photocopy machine. It gets sneezed onand splashed with snot on cold mornings. It gets soaked with leaking oil, grease,and coffee. Basically, it gets used ... because it's tremendously useful. Thestraightforward guidance it provides will help you ensure the efficiency andlifespan of your pumping systems.

To order your copy of Everything You Need to Know About Pumps,call (615) 361-7295 or order online atwww.bachusinc.com/books.html

Do YouKnow & Understand

Your Pumps?

LarryBachus-datescartoon:Layout 1 11/6/12 3:56 PM Page 1

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“I thought this seminar was one of the best I’ve attended in my career. Larry gave me the practical

tools/steps to analyze a pump system. Now I feel I can go back to my plant and look at a few systems that we

seem to be working on too much.”

– Attendee comment, Houston 2010

For more information & to register for the Aug. 20-22 Pump Guy Seminar in Chicago

or October 1-3 in Philadelphia, visit FlowControlNetwork.com/PumpGuy.

“Excellent course! All my years in instrumentation I never realized how important it is to research the

performance of a pump by looking at the pump curve. It was all Greek to me before, but now I understand

what to look for when problems arise.”

– Attendee comment, New Orleans 2012

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This video explains how to correct pump soft foot via a three-step process: 1. a rough alignment;

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THINK TANK | Filtration & Separation

ABSOLUTE FILTRATION: The absolute filtration rat-ing, or cut-off point, of a filter refers to the diameter of the largest spherical glass particle, normally expressed in micrometers (mm), which will pass through the filter under laboratory conditions.

BACKWASH: To clean a filter element by reversing the direction of flow through it.

COALESCING FILTRATION: A steady state process whereby aerosols are caused to come together into even larger droplets as they pass through the filter element’s fiber matrix, eventually becoming large enough to be gravitationally drained.

CARTRIDGE: A porous device, usually fitting in a filter housing, which performs the actual process of filtration.

EFFECTIVE AREA: The area of a medium that is exposed to flow and usable for its intended purpose—coalescing, filtering, or separating.

FILTER EFFICIENCY: A method of expressing a filter’s ability to trap and retain contaminants of a given size. Usually given as a percent.

FILTRATION RATING: A measurement of the average size of the pores of the filter medium.

HYDROPHOBIC: Non-water wetting. Having an antago-nism for water. Not capable of uniting or mixing with water.

MICRON: A unit of length in the metric system. One-millionth of a meter or 0.000039 of one inch. Contaminant size is usually described in microns.

NOMINAL FILTRATION: The nominal filtration rating refers to a filter capable of cutting off a percentage by weight of solid particles of a specific contaminant (usu-ally again glass beads) greater than a stated micron size, normally expressed in micrometers (mm), i.e. 90 percent of 10 micron.

PLEATED: A filter element whose medium consists of a series of uniform folds and has the geometric shape of a cylinder, cone, disc or plate.

PRE-FILTER: Filter for removing gross contaminate before the product stream enters a separator/filter.

PRESSURE DROP: The difference in pressure between two points, generally at the inlet and outlet of a filter.

SEPARATOR: A device whose primary function is to iso-late contaminants by physical properties other than size.

WOVEN: A filter medium made from strands of fiber, thread, or wire interlaced into a cloth on a loom.

Rosedale Products (www.rosedaleproducts.com), a devel-oper of technology for liquid filtration systems, provided the terms and definitions for this word search.

GLOSSARY OF TERMS:

FILTRATION & SEPARATION


S S R S R O T A R A P E S E P A R A T O F

D E T T A E L P I B A C K W A S H T A N S

B A C K W C P L E A T E D C E M I C R O R

A E R A E V I T C E F F E F E P T A R I M

F Y N S L F T P R R N P E E I R O A D T I

I C N O C I B O H P O R D Y H E P L E A P

L N O E I C A R T R I D G I T - L I R R R

T E R I V T D D U F T T C F N F E F U T E

R I D N L A A E F C A E R F O I A - S L F

A C E T F P W R L R R L T L R L T E S I E

T I R T R F L U T N T U N N C T E R E F C

I F U T U R A S V L L L C R I E O P R G R

O F S G T F I S D C I R O T M R C P P N E

N E S F I L T E R E F F I C I E N C Y I S

R R E U I R S R D N L T E O R I R E S C R

A O R W O V I P R L A C T T F P G C O S F

T T P P - P I R S E N R A E U D D H E E N

I L H Y D R O P H O I A O R I L S R O L O

N I T B A W O V E N M P R R T A O L R A L

G F P R E - F I L T O R T R K I R S N O F

O S O P A R A T U R N R V C F A D L B C A

Y R O T T T M I C R A N A E F R O G I A I

S R R R E R I D I C L B U E S P Y C E I E

ABSOLUTE FILTRATION

BACKWASH

COALESCING FILTRATION

CARTRIDGE

EFFECTIVE AREA

FILTER EFFICIENCY

FILTRATION RATING

HYDROPHOBIC

MICRON

NOMINAL FILTRATION

PLEATED

PRE-FILTER

PRESSURE DROP

SEPARATOR

WOVEN

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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buy gift card. Best Buy is North America’s leading consumer electronics retailer. You can use your gift card in the store or online at www.BestBuy.com.

Fax solution to: (205) 408-3799If there are no completely correct entries, a winner will be selected from among the entries with the most words found.

Solve This Word SearchWin a $50 Best Buy Gift Card

February Winner: Shannon Bailey, Maintenance Supervisor

Decatur Utilities, Decatur, Ala.

THINK TANK | Flowmeter Operation

quiz corner: Measuring the Flow of Mixed Liquids


CommentaryIf the component liquids were miscible to form a homoge-

neous fluid, any orientation within the limits of the flowmeter

technology would be possible. Answer D would appear to be

correct.

However, oil and water are generally not miscible, so sepa-

ration of the oil and water could occur in the horizontal piping

upstream of the flowmeter. This can affect flowmeter perfor-

mance because the liquid entering the flowmeter would not

be homogeneous. Answer C is not necessarily correct.

Locating the flowmeter in a vertical pipe flowing upward

mitigates the potential separation problem encountered in

horizontal pipe. However, it does not ensure that the flow is

homogeneous because the oil and water may have already

separated upstream of the vertical pipe. Answer A is not nec-

essarily correct. Similarly, locating the flowmeter in a vertical

pipe flowing downward will cause Answer B to not necessarily

be correct.

Additional Complicating FactorsThere is no definitive correct answer. Such flow measurement

applications should be engineered carefully on an individual

basis.

B N M G T A N G E N T I A L F L O W P H

I B U O L O G I C O T G R R V O N G S I

E R Y U S I N G L E U W O E I M S V L G

R S G R E S U E L G N I S B R B B I L L

E V S U A N E I P I S W I M U N M R W N

B I N U R N G N I T N O O A S Y A U R R

M R T A E U R T O M R R U H F R H S R W

A U O N E L B E L T M Q A C I A C F C P

H S I N O N G O T G S T R G T N G I I I

C F T N O L P N I A S I G N R R N L G R

G I A N E W T O I B U O P I A I I T O L

N L S R O L O I B S N Q T P T T P R L R

I T L B I O B U R D E N R M I A M A O M

M R U N I D R U B O I B U U O U U T I N

U A P I S O N O E O I L T P N Q P T B A

P T W A R G N N O I T A S L U P W W O L

M I O L D N O I T A S L U P W O L I L R

P O L B N C H R O M A T O G R A P H Y R

L N S A F T A N G E N T A I L F L O W P

A R L I G N I S N R L O N T U N R A N T

/Div. of Aerospace Control Products, Inc.1314 West 76th Street, Davenport, IA 52806 • FAX: 563-391-9231E-mail address: [email protected]

The originators of gas laminar flowmeters

GAS FLOW ACCURACYASSUREDwith Model 60B Flow Computer

Model 60B FlowComputer

The 60B Flow Computers con-stantly process pressure, temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (± .75% of point-NIST traceable) display of Standard (Mass)and Volumetric flow. Totalizers and optionaloutputs are available.

Save downtime and money with the FCS 9003 portable Flow Calibrator. It utilizesa custom Windows™ based program to provide superior calibration of many dif-ferent flowmeter types. The portability of the system saves test time and the soft-ware compensates for flowmeter types and test conditions eliminating manualcalculations. Print and store compliance data reports after each calibration.

For more information on the Model 60B Digital Flow Computers, the FCS9003 Portable Calibrator or any of these CME products:

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Write in 28 or Request Info Instantly at www.FlowControlNetwork.com

March Solution: Biopharmaceutical Processing

What piping orientations are acceptable for a flow-

meter to measure the flow of an 80/20 mixture of

a liquid having a specific gravity of 0.80 and water?

A. Flow up

B. Flow down

C. Flow horizontal

D. All of the above

David W. Spitzer David W. Spitzer is a regular con-

tributor to Flow Control magazine and a principal in Spitzer

and Boyes, LLC, offering engineering, seminars, strategic,

marketing consulting, distribution consulting, and expert

witness services for manufacturing and automation com-

panies. Mr. Spitzer has more than 35 years of experience

and has written over 10 books and 250 articles about flow

measurement, instrumentation and process control.

David W. Spitzer | Flow Measurement | Flowmeter

| Liquid Separation | Piping Orientation

Find related content @ flowcontrolnetwork.com… Search on:

FLOWSTREAM

By David W. Spitzer

Endress+Hauser, Inc2350 Endress PlaceGreenwood, IN [email protected]

Sales: 888-ENDRESSService: 800-642-8737Fax: 317-535-8498

Flowing with great possibilities.

As a direct, digital Coriolis flowmeter, the Promass 100

opens entirely new perspectives for demanding applications

in life sciences, biotechnology, food and chemical industries

• Compact design without limitation of functionality

• Ideal for skid-mounted process facilities

• Simultaneous measurement of mass or volume

flow, corrected volume, density, temperature and

viscosity (Promass I)

• Seamless integration into process control and asset

management systems via EtherNet/IP and Modbus RS485

(HART® and PROFIBUS DP currently in preparation)

• -odern webserver technology for fast onsite device

configuration without additional software

• Industry optimized sensors for each application

www.us.endress.com/promass-100

Proline Promass 100Compact without compromise

Proline simply clever


Hands-on training through real-life simulation.

A one-of-a-kind training opportunity

What makes Endress+Hauser unique is our PTUTM (Process

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with on-line instrumentation and controls. Customers gain

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These “mini process plants” feature Endress+Hauser

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HART®, PROFIBUS® PA, and FOUNDATIONTM Fieldbus.

Visit www.us.endress.com/training for information

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Endress+Hauser, Inc2350 Endress PlaceGreenwood, IN [email protected]

Sales: 888-ENDRESSService: 800-642-8737Fax: 317-535-8498


Documents

Flow Control May 2013