User Appl i cat ion Guide

The mass flow experts for flow, level

and temperature instrumentation

Power and Energy Industry

YEARSOF

SERVICE

40

rom the early 1960s, Fluid Components Internationalrecognized the need for flow and level instrumentationwhich met specific customer requirements and

demands for the Power and Energy Industry. By utilizing ThermalDispersion and Coriolis technology exclusively in all FCI flow,level, interface, temperature switches and mass flow meters, ourproducts solve typical Power and Energy Industry applicationchallenges with standard product features such as: No moving parts All welded materials of construction Direct mass flow measurement No pressure drop Explosion-proof design Wide flow range Low flow capability

By closely monitoring the everchanging requirements for thePower and Energy Industry, FCI has maintained its reputation asthe technology leader with new product features such as: Modern digital communications with HART, Modbus,

Profibus, Ethernet and ASI Fail-safe mode selection per Namur NE43 Compliance with the latest approval requirements

of FM, CSA, CRN, ATEX, CE Mark and PED Application focused marketing and engineering research

and design Secondary sealed flow element sensor design Integral flow conditioners Two-wire loop-power flow, level and

interface detection

FCI Power and Energy Industry customers Detroit Edison Energy Northwest Duke Power First Energy Corporation Bridgeport Resco Duquesne Light Florida Power & Light Georgia Power GPU Nuclear Ameren/CIPS United Pacific Controls

FCI Power and Energy Industry customers forEngineering, Procurement & Construction (EPC) Bechtel Group Sargent & Lundy Black & Veatch Duke Engineering & Services Fluor Foster Wheeler VECO B.E. & K. Inc. Washington Group Intl Parsons Day & Zimmerman Intl Chicago Bridge & Iron

Solv ing cr i t i ca l process appl i cat ions for the Power and Energy Industry

Pulverized air flow

The measurement and control of mill air flow in coal-fired boilersto minimize pulverizer performance problems is an industry-widechallenge. Minimizing Nox and maximizing plant efficiency has nowtaken center stage for this task. Measurement of air flow is importantin controlling mill slugging, feeder runback and coal spillage. It is alsoa main factor in minimizing emissions and maximizing fuel responseto the furnace, thus maximizing efficiency for these plants. FCI’s MTSeries multipoint mass flow meters measure wide flow rate rangesin high temperature applications. The no moving parts design preventshighly corrosive fly ash from clogging or fouling.

Taiwan Power Korea Electric Power Comision Federal

De Electricidad Niagara Mohawk Gulf Power Houston Lighting

& Power General Electric American Combustion

Condenser air in-leakage

Changes in the discharge flow represents air in-leakage through thecompressor. The negative effects of air in-leakage in the vacuumsystem are well understood. FCI's GF90 Series mass flow meter detectssmall changes in flow that represent changes in efficiency of thecompressor. Pre-requirements for successful monitoring requirelow flow sensitivity, wide flow range measurement, repeatabilityand accuracy -- all of which are standard features of FCI thermalmass flow meters.

Hydrogen flow monitoring

Hydrogen is a commonly used cooling agent in power plant turbinegenerators. Leaking hydrogen gas can pose a safety concern in thepower plant. FCI’s GF90 Series mass flow meters detect increase inusage; thereby alerting operators of leaks. In addition to monitoringfor hydrogen leaks, plants need to measure the flow rate for custodytransfer billing verification from the gas supplier to the utility. Also,multiple plants typically draw from a common hydrogen supply byusing FCI’s GF92 inline unit. FCI’s GF Series mass flow meters measurethe flow at each location, so each plant can be assessed theirappropriate share of hydrogen usage.

Reverse flow vent monitoring

To ensure critical flows and detect changes in the direction of airpurge in and out of chemical plants, the solid-state RF83 bi-directionalflow monitor is the best suited instrument available. It may be mountedon the inlet ducts to monitor all flow into the building. If the flowreverses, safety alarms will trip for failure notification of the fans.

Pump protection

FCI’s FLT93S FlexSwitch® is the ideal instrument to protect pumpsfrom failure due to low flow operation. The no moving parts design,capable of low flow sensing, is well suited to identify a wide varietyof product flows in harsh industrial environments. The dual switchpoints may be set to alarm low flow or high temperature, both indi-cations of conditions that cause pump failure.

Compressed air flow monitoring

Frequently, in a plant environment, there is a controller that monitorsthe use of compressed air within the facility. The controller auto-matically determines the optimum number of compressor units thatneed to be in operation at any given time to handle the facility load. Byonly operating the units that the demand requires, a tremendousamount of energy is saved. The demand is determined by the totalmass flow of air used by the plant, and FCI’s ST98 FlexMASSter®

Series mass flow meters are designed specifically for this purpose.The controller then sets the compressor usage based on the massflow rate indicated by the ST98.

Seal gas detection

Coolant and lubricant seal leakage are a serious threat to the effi-ciency of pumping systems. Fluid contamination to the product andloss of product through damaged seals are avoided with FCI’sFLT93L inline FlexSwitch or FR78 inline low flow monitor. Even a leakas small as 1.0 cc/sec is detected by these highly sensitive instruments.Because the FCI sensor elements operate without obstructing the sealvent line, there is no excessive pressure drop if a severe seal ruptureoccurs. For slurry pumps, the dual switch point option may be usedto identify either a low seal water flow or a high flow seal rupture.

CI introduced the first thermalflow switch /monitor in 1964and has since established a

worldwide reputation for the design andproduction of precision high performanceflow, level and temperature instrumentation.With reliability second to none, FCI hasplaced over 200,000 units in the fieldcovering the full range of liquid, gas andslurry process requirements. FCI productsservice some of the world's most demandingprocesses in industries such as food &beverage, pharmaceutical, chemical, oiland gas, pulp and paper, power and energy,water and wastewater, nuclear power,aerospace and more. FCI offers a broadrange of instrumentation solutions andservices, from off-the-shelf devices to customengineered systems. FCI's engineeringstaff provides expertise in mechanical,electronic and thermo-dynamic disciplinesoffering innovative solutions to specializedcustomer application needs, configurationobjectives, software enhancements, andmaterial problems.

Thermal Dispersion principleThe typical sensing element contains twothermowell-protected precision platinumResistance Temperature Detectors (RTDs).When placed in the process stream, oneRTD is heated and the other RTD senses theprocess temperature. The temperaturedifference between the two RTDs is relatedto the process flow rate as well as the

properties of the process media. Higherflow rates or denser media cause increasedcooling of the heated RTD and a reductionin the RTD temperature difference.

FlexSwitch® FLT93 SeriesThe FLT93 Series utilizes proprietary thermaldispersion technology to provide the highestreliability in flow, level and temperaturedetection. The sensing element is composedof two matched RTD's. One RTD is prefer-entially heated. The other RTD is unheatedand thermally isolated to provide continuousprocess condition temperature and baselineindication. At no flow or under dry condi-tions, the temperature differential betweenthe two RTDs is greatest.

For flow / no flow detectionNo-flow conditions produce a large signal.As flow increases, the heated RTD iscooled and proportionally reduces thetemperature differential. Changes in flowvelocity directly affect this rate of heatdissipation. An electronic circuit normalizesthe differential measurement with theprocess media temperature and converts

the RTD temperature/resistance differentialinto a DC voltage signal. This signal isprovided at output terminals and used todrive two adjustable setpoint alarm circuitsthat are independently field configurablefor specific flow service applications.

For liquid level /interface detection Dry conditions (no liquids present) producethe greatest temperature differential. Thesignal decreases when the level element issubmerged as the cooling effects of thefluid drive the temperature /resistancedifferential downward. Since all processfluids have different thermo physicalproperties, different fluids exhibit uniqueheat transfer characteristics. Interfacedetection between non-miscible fluids canbe factory or field calibrated to alarmwhen the fluid changes from liquid tofoam, between two different fluids, orbetween fluid and rag layer or emulsion.

continued on back cover

Product development, testing and calibration are performed in FCI’s laboratory using NIST traceableequipment, which ensures highly reliable performance in hundreds of applications.

Thermal mass flow technology supports virtuallyall gas or air measurement needs. It is especiallywell suited for dirty gas because of its no-movingparts design with no orifices, bearings, or sealsto foul or fail.

HeatedSensor

UnheatedSensor

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Serv ing cr i t i ca l process instrumentat ion needs around the wor ld

FCI’s complete line of flow, level and temperature instrumentation

Doc. No. 07SA011394A

� For temperature detectionThe unheated RTD serves as the baselinefor establishing the differential temperatureand continuous monitoring of the processtemperature. Being thermally isolated, theunheated RTD provides accurate indicationand detection of process fluid temperatures.Simultaneous temperature and flow andlevel detection can provide comprehensiveprocess monitoring as well as criticallysupplement operator process health andefficiency awareness.

NuTec® 2000 Series� 2-wire loop-power andnon-intrusive switchesExtraordinarily responsive and accurate,the versatile NuTec flow/ level switch seriesoffers superior reliability in extreme processconditions. The FS2000 and LS2000 switchesfeature the first 2-wire thermal flow/noflow and level detection switches. Theseinsertion switches are designed withFCI's proven thermal mass flow sensortechnology in a rugged package that iseasy to install and requires minimalmaintenance. The FS2000L inline flowswitch has an advanced non-intrusive sensordesign constructed of 316L stainless steelwith up to a 10 Ra electropolish finishapproved for 3A sanitary and high purityapplications. The FS2000L is available withinline sizes of 1/2 inch, 1 inch and 2 inchesfor easy installation using male NPT,butt-weld or sanitary flanges.

FlexMASSter® ST Seriesand GF Series mass flow metersBecause the relationship between flow rateand cooling effect directly relates to massflow in gas applications, FCI thermal massflow meters provide a highly repeatable andaccurate measurement of gas or air massflow rates. The ST98 Series "smart"electronics, equipped with advancedmicro-processor-based circuitry, enable

customers to reconfigure the signal outputseasily, as well as, display or alarm in thefield by using either a built-in key pad ora handheld communicator. The GF Seriesoffers wide turndown rations up to 800:1with multiple gas calibrations with analogelectronic circuitry.

FlexMASSter technology delivers perform-ance and value by offering the mostinnovative, accurate and cost effective gasmass flow measurement systems availablein the industrial flowmetering marketplacetoday. This highly reliable instrumentprovides the durability and speed requiredfor today's harsh process environmentsand delivers true direct mass flow meas-urement. FCI's FlexMASSter simplifies gasmass flowmetering with a single processpenetration, eliminating costly temperatureor pressure transmitters and a flow com-puter required with other technologies.

CMF FlexCOR® SeriesThe CMF FlexCOR Series Coriolis flowmeters push development a giant leapforward in Coriolis measurement tech-nology. Unaffected by variations in pressure,temperature, density, electrical conductivityand viscosity, the FlexCOR Series provideshighly accurate mass flow measurementover wide flow ranges while utilizing itsadvanced technology to achieve unsur-passed operational performance stressingsafety, reliability and quality.

VORTAB® flow conditionersFCI ensures the field performance of itshighly accurate mass flow meter productlines by offering VORTAB flow conditioners.VORTABs ensure accurate, repeatable gasflow measurement and are the efficientalternative to long lengths of straight pipingor ducting upstream of a flow meter instal-lation location. VORTAB units reduce oreliminate pressure drop, swirl, jetting and

more, while requiring just six diameters ofpipe upstream from the flow meter. Eachof the three available flow conditionerconfigurations consist of a short sectionof swirl reduction tabs combined withthree arrays of patented VORTAB profileconditioning tabs.

FCI’s extensive instrument testand calibration laboratoryFCI maintains an extensive, instrumenttest and calibration laboratory at its head-quarters in San Marcos, California.Utilizing the latest in advanced, computerizeddata acquisition systems and calibrationtest equipment, this facility permits com-prehensive product development, testing,and calibration. Any FCI product can becalibrated in accordance with customerspecifications. Laboratory standards aremaintained with NIST (National Instituteof Standards and Technology) traceableCavitating Venturis (CVs) and precisioncalibrated, pressure and temperaturecorrected turbine flow meters. Combustibleand non-combustible gas calibration flowstands allow for the calibration of FCIproducts in a wide range of gases as gasmixtures in flow stand sizes as small as1/8 inch to 30 inches [3 to 760 mm] indiameter. A variety of flow profiles fromlaminar to turbulent conditions aregenerated to duplicate actual field condi-tions. Flow rates from 0 to 20,000+ SCFM[0 to 34,000 NCMH], velocities from 0 to800 SFPS [0-240 NMPS], pressures fromvacuum to 3000 psig [200 bar(g)], andtemperatures from -100° to 850°F [-70°to + 454°C].

FCI on-site instrumentcalibration and trainingIn-situ calibration is available from FCI'sField Service Engineers where precise testand calibration is accomplished in actualmedia conditions.

©Copyright 2006 by Fluid Components International LLC. All rights reserved. Subject to change without notice.

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